JPH0719887Y2 - Car carpet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial field of application] The present invention relates to a terminal-treated automobile carpet.

2. Description of the Related Art Conventionally, as a carpet for an automobile, there has been known a carpet having a peripheral edge portion of a carpet body subjected to an end treatment by overlocking, that is, edging with sewing with an overlock thread. In this way, the carpet subjected to the terminal treatment by the overlock processing can effectively prevent the pile yarn from being frayed at the peripheral portion of the carpet body, and the appearance can be secured. Further, in the case where a notch for exposing the trunk opener, the heater duct outlet, the shift lever, the parking brake, etc. is formed such as a front carpet of an automobile, resin, vinyl chloride, By separately mounting a frame member made of rubber or the like, the pile thread around the peripheral edge of the notch is prevented from fraying.

[Problems to be solved by the invention] By the way, in the above carpet in which the peripheral portion of the carpet body is overlocked to prevent fray of the pile yarn, the overlock yarn is caught or the overlock yarn is cut due to the influence of frictional heat. It may happen. In this case, the pile thread of the carpet body is frayed from that part,
This affects the overlock yarn of the entire carpet, and there is a problem that the terminal processing function due to the overlock processing is hindered.

Further, in the above-mentioned carpet in which a frame material is attached to the peripheral edge portion of the cutout portion to prevent fray of the pile yarn, there is a gap between the carpet and the frame material, and there is no sense of unity, and the appearance is poor. Furthermore, there is a problem that it is necessary to separately attach the frame member, which requires extra man-hours for attachment.

The present invention has been made in view of the above-mentioned problems, and its purpose is to provide a good-looking appearance and to manufacture with a small number of manufacturing steps.
It is an object of the present invention to provide an automobile carpet that is effective in preventing fraying of the edges of the carpet body.

[Means for Solving the Problems] A carpet for an automobile of the present invention comprises a carpet main body having a predetermined shape, and an unsolidified resin injected into at least a concave portion of the mold at the edge of the carpet main body by using the mold. After that, it is characterized by comprising a resin terminal portion whose surface is molded and solidified and fixed.

As the carpet body, a conventional one such as a tufted carpet in which fibers are tufted on a base cloth, or a needle punched carpet in which fibers are laminated with needles can be used after being formed into a predetermined shape. The fibers constituting the carpet may be any of nylon, polyester, polyethylene, polypropylene and the like. The carpet body may be formed of only the carpet material or a backing layer formed on the back surface of the carpet material.

The resin end portion is obtained by injecting an unsolidified resin into a mold having a concave portion of a predetermined shape, press-bonding to the edge portion of the carpet main body using the mold, and then solidifying and fixing the surface molded. It is a part. The resin terminal portion is formed on at least a part of the edge portion of the carpet body, that is, the peripheral edge portion of the carpet body, and, if a cutout portion is formed on the carpet main body, the peripheral edge portion of the cutout portion or the like. be able to.

The shape of the resin end portion can be any shape such as a molding shape having a curved surface whose surface bulges in an arcuate convex shape in a cross section, or a substantially quadrangular shape, as illustrated in Examples described later. Alternatively, the surface may be a curved surface that bulges in an arcuate concave-convex shape in a vertical cross section. The width and size of the resin end portion are appropriately set according to the location where the resin end portion is formed, the application of the carpet, and the like.
When the resin end portion is formed on the peripheral portion of the carpet body, the width dimension of the resin end portion is set to 3 to 20 mm, and when the resin end portion is formed on the peripheral portion of the cutout portion, the width dimension of the resin end portion is formed. Can be 3 to 20 mm.

As the unsolidified resin for forming the resin end portion,
A liquid or semi-liquid resin such as a two-component reaction curable resin such as urethane, epoxy and polyester, and a thermoplastic resin such as polypropylene, polyethylene and polyvinyl chloride can be used. These unsolidified resins are solidified by cooling or a chemical reaction in a mold having a predetermined shape and fixed to the carpet body. The hardness and elasticity of the resin after solidification can be appropriately set according to the place where the resin end portion is formed, the type of carpet, and the like.

As a means for forming this resin end portion, for example, the above-mentioned unsolidified resin is filled in the concave portion of a predetermined shape formed in the mold, and is pressed and held on the carpet body. This allows
The liquid or semi-liquid unsolidified resin penetrates between the fibers of the carpet body. Further, the pressed carpet body is bent and elastically deformed so as to enter the concave portion of the mold, with the portion directly contacting the mold as a fulcrum. Therefore, in the concave portion of the mold, pressure is applied to the unsolidified resin and the fibers of the carpet main body in a entangled state, the unsolidified resin is solidified in the concave shape of the mold, and firmly fixed to the carpet main body as a resin end portion. To be done. The pressing by the mold is performed on a flat plate-shaped lower mold, but may be performed on a lower mold having a convex portion smaller than the concave portion in a shape corresponding to the concave portion of the predetermined shape, This is preferable because a larger pressure is applied to the recess.

[Operation] As described above, in the automobile carpet of the present invention, the liquid or semi-liquid unsolidified resin is solidified in the recesses of the predetermined shape while being inserted between the fibers of the carpet main body. The resin end portion is molded and integrally fixed to the portion. Therefore, since the resin end portion is solidified in a state where the fibers of the carpet body are completely wrapped, it is possible to effectively prevent fraying from the edge portion of the carpet body. Further, the carpet main body and the resin end portion are well integrated, and these are firmly fixed.

[Embodiment] An embodiment of an automobile carpet of the present invention will be specifically described below with reference to FIGS. 1 to 5.

This embodiment is an example applied to a front carpet of an automobile. FIG. 1 is a perspective view showing the entire carpet of this embodiment. 2 to 4 show a step of forming a resin terminal portion on the peripheral portion of the cutout portion formed in the carpet body and performing terminal treatment. FIG. 5 is a perspective view showing a cutout portion after a terminal treatment in which a resin terminal portion is formed.

As shown in FIG. 1, the carpet of the present embodiment has a carpet body 1 having a cutout 2 for exposing the shift lever and a cutout 3 for exposing the parking brake, and a cutout. It is composed of a resin terminal portion 4 formed on the peripheral portions of 2 and 3. The carpet body 1 is
A needle-punched carpet in which fibers 12 made of polypropylene are laminated with needles. The resin end portion 4 is made of a non-solidified resin made of urethane which is a two-component curable resin.
It is solidified in the state of being entangled in 12. Resin terminal part 4
As shown in FIG. 4 and FIG. 5, the shape of is a circular arc convex surface whose upper surface bulges upward when viewed in cross section. The width of the resin terminal portion 4 is 8 mm.

The method for manufacturing the carpet of this embodiment will be described with reference to FIGS. 1 to 4.

Fiber 12 made of polyethylene is needle-punched on a base cloth 11 to form a needle-punched carpet, and a polyethylene film (300 g /
m ² ) was coated. This was molded into a predetermined shape by normal pressure molding, and then a cutout 2 for a shift lever and a cutout 3 for a parking brake were formed by a normal punching machine to obtain a carpet body 1.

Next, as shown in FIG. 2, a circular arc concave portion 51 is formed along the peripheral edge portion 13 of the cutout portion 2 of the carpet main body 1 and a pressing die 5 is used. Liquid non-solidified resin made of urethane, which is a curable resin, and isocyanate, which is a curing agent, are poured in, pressed along the peripheral edge of the notch ² , and pressed and held at a pressure of approximately 2 kg / cm ^2. did. Thereby, the liquid or semi-liquid unsolidified resin,
It enters between the fibers 12 of the carpet body 1. Further, in the pressed carpet main body 1, as shown in FIG. 3, the peripheral edge portion 13 has the rim 5 with the end 52 of the mold 5 directly contacting as a fulcrum.
It is curved and elastically deformed so as to enter the circular arc concave portion 51. Therefore, pressure is applied to the unconsolidated resin and the fibers 12 of the peripheral portion 13 in the arc concave portion 51 of the mold 5 in a entangled state. Then, the unsolidified resin is molded and solidified in the shape of the arcuate concave portion 51 of the mold 5, and is firmly fixed to the carpet body 1 as the resin end portion 4 as shown in FIG.

In this embodiment, the pressing by the mold 5 was performed on the flat plate-shaped lower mold, but instead of this, as shown in FIG. 6, a shape corresponding to the circular arc concave portion 51 is used. Lower mold 6 having an arcuate convex portion 61 whose height is lower than the arcuate concave portion 51
It is also possible to carry out the pressing on the above. In this case, type 5
The pressure inside the arcuate concave portion 51 increases, and the adhesion between the carpet main body 1 and the resin terminal portion 4 is further strengthened.

Further, the resin terminal portion 4 formed on the peripheral portion of the notch portion 3 for the parking brake formed on the carpet body 1 can be manufactured by the same method, and therefore the description thereof will be omitted.

Furthermore, it is also possible to form a resin end portion on the peripheral portion of the carpet body 1 in the same manner as above.

In the above-described automobile carpet according to the present embodiment, the resin end portion 4 is solidified while completely enclosing the fibers 12 of the carpet body 1, and further, the fixation between the carpet body 1 and the resin end portion 4 is strong. Is. Therefore, it is possible to effectively prevent fraying from the peripheral portion of the cutout portion 2 of the carpet body 1. Further, the resin end portion 4 is molded as an arc convex surface by the arc concave portion 51 of the mold 5, and the carpet body 1 and the resin end portion 4 are integrally fixed, so that the appearance is good and further It is also possible to preliminarily color the non-solidified resin in the same color as that of the carpet main body 1, so that the appearance can be greatly improved.

Further, in terms of processing, since the resin end portion 4 is directly molded on the carpet body 1 by the mold 5, it is not necessary to attach the frame material as a separate component as in the conventional case, and the frame material forming step and the attaching step can be reduced. .

Further, in this embodiment, since the two-component curing type urethane resin is used as the unsolidified resin, it is not necessary to apply heat and pressure when solidifying the unsolidified resin.

Therefore, the carpet body 1 is not damaged by heat and high pressure. The same effect is obtained when a thermoplastic resin is used as the unsolidified resin.

[Effect of the Invention] As described in detail above, the automobile carpet of the present invention is
The resin end portion is molded and firmly fixed so as to completely wrap the fibers at the edge of the carpet body. Therefore, the carpet body and the resin end portion are well integrated, and the appearance is good, and the fraying from the edge portion of the carpet body can be effectively prevented. Since the unsolidified resin is injected into the concave portion of the mold and pressure-bonded to the carpet main body, the unsolidified resin does not protrude from the concave portion of the mold and the appearance is improved.

Further, since the resin end portion is directly molded on the carpet body, it is possible to reduce the conventional molding and mounting steps of separate parts.

[Brief description of drawings]

1 to 5 show an embodiment of the present invention. FIG. 1 is a perspective view of the entire carpet. 2 to 4 are schematic cross-sectional views showing a step of forming a resin end portion on the peripheral edge portion of the cutout portion formed in the carpet body, and FIG. 2 is a diagram in which the unsolidified resin is poured into the arcuate concave portion. FIG. 4 is a schematic cross-sectional view showing a state in which the mold is in contact with the peripheral portion of the cutout portion, and FIG. 3 is a schematic cross-sectional view showing a state in which the mold is pressed and held;
The figure is a schematic cross-sectional view showing a state in which the mold is raised.
FIG. 5 is a perspective view of the cutout portion after the resin terminal portion is formed. FIG. 6 is a schematic cross-sectional view showing an example in which pressing is performed on a lower mold having an arcuate convex portion having a shape corresponding to the arcuate concave portion. 1 ... Carpet body 2, 3 ... Notched part 4 ... Resin end part, 5 ... Mold 6 ... Lower mold, 12 ... Fiber 13 ... Edge part, 51 ... Arc concave part 61 ... Arc convex part

Claims (1)

[Scope of utility model registration request] 1. A carpet main body having a predetermined shape, and an unsolidified resin injected into a concave portion of a mold is pressure-bonded to at least a part of an edge of the carpet main body using the mold, and then solidified and fixed. An automotive carpet characterized in that it comprises a resin end portion whose surface is molded.