JP2003165373A - Floor mat and method of manufacturing the floor mat - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a floor mat capable of dispensing with an accurate positioning, excellent in visual appearance, preventing a surface layer carpet and lining material from being separated from a peripheral edge part, and making it less prone for fibers to fall down and a manufacturing method of the floor mat. <P>SOLUTION: This floor mat 10 comprises a base layer 11, a carpet layer 12 stacked on the upper surface of the base layer 11, and a band-shaped raised part 15 having a flat part 13 and a peripheral edge part 14 surrounding the peripheral area of the flat part 13 and having at least a part of the peripheral edge part 14 raised in an upper surface direction. Since the band-shaped raised part 15 is provided, soil, sand, mud, or gravel can be held by the flat part 13. The floor mat 10 further comprises a covering part 16 for covering at least the peripheral edge part of the carpet layer 12 on the band-shaped raised part 15. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a floor mat and a method for manufacturing the same, and more particularly to a floor mat that can be used for automobiles, houses, stores, or offices, and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, in an automobile, a floor mat is laid in order to prevent soil, sand, mud, gravel or the like adhering to shoes from adhering to the floor and soiling the floor.

As this floor mat, it is known that the floor mat is provided with a surface material layer such as a carpet and a base layer made of rubber or the like for supporting the surface material layer, and the periphery is overlocked. In such a floor mat, the thread on the peripheral edge of the overlock processing may be worn out, and the overlock processing is disadvantageous in terms of cost.

Therefore, a floor mat in which overlocking is unnecessary by raising the peripheral edge of the floor mat is disclosed, for example, in Japanese Patent Laid-Open No. 6-24265. However, with such a floor mat,
Since it is necessary to punch the floor mat into a mat shape after molding, there is a problem that highly accurate alignment is required, a problem that the carpet layer and the base layer are easily peeled from the peripheral portion, and fibers are easily dropped, There was a problem that the unprocessed feeling of the peripheral part remained and the aesthetics was spoiled.

FIG. 5 shows, for example, Japanese Patent Laid-Open No. 2001-58536.
It is a perspective view which shows the other floor mat disclosed by the publication, and FIG. 6 is a schematic sectional drawing of the floor mat of FIG. In these drawings, a floor mat 1 includes a surface carpet 2 and a backing material 3. The surface carpet 2 includes a raised fabric 2a and a base cloth 2b, and the backing material 3 is joined to the base cloth 2b of the surface carpet 2. The floor mat 1 includes a central plane portion 1a and a jetty-shaped peripheral edge portion 1b, and the jetty-shaped peripheral edge portion 1b is provided around the central flat surface portion 1a. The floor mat 1 is provided with anti-slip projections 3 a on the back surface of the backing material 3.

The floor mat 1 is the floor mat 1
It is manufactured by cutting the peripheral portion of and simultaneously performing compression molding. According to this manufacturing method, the problem of alignment and the problem of impairing aesthetics described in JP-A-6-24265 are solved.

[0007]

However, the problem that the surface carpet 2 and the backing material 3 are easily separated from the peripheral portion of the floor mat 1 and the fibers are likely to fall off has not been solved yet. .

The present invention has been made in order to solve the above-mentioned problems. It does not require highly accurate alignment, has an excellent aesthetic appearance, and the surface carpet and the base material are not separated from the peripheral portion, and the fibers are An object of the present invention is to provide a floor mat that does not easily fall off and a method for manufacturing the floor mat.

[0009]

The invention according to claim 1 of the present invention has a base layer and a carpet layer laminated on the upper surface of the base layer, and surrounds the flat portion and the periphery of the flat portion. A floor mat comprising a peripheral portion, and at least a part of the peripheral portion having a belt-shaped raised portion raised in the upper surface direction, wherein the floor mat has at least a peripheral edge portion of the carpet layer in the belt-shaped raised portion. A floor mat having a covering portion for covering.

The invention according to claim 2 has a base layer and a carpet layer laminated on the upper surface of the base layer, and comprises a flat portion and a peripheral portion surrounding the flat portion. A method of manufacturing a floor mat having at least a part of a strip-shaped ridge raised in the upper surface direction,
A step of laminating a base layer material forming a base layer and a carpet layer material forming a carpet layer and cutting them into substantially the same size, and pressing a mold capable of forming the strip-shaped ridges to these laminated bodies. And pulling the peripheral edge of the carpet layer material toward the base layer and forming the strip-shaped ridge at the same time; and forming a coating portion that covers at least the peripheral edge of the carpet layer in the strip-shaped ridge. It is a method including and.

According to a third aspect of the present invention, the steps of cutting the laminate of the base layer material and the carpet layer material, the step of forming the band-shaped ridges, and the step of forming the covering portion in the second aspect are performed by an upper mold. And using a lower mold.

According to the first aspect of the present invention, since the edge portion on the peripheral edge side of the carpet layer on the strip-shaped raised portion is covered with the covering portion, the appearance is excellent, and moreover, the carpet layer and the base layer are provided from the peripheral edge portion of the floor mat. A floor mat is obtained in which fibers do not peel off and fibers do not easily fall off.

According to the second aspect of the invention, since the base layer material and the carpet layer material are cut into substantially the same size before molding, highly accurate alignment is unnecessary. Further, since the peripheral edge portion of the carpet layer material is pulled toward the base layer side and the strip-shaped raised portion is formed at the same time, the floor mat can be easily manufactured.

According to the invention of claim 3, the step of cutting the laminate of the base layer material and the carpet layer material, the step of forming the strip-shaped raised portion and the step of forming the covering portion in the second aspect are the upper molds. Also, since it is performed using the lower mold, the manufacturing process of the floor mat can be simplified.

[0015]

1 is a schematic enlarged cross-sectional view showing a main part of a floor mat according to an embodiment of the present invention. In the figure, a floor mat 10 has a base layer 11 and a carpet layer 12 laminated on the upper surface of the base layer 11, and includes a flat portion 13 and a peripheral edge portion 14 surrounding the flat portion 13. Thus, at least a part of the peripheral edge portion 14 has a strip-shaped raised portion 15 that is raised in the upper surface direction. By providing such a band-shaped ridge 15, the flat portion 13 can hold soil, sand, mud, gravel, or the like. Therefore, it is preferable that the entire circumference of the peripheral edge portion 14 is formed by the strip-shaped raised portion 15.

The floor mat 10 further includes a strip-shaped raised portion 1.
The covering portion 16 is provided so as to cover at least the peripheral edge portion of the carpet layer 12 in FIG. Carpet layer 12
Since the edge portion on the peripheral side is covered by the covering portion 16,
The appearance is excellent, and the carpet layer 12 and the base 11 are less likely to be peeled off from the peripheral portion 14 and the fibers are less likely to fall off. The covering portion 16 may be provided not only when it is provided so as to project in the upper surface direction, but also where it is provided so as to project in the outer peripheral direction of the floor mat 10.

The angle θ formed by the covering portion 16 and the plane including the lower surface of the flat portion 13 is substantially vertical, that is, 8
It is preferably in the range of 5 to 95 °. This allows
When the floor mats 10 are abutted against each other, the floor mats 10 can adhere to each other over a wide area.
It is possible to resist the force applied to the floor mat 10, and since there is no space for dust and sand to enter, it is difficult to stain the floor. Further, since it is not necessary to overlap the floor mats 10 with each other, a sense of unity between the floor mats 10 is created, and the aesthetic appearance is excellent. Since not only the floor mats 10 but also the floor mat 10 and the floor wall (not shown) can be in close contact with each other,
Dirt, sand, mud, gravel, etc. cannot enter the floor, and the floor can be effectively prevented from being soiled.

Furthermore, it is sufficient that the strip-shaped raised portion 15 is capable of holding gravel or the like by being raised toward the upper surface,
Although the height (t) of the protrusion is not particularly limited,
The thickness is preferably 5 mm or more, and is preferably 35 mm or less from the viewpoint of shape retention of the strip-shaped ridge 15.

The groove portion 1 formed in the strip-shaped raised portion 15
The cross-sectional shape of 5a is not particularly limited,
For example, a semi-circle, a semi-ellipse, a polygon (for example, a trapezoid, a square, a triangle, etc.) can be mentioned. In this way, the groove 15a in which the strip-shaped ridge 15 is opened in the lower surface direction
When provided with, the peripheral side wall 15b of the strip-shaped ridge 15
If the wall thickness of the base layer 11 constituting the
Since it may be difficult to maintain the shape of 5,
The wall thickness of the base layer 11 constituting the peripheral side wall 15b (t _a) is preferably more than 2 mm. When the wall thickness of the base layer 11 forming the peripheral side wall 15b is not uniform, the wall thickness at the thinnest part is referred to.

The flat side wall 15 of the strip-shaped ridge 15
Even if the base layer 11 constituting c is thin, the strip-shaped ridge 15
Since it may be difficult to maintain the shape of, the wall thickness (t _b ) of the base layer 11 forming the side wall 15c on the flat portion side is preferably 1.0 mm or more. further,
Base layer 11 that constitutes the ceiling portion 15d of the strip-shaped raised portion 15
If the wall thickness is smaller than the wall thickness of the base layer 11 forming the peripheral side wall 15b, the ceiling portion 15d is deformed by the force acting on the peripheral side wall 15b, and the floor mats are likely to adhere to each other.

Note that, in FIG. 1, a large number of protrusions 11a protruding from the lower surface side of the base layer 11 in the lower surface direction may be provided. By providing such a protrusion 11a, it becomes difficult to slip and it is possible to prevent the floor mat from moving.

Further, the width (W) of the strip-shaped raised portion 15 may or may not be constant, but a constant width is more aesthetically pleasing. The width (W) of the strip-shaped ridge 15 is preferably about 10 to 50 mm.

The preferred floor mat 10 of the present invention in which the base layer 11 and the carpet layer 12 are laminated and integrated can be manufactured, for example, as follows.

First, materials for forming the carpet layer 12 and the base layer 11 are prepared. Examples of the material constituting the former carpet layer 12 include tufted carpet,
Needle punch carpet, mattress, hook carpet,
Wilton carpet, Akisminster carpet, etc. can be mentioned. Examples of the material forming the latter base layer 11 include thermoplastic resin sheets (for example, polyvinyl chloride, ethylene-vinyl acetate copolymer,
Polyethylene, etc., thermoplastic elastomer sheet (for example, styrene thermoplastic elastomer, polyolefin thermoplastic elastomer, polyvinyl chloride elastomer, etc.), thermosetting resin sheet (for example, phenol resin, polyurethane, unsaturated polyester resin, etc.) ,
Alternatively, a natural or synthetic rubber sheet (for example, styrene-butadiene rubber, butadiene rubber, isoprene rubber, nitrile-butadiene rubber, etc.) can be used. The hardness of the material forming the base layer 11 (Shore A hardness) is preferably about 50 to 90, and is 65.
It is more preferably about 75.

Next, for example, when the material forming the base layer 11 is a thermoplastic resin sheet or a thermoplastic elastomer sheet, the material forming the base layer 11 and the material forming the carpet layer 12 are laminated. After that, the material forming the base layer 11 is heated to a moldable temperature, and then cold pressing is performed to cover at least the peripheral edge portion of the strip-shaped ridge 15 and the carpet layer 12 thereon and the covering portion. 16 so as to form the floor mat 10
Can be manufactured. When laminating the thermoplastic resin sheet or the thermoplastic elastomer sheet extruded from the extrusion molding nozzle with the material forming the carpet layer 12, it is possible to omit the step of heating the base layer 11 to a temperature at which it can be molded. It is possible. When the material forming the base layer 11 is a thermosetting resin sheet or a rubber sheet, the floor mat 10 can be manufactured by performing hot pressing instead of cold pressing.

Next, according to a preferred embodiment of the present invention,
A case where the floor mat 10 is cut and molded using a mold will be described. 2 to 4 show that the laminate material of the floor mat 10 in which the material forming the base layer 11 and the material forming the carpet layer 12 are laminated is cut by a mold,
It is a schematic sectional drawing which shows the process of shape | molding. First, for example, the material forming the base layer 11 and the carpet layer 12 described above.
A material for the floor mat 10 is prepared by laminating the material for forming the floor mat 10 and the upper die 21 and the lower die 22 as shown in FIG.
It is loaded into the molding apparatus 20 equipped with. Next, as shown in FIG. 3, the upper mold 21 is lowered in the direction of arrow A to
Also, the laminate material of the floor mat 10 is cut by the cutting portions 23a and 23b of the lower mold 22. In the present invention, since the material forming the base layer 11 and the material forming the carpet layer 12 are cut into substantially the same size in advance by a mold, it is not necessary to perform highly accurate alignment. Further, cutting and molding of the laminated material can be continuously performed by the same mold, and the manufacturing process can be simplified. Note that it is not always necessary to cut with a mold, and the laminate material may be cut with another cutting device if desired.

Here, the gap g (see FIG. 2) at the outer peripheral portion between the upper mold 21 and the lower mold 22 is preferably 0 to 1 mm. This is because if the gap g is 1 mm or more, the cuttability is poor. Further, the angle α at the cutting portion 23b of the lower mold 22 is preferably 45 ° to 90 ° so that the cutting property and durability are excellent. further,
In order to reduce the contact area between the metal molds, from the position B 1 mm or more above the cutting portion 23a of the upper metal mold 21, as shown in FIG. Is preferred. If the distance from the cutting portion 23a is not 1 mm or more, there is a problem in strength of the upper mold 21. Further, even if it is cut by 0.5 mm or more, the strength is poor and the durability is reduced. Furthermore, if it is less than 0.05 mm, the effect is small,
Moreover, it is difficult to process the upper mold 21.

Next, as shown in FIG. 4, the upper die 21 is lowered to the bottom dead center to deform the end portion of the laminated material.
That is, the material forming the base layer 11 of the laminated body material is in a melted state having fluidity, and the vicinity 10 a of the laminated body material is pressed by the upper mold 21 against the convex portion 24 of the lower mold 22. Then, at the same time as the material forming the carpet layer 12 is pulled inward, the resin forming the material forming the base layer 11 flows into the recesses 25 of the lower mold 22 to form the strip-shaped ridges 15, and at the same time, the covering portion is formed. 16 is formed.
Since the covering portion 16 covers the peripheral edge of the carpet layer 12 so as to be embedded therein, it has an excellent appearance, and the carpet layer 12 and the base layer 11 are not separated from the peripheral edge.
It is possible to manufacture the floor mat 10 in which fibers do not easily fall off. In addition, in FIG. 4, the covering portion 16 is provided so as to project in the outer peripheral direction of the floor mat 10.

Here, the height i of the convex portion 24 of the lower mold 22 is
Is preferably 2 to 25 mm, more preferably 3 to 8 mm. If the height i is 2 mm or less, only the floor mat 10 having a poor dust outflow prevention property can be manufactured, and the material forming the carpet layer is insufficiently drawn in at the time of molding, so that the covering is insufficient. The formation of the portion 16 is insufficient. On the other hand, when the height i exceeds 25 mm, the amount of drawing of the material forming the carpet layer is too large, the resin is likely to be exposed, and the appearance tends to deteriorate, and moreover, in the corner portion of the material forming the carpet layer. The difference between the pull-in amount and the pull-in amount in the straight line portion is too large, which makes stable production difficult.

[0030]

As described above, according to the first aspect of the invention, since the edge portion of the carpet layer on the strip-shaped ridge is covered by the covering portion, the appearance is excellent and the floor mat The carpet mat and the base layer are not separated from the peripheral edge portion, and the effect is obtained that the floor mat in which the fibers do not easily fall off is obtained.

According to the second aspect of the present invention, since the base layer material and the carpet layer material are cut into substantially the same size before molding, highly accurate alignment is unnecessary. Further, since the peripheral edge portion of the carpet layer material is pulled toward the base layer side and at the same time the strip-shaped raised portion is formed, the floor mat can be easily manufactured.

According to the invention of claim 3, the step of cutting the laminate of the base layer material and the carpet layer material, the step of forming the band-shaped ridges, and the step of forming the covering portion in the upper mold are carried out. Moreover, since it is performed using the lower mold, there is an effect that the manufacturing process of the floor mat can be simplified.

[Brief description of drawings]

FIG. 1 is a schematic enlarged sectional view showing a main part of a floor mat according to an embodiment of the present invention.

FIG. 2 is a schematic cross-sectional view showing a process of cutting and molding a laminate material of a floor mat in which a material constituting a base layer and a material constituting a carpet layer are laminated with a mold.

FIG. 3 is a schematic cross-sectional view showing a process of cutting and molding a laminate material of a floor mat in which a material constituting a base layer and a material constituting a carpet layer are laminated with a mold.

FIG. 4 is a schematic cross-sectional view showing a process of cutting and molding a laminate material of a floor mat in which a material forming a base layer and a material forming a carpet layer are laminated with a mold.

FIG. 5 is a perspective view showing a conventional floor mat.

6 is a schematic cross-sectional view of the floor mat of FIG.

[Explanation of symbols]

10 ... Floor mat, 10a ... Edge vicinity, 11 ... Base layer, 12 ... Carpet, 13 ... Flat part, 14 ... Peripheral part,
15 ... Strip-shaped ridges, 15a ... Grooves, 15b ... Peripheral side sidewalls, 15c ... Flat part side sidewalls, 15d ... Ceiling section, 16 ... Covering section, 20 ... Molding device, 21 ... Upper mold, 22 ... Lower mold,
23a, 23b ... Cutting part, 24 ... Convex part, 25 ... Recessed part.

Claims (3)

[Claims] 1. A base layer and a carpet layer laminated on an upper surface of the base layer, the flat layer and a peripheral portion surrounding the flat portion. At least a part of the peripheral portion is the upper surface. A floor mat having a strip-shaped raised portion that is raised in a direction, wherein the floor mat includes a covering portion that covers at least a peripheral side end portion of the carpet layer in the strip-shaped raised portion. . 2. A base layer and a carpet layer laminated on the upper surface of the base layer, the flat portion and a peripheral portion surrounding the flat portion. At least a part of the peripheral portion is the upper surface. A method of manufacturing a floor mat having a strip-shaped ridge raised in a direction, comprising laminating a base layer material forming a base layer and a carpet layer material forming a carpet layer, and cutting them into substantially the same size, A step of pressing a mold capable of forming the strip-shaped raised portion against these laminated bodies to draw the peripheral portion of the carpet layer material toward the base layer side and at the same time forming the strip-shaped raised portion; Forming a covering over at least a peripheral edge of the carpet layer in. 3. The step of cutting the laminate of the base layer material and the carpet layer material, the step of forming the strip-shaped raised portion and the step of forming the covering portion are performed using an upper mold and a lower mold. The method according to claim 2, wherein the method is performed as follows.