JP5018070B2 - Mat material, mat material pre-processing apparatus, and mat material manufacturing method - Google Patents

Description

  The present invention relates to a mat material, a mat material pretreatment device, and a mat material manufacturing method, and more specifically, a mat material that can improve the appearance of a product even when the basis weight of a skin layer is large, The present invention relates to a mat material pre-processing apparatus and a mat material manufacturing method.

  Conventionally, as a mat material to be laid in the interior of an automobile or the like, a pile layer (skin layer) is provided on the entire surface of the base material, and the peripheral portion is processed into a terminal to protect the peripheral portion including the cut surface (for example, , Overlock sewing, etc.) are known (for example, see Patent Documents 1 and 2).

In such a conventional mat material, the mat material is installed because the terminal processing portion of the processed mat material exists in a frame shape and stands out in a different appearance from the central portion in the installed state indoors. It appears as a boundary between the floor of the room. For this reason, the design of the mat material has been impaired, for example, the sense of unity in design is impaired. In addition, the mat processed end portion of the mat material has a different tactile sensation from the central portion, which may cause the user to feel uncomfortable.
In particular, when a pile having a high weight per unit area (for example, 800 g / m ² or more) is used in order to give a high-class feeling to the mat material, as shown in FIG. Part) involves a lot of pile ends 110 on the inside thereof, which makes the appearance of a very thick. In addition, since many pile ends 110 are wound, the pile ends 110 can be seen from the gaps in the terminal processing portion 108 and the appearance is poor.

  Further, as shown in FIG. 14, when the back sheet layer 104 having a plurality of anti-slip protrusions 104 a is provided on the back surface side of the mat member 101, the protrusions are formed from the gaps in the terminal processing part 108. The portion 104a may protrude and become unsightly.

  Furthermore, in the conventional mat material manufacturing method, pile scraps are usually collected on the product when the product shape is extracted from the carpet raw fabric, and the pile scraps are manually removed, which is a complicated operation. It was.

JP 2000-83796 A JP 2003-291711 A

  The present invention has been made in view of the above situation, and even when the basis weight of the skin layer is large, the mat material, the mat material pretreatment device, and the mat material can improve the appearance of the product. An object is to provide a manufacturing method.

The present invention is as follows.
1. A substrate;
A fibrous skin layer having a cut portion formed by cutting a portion provided on the entire surface of the base material and provided at a terminal portion of the surface of the base material;
An end protection means having a covering portion that covers a cut portion of the skin layer, a side portion of the base material, and a terminal portion on the back surface side of the base material;
The basis weight of the skin layer is 800 g / m ² or more, and the end portion of the skin layer is formed in a fan shape so as to cover the upper end portion of the surface of the base material ,
Provided on the entire back surface of the base material, and has a plurality of anti-slip protrusions, and further cuts the protrusion provided at the end of the back surface of the base material among the plurality of protrusions. Further comprising a back sheet layer having a cut portion formed by
The mat member according to claim 1, wherein the covering portion of the end protection means covers a terminal portion including a cut portion of the skin layer, a side portion of the base material, and a cut portion of the back sheet layer .
2. The height of the skin layer is 10 mm or more . Matt material described.
3. A table on which an initial mat material provided with a fibrous skin layer over the entire surface of the substrate is placed;
Cutting means for cutting a skin layer provided at a terminal portion of the surface of the base material of the skin layer of the initial mat material placed on the table,
The initial mat member includes a back sheet layer provided on the entire back surface of the base material and having a plurality of anti-slip protrusions, and the cutting means is the initial mat placed on the table. A mat material pre-processing apparatus, characterized in that a projection provided at the end of the back surface of the base material among the plurality of projections of the material can be cut .
4). A table on which an initial mat material provided with a fibrous skin layer over the entire surface of the substrate is placed;
Cutting means for cutting a skin layer provided at a terminal portion of the surface of the base material of the skin layer of the initial mat material placed on the table ,
The cutting means includes a rotary shaft that is rotatably provided around an axis that intersects the upper surface of the table, a rotary cutter that is provided on the rotary shaft and that cuts the skin layer, and is provided on the rotary shaft and that rotates. A mat material pretreatment device , comprising: a rotating brush that separates cutting waste cut by a cutter from an end portion of the skin layer .
5. 2. The air injection means for injecting air toward the outer surface side of the skin layer cut by the cutting means . Or 4. The pretreatment device for the mat material described.
6). The table is provided with a recovery passage for recovering the cutting waste cut by the cutting means, and the air injection means is configured such that air injected toward the outer surface side of the skin layer enters the recovery passage. 4. Arranged to flow along The pretreatment device for the mat material described.
7). Cutting the skin layer provided at the end portion of the surface of the base material of the initial mat material provided with a fibrous skin layer over the entire surface of the base material;
Covering the cut portion of the skin layer, the side portion of the base material, and the end portion of the back surface side of the base material by the covering portion of the end protection means,
In the step of cutting the skin layer, the above-mentioned 3. To 6. A method for producing a mat material, comprising the step of cutting the skin layer using the pretreatment device for a mat material according to any one of the above .

According to the mat material of the present invention, the fibrous skin layer is provided with a cutting portion obtained by cutting a portion provided at the end portion of the surface of the substrate, and the skin layer is cut by the covering portion of the edge holding means. Part, the side part of the base material, and the end part on the back side of the base material, so that the entrainment of the epidermis layer inside the covering part can be suppressed, and the end part of the epidermis layer is formed from the gap of the covering part. It can suppress seeing. In particular, when a decorative yarn (pitch yarn) is employed as the covering portion, it is possible to use a single hook for the conventional two yarns, and it is possible to ensure a linear appearance without overlapping the decorative yarns. Further, the basis weight of the skin layer is 800 g / m ² or more, and the end portion of the skin layer is formed in a fan shape so as to cover the upper end portion of the surface of the base material. The covering portion is difficult to see due to the portion, and the peripheral portion of the mat member can be integrated with the central portion of the mat member. As a result, the appearance of the product can be improved even when the basis weight of the skin layer is large.
In addition, since it further includes a back sheet layer, the covering portion of the end protection means covers the end portion including the cut portion of the skin layer, the side portion of the base material, and the cut portion of the back sheet layer . Further, it is possible to prevent the anti-slip protrusion from projecting through the gap between the covering portions.
Moreover, when the height of the skin layer is 10 mm or more, the end portion of the skin layer is easily formed into a fan shape, and the peripheral edge of the mat material can be more reliably integrated with the center portion. .

According to the mat material pre-processing apparatus of the present invention, the skin layer provided at the end of the surface of the base material among the skin layers of the initial mat material placed on the table is cut by the cutting means. And in this pre-processed initial mat material, if the covering part of the edge protection means covers the cut part of the skin layer, the side part of the base material and the end part on the back side of the base material, the inside of the covering part Involvement of the skin layer into the skin can be suppressed, and the appearance of the skin layer from the gaps in the covering portion can be suppressed. In particular, when a decorative yarn (pitch yarn) is employed as the covering portion, it is possible to use a single hook for the conventional two yarns, and it is possible to ensure a linear appearance without overlapping the decorative yarns. In addition, since the end portion of the skin layer can be formed in a fan shape so as to cover the upper portion of the end portion of the surface of the base material, the end portion of the skin layer makes it difficult to see the covering portion, and the peripheral portion is connected to the central portion. It can have unity. As a result, even when the basis weight of the skin layer is large, it is possible to provide a mat material with improved appearance of the product.
In addition, when the initial mat member includes a back sheet layer and the cutting means is configured to be able to cut a predetermined protrusion, the cutting means can prevent the slip from a plurality of protrusions. The protrusion provided at the end of the back surface of the substrate is cut. And in this pre-processed initial mat material, if the end part including the cut part of the skin layer, the side part of the base material and the cut part of the back sheet layer is covered by the covering part of the edge protecting means, the covering part It can suppress that the projection part for slip prevention protrudes from the clearance gap.
Further, when the cutting means has a rotating shaft, a rotating cutter and a rotating brush, the cutting scraps cut by the rotating cutter can be forcibly separated from the end portion of the skin layer by the rotating brush. it can. In addition, when the product shape is extracted from the raw fabric, the scraps gathered on the product can be forcibly separated from the end portion of the skin layer by the rotating brush.
In the case where the air injection means is further provided, the air injection means injects air toward the outer surface side of the skin layer cut by the cutting means, the skin layer is aligned in an upright state, and the skin is cut by the cutting means. The layer can be cut more accurately.
Further, when a recovery passage is provided in the table, and the air injection means is arranged to flow the air injected toward the outer surface side of the skin layer along the recovery passage. The cutting waste is driven to the recovery side through the recovery passage by the airflow flowing through the recovery passage by the jet air from the air injection means. As a result, cutting waste can be collected without being scattered around. Further, since the cutting waste is collected by using the air jet means having the function of aligning the skin layers, it can be configured more simply and inexpensively.

According to the method for manufacturing a mat material of the present invention, in an initial mat material in which a fibrous skin layer is provided on the surface of a base material, the skin layer provided at the end portion of the base material surface of the skin layer is cut. Then, the cut portion of the skin layer, the side portion of the base material, and the end portion on the back surface side of the base material are covered with the covering portion of the end portion protection means. Thereby, the entrainment of the skin layer inside the covering portion can be suppressed, and the appearance of the skin layer from the gap between the covering portions can be suppressed. In particular, when a decorative yarn (pitch yarn) is employed as the covering portion, it is possible to use a single hook for the conventional two yarns, and it is possible to ensure a linear appearance without overlapping the decorative yarns. In addition, since the end portion of the skin layer can be formed in a fan shape so as to cover the upper portion of the end portion of the surface of the base material, the end portion of the skin layer makes it difficult to see the covering portion, and the peripheral portion is connected to the central portion. It can have unity. As a result, even when the basis weight of the skin layer is large, it is possible to provide a mat material with improved appearance of the product.
The step of cutting the skin layer, since in the step of cutting the skin layer by using a pre-processing apparatus of the above-mentioned mat member, it is possible to more suitably cut the skin layer.

1. Matt material Embodiment 1 The mat material according to the present invention includes a base material, a fibrous skin layer, and end protection means described below. This mat material can further include, for example, a back sheet layer to be described later.

  The configuration, shape, material and the like of the “base material” are not particularly limited. This base material 2 can have, for example, a base fabric 2a having elasticity (cushioning properties) and a backing layer 2b laminated on the upper surface of the base fabric 2a and provided with a skin layer 3 on the upper surface ( (See FIG. 10).

The above-mentioned “skin layer” is not particularly limited in terms of its material, shape, etc., as long as it has a cut portion that is provided on the entire surface of the substrate and cuts a portion provided on the end of the surface of the substrate. Absent. The basis weight of the skin layer is 800 g / m ² or more, and the end portion of the skin layer is formed in a fan shape so as to cover the upper end portion of the surface of the substrate.

Examples of the skin layer include a pile layer made of a cut pile, a loop pile, or the like.
The basis weight of the skin layer is preferably 1000 g / m ² or more (particularly 1200 g / m ² or more). This is because the high-quality feeling of the mat material can be further enhanced and the end portion of the skin layer can be easily formed in a fan shape. The basis weight of the skin layer can be, for example, 3000 g / m ² or less (preferably 2500 g / m ² or less). The weight per unit area means the weight of the skin layer per unit area.
The height t (see FIG. 10) of the skin layer is preferably 10 mm or more (particularly 15 mm or more). This is because the end portion of the skin layer can be easily formed in a fan shape. Moreover, the height of the said skin layer can be 25 mm or less (preferably 20 mm or less), for example.
The cutting width w (see FIG. 8) of the cut portion of the skin layer can be appropriately selected according to the basis weight and pile length of the skin layer, but is preferably 2 mm to 6 mm. This is because the upper end portion of the surface of the base material can be more reliably covered with the end portion of the skin layer. In addition, the cut part of the said skin layer is usually provided over the whole peripheral side of a skin layer.

  As long as the "end protection means" has a covering portion that covers the cut portion of the skin layer, the side portion of the base material, and the end portion on the back surface side of the base material, its configuration, shape, material, etc. are not particularly limited. .

Examples of the end protection means include (1) a form having a sewing thread that penetrates the base material and connects both ends of the cover portion on the front and back sides of the base material by sewing, and (2) the cover portion is substantially U-shaped. And the like in which the covering portion is welded to the base material.
In the form (1), examples of the covering portion include a decorative yarn (powder yarn), a tape material, and a substantially U-shaped resin material.
In the form (1), the sewing thread is provided, for example, so as to be substantially parallel to the side portion of the base material, or is separated from the side portion of the base material as it goes from the front surface side to the back surface side of the base material. Or can be provided.

  The “back sheet layer” is provided on the entire back surface of the base material, and has a plurality of anti-slip protrusions, and further, at the end of the back surface of the base material among the plurality of protrusions. As long as it has a cutting part formed by cutting the provided protrusion, its configuration, shape, material, etc. are not particularly limited. When this back sheet layer is provided, the covering portion of the edge protection means includes a cut portion of the skin layer, a side portion of the base material, and a terminal portion including a cut portion of the back sheet layer (the end portion on the back side of the base material). Is covered.

2. Matt material pre-processing apparatus The mat material pretreatment apparatus according to the present invention includes a table and cutting means described below. This pre-processing apparatus can further include, for example, air injection means described later.
In addition, as said mat | matte material, for example, the above-mentioned Embodiment 1. The configuration of the mat material described in the above can be applied.

  The “table” is not particularly limited in its configuration, mounting form, and the like as long as an initial mat member having a fibrous skin layer provided on the entire surface of the substrate is placed. The initial mat material placed on the table is usually sent in the feeding direction S (see FIG. 5) by the feeding mechanism and / or the operator.

Examples of the “initial mat material” include those described in the first embodiment. The configuration of the mat material described in the above can be applied. However, in the skin layer of the initial mat material, the first embodiment. The cut portion of the skin layer of the mat material is not formed. In addition, the back mat layer of the initial mat member is provided with the first embodiment. The cut portion of the back sheet layer of the mat material is not formed.
For example, (1) a mode in which the skin layer 3A of the initial mat material 1A is placed on the table 11 with the skin layer 3A on the lower side (see FIG. 3), (2) the skin The form which mounts the back surface side of the base material of an initial mat | matte material on the upper surface of a table with a layer as an upper side can be mentioned. Among these, it is preferable that it is the said (1) form. This is because the initial mat material can be smoothly fed in the feeding direction.

For example, as shown in FIG. 5, the table can be provided with a collection passage for collecting cutting waste cut by the cutting means. For example, the recovery passage 20 can extend along the feeding direction of the initial mat material. Thereby, cutting waste can be collected more reliably.
Above the table 11, for example, a guide member 23 that contacts the back side of the base material 2 </ b> A of the initial mat member 1 </ b> A placed on the table 11 and performs vertical positioning can be provided. (See FIG. 3). Thereby, an outer skin layer can be cut | disconnected more correctly.

  As long as the “cutting means” cuts the skin layer provided at the end of the surface of the base material among the skin layers of the initial mat material placed on the table, its configuration, cutting form, etc. are not particularly limited. .

  The cutting means is capable of cutting, for example, a protrusion provided at the end of the back surface of the base material among the plurality of protrusions provided on the back surface of the back sheet layer of the initial mat material placed on the table. Can be configured. In this case, the skin layer and the protrusion can be cut sequentially, but the skin layer and the protrusion are preferably cut simultaneously. This is because the cutting means can be configured more simply and inexpensively.

Examples of the cutting means include a rotary cutter mechanism, a reciprocating cutter mechanism, and a shearing mechanism. Of these, a rotary cutter mechanism is preferable. This is because the cutting means can be configured more simply and inexpensively.
For example, as shown in FIG. 3, the rotary cutter mechanism 13 includes a rotary shaft 28 that is rotatably provided around an axis that intersects the upper surface of the table 11, and a rotary layer 28 that is provided on the rotary shaft 28 and cuts the skin layer 3A. The first rotary cutter 33 can be included.
In the case described above, it is preferable that the rotary cutter mechanism 13 further includes a second rotary cutter 34 provided on the rotary shaft 28 and cutting the protrusion 4aA. Further, it is preferable that the rotary cutter mechanism 13 further includes a rotary brush 36 that is provided on the rotary shaft 28 and separates the cutting waste cut by the first rotary cutter 33 from the end portion of the skin layer 3A. The outer diameter of the rotating brush can be set to a value larger than the outer diameter of the rotating cutter, for example. Thereby, cutting waste can be separated more reliably. Furthermore, the rotating shaft 28 may be provided with a guide member 35 that contacts the side surface of the base material 2A of the initial mat member 1A placed on the table 11 and performs left-right positioning, for example. . Thereby, an outer skin layer can be cut | disconnected more correctly.

  As long as the “air injection means” injects air toward the outer surface side of the skin layer cut by the cutting means, its configuration, injection form, etc. are not particularly limited.

For example, the air ejecting means may be disposed so that air ejected toward the outer surface side of the skin layer flows along a recovery passage provided in the table.
The air injection means includes, for example, an injection nozzle provided so that one end opening portion is directed toward the outer surface side of the skin layer, and an air supply source that supplies air to the injection nozzle. be able to. For example, as shown in FIGS. 5 and 6, the injection nozzle includes a first injection nozzle 38 that is directed toward the outer surface side of the skin layer 3 </ b> A constituting the linear portion of the peripheral portion of the initial mat member 1 </ b> A, and the first injection nozzle 38. A second injection nozzle 39 provided close to the one injection nozzle 38 and directed toward the outer surface side of the skin layer 3A constituting the corner portion (R portion) of the peripheral edge portion of the initial mat member 1A. be able to. Thereby, the cut | disconnected skin layer can be aligned more reliably in the linear site | part and corner part of the peripheral part of an initial mat material.

3. Manufacturing method of mat material Embodiment 3 The mat material manufacturing method according to the present invention includes a cutting step and a covering step described below.
In addition, as said mat | matte material, for example, the above-mentioned Embodiment 1. The configuration of the mat material described in the above can be applied.

As long as the “cutting step” is a step of cutting the skin layer provided at the end of the surface of the base material among the skin layers of the initial mat material provided with a fibrous skin layer on the surface of the base material, The cutting form, timing, etc. are not particularly limited. This cutting step is performed, for example, in the above-described second embodiment. It can be a step of cutting the skin layer using the pretreatment device described in 1. Further, as the initial mat material, for example, the above-described Embodiment 2. The configuration of the initial mat material described in the above can be applied.
As long as the “coating step” is a step of covering the cut portion of the skin layer, the side portion of the base material, and the end portion of the back surface side of the base material with the covering portion of the edge protecting means, the covering form The timing is not particularly limited. As this end holding means, for example, the first embodiment described above. The configuration of the end holding means described in the above can be applied.

  Hereinafter, the present invention will be specifically described with reference to the drawings.

(1) Configuration of Mat Material As shown in FIGS. 10 to 12, the mat material 1 according to the present embodiment is laminated on a felt base fabric 2a having elasticity (cushioning property) and an upper surface of the base fabric 2a. And a backing layer 2b. A pile layer 3 (illustrated as “skin layer” according to the present invention) made of a cut pile is planted over the entire surface of the backing layer 2b. A rubber back sheet layer 4 is provided on the entire back surface of the base fabric 2a.

At the entire peripheral edge of the pile layer 3, a cut portion 6 is formed by cutting a portion provided at the end portion of the surface of the substrate 2. The cutting width w (see FIG. 8) of the cutting part 6 is 4 mm. The basis weight of the pile layer 3 is 2000 g / m ² . The height t (see FIG. 10) of the pile layer 3 is 17 mm. And the terminal part of the pile layer 3 is formed in the fan shape so that the upper part of the terminal part of the surface of the base material 2 may be covered with own weight.

  A plurality of protrusions 4 a for preventing slipping are formed on the back surface of the back sheet layer 4. And in this back sheet layer 4, the cutting part 7 formed by cut | disconnecting the projection part 4a provided in the terminal part of the back surface of the base material 2 among these several projection parts 4a is formed.

  Overlock sewing is applied to the entire periphery of the mat member 1. And the terminal part containing the cutting part 6 of the pile layer 3, the side part of the base material 2, and the cutting part 7 of the back sheet layer 4 is coat | covered with the decoration thread 8 (it illustrates as a "covering part" concerning this invention). Has been. Both ends of the decorative yarn 8 are connected by sewing threads 9 that penetrate the base material 2 and extend substantially parallel to the side portions of the base material 2.

(2) Configuration of Pre-processing Device As shown in FIGS. 1 and 2, the pre-processing device 10 according to the present embodiment is an initial mat member 1A (FIG. 7) in which a pile layer 3A is provided over the entire surface of the base material 2A. A table 11 on which is mounted). A main part of a rotary cutter mechanism 13 (illustrated as “cutting means” according to the present invention) is accommodated in a cover 12 provided below the table 11.

  On the upper surface of the table 11, the pile layer 3A of the initial mat member 1A is placed with the pile layer 3A facing down. Further, a presser member 15 is provided above the table 11 to press the initial mat member 1A on the table 11 from above. The table 11 is provided with a feed dog 16 (see FIG. 2) for contacting the initial mat member 1A on the table 11 from below and feeding it in the feed direction S (see FIG. 5). The pressing member 15 is pressed by a pressing mechanism (not shown) provided in the storage body 17. The feed dog 16 is reciprocated along a predetermined path by a drive mechanism (not shown).

  As shown in FIGS. 3 to 5, the table 11 is provided with a collection passage 20 for collecting cutting waste, which will be described later. The collection passage 20 is formed in a box shape having an upper opening. The recovery passage 20 includes a wide portion 20a and a narrow portion 20b continuous to the wide portion 20a, and extends along the feed direction S as a whole. An upper portion of the waste shooter 21 extending obliquely downward is connected to one end side of the narrow portion 20b of the recovery passage 20. The waste shooter 21 is connected to an intake source (not shown), and a suction airflow is generated therein. The storage body 17 is provided with a substantially L-shaped guide member 23 via a guide stay 22. This guide member 23 contacts the protrusion 4aA of the back sheet material 4A of the initial mat material 1A placed on the table 11 to perform vertical positioning (see FIGS. 3 and 5).

  The rotary cutter mechanism 13 includes a drive motor 26 supported by a base member 25 as shown in FIG. A motor-side pulley 27 is connected to the drive shaft 26 a of the drive motor 26. The base member 25 supports a rotating shaft 28 via a bearing 29 so as to be rotatable around a vertical axis. A cutter side pulley 30 is integrally fixed to the lower end side of the rotary shaft 28. A timing belt 31 is wound around the cutter side pulley 30 and the motor side pulley 27. Accordingly, the rotating shaft 28 is rotationally driven in a predetermined rotational direction R (see FIG. 5) by the driving force of the driving motor 26.

  As shown in FIG. 3, the upper end side of the rotating shaft 28 protrudes upward from the upper surface of the table 11. A first rotary cutter 33 is fixed to the upper end side of the rotary shaft 28. The first rotating cutter 33 is for cutting the pile layer 3A provided at the end of the surface of the base material 2A in the pile layer 3A of the initial mat member 1A on the table 11. A second rotary cutter 34 is fixed above the first rotary cutter 33 on the upper end side of the rotary shaft 28 at a predetermined interval. The second rotating cutter 34 has a protrusion 4aA provided at the end of the back surface of the base 2A among the plurality of protrusions 4aA provided on the back surface of the back sheet layer 4A of the initial mat member 1A on the table 11. It is for cutting. A cylindrical guide member 35 is provided between the first and second rotary cutters 33 and 34 on the upper end side of the rotary shaft 28. The guide member 35 contacts the side surface of the base material 2A of the initial mat material 1A placed on the table 11 and performs left-right positioning. Further, a rotary brush 36 is provided immediately below the first rotary cutter 33 on the upper end side of the rotary shaft 28. The rotary brush 36 is for separating the pile scraps cut by the first rotary cutter 33 and pile scraps gathered when the product shape is extracted from the carpet original fabric from the end portion of the pile layer 3A. The outer diameter of the rotating brush 36 is set to a value slightly larger than the outer diameter of the first rotating cutter 33.

As shown in FIG. 2, the storage body 17 is provided with a first injection nozzle 38 and a second injection nozzle 39 via a guide stay 22. Further, the storage body 17 is provided with a third injection nozzle 40. An air supply source (not shown) that supplies air to each of the injection nozzles 38 to 40 is connected to one end side of the first to third injection nozzles 38 to 40. As shown in FIG. 5, the first injection nozzle 38 has one end opening 38 a on the outer surface side of the pile layer 3 </ b> A immediately before cutting that forms a linear portion of the peripheral portion of the initial mat member 1 </ b> A on the table 11. It arrange | positions so that it may face. Further, as shown in FIG. 6, the second injection nozzle 39 has an opening 39a at one end thereof that is outside the pile layer 3A immediately before cutting, which forms the corner portion (R portion) of the peripheral edge of the initial mat member 1A. The first injection nozzles 38 are arranged in parallel so as to be directed toward the side surface. Furthermore, the air jetted obliquely downward from the first and second jet nozzles 38 and 39 toward the outer surface of the pile layer 3A flows in the feed direction S along the recovery passage 20. . Further, as shown in FIG. 5, the third spray nozzle 40 has one end opening 40 a on the outer surface of the pile layer 3 </ b> A after cutting that forms a linear portion of the peripheral portion of the initial mat member 1 </ b> A on the table 11. It arrange | positions so that it may face toward the side.
In the cutting process of the pile layer 3A, it is assumed that air is constantly jetted from the first to third jet nozzles 38 to 40.

(3) Manufacturing method of mat material Next, the manufacturing method of the mat material which concerns on a present Example is demonstrated.
First, as shown in FIG. 7, an initial mat member 1A provided with a pile layer 3A over the entire surface of the substrate 2A is prepared. Next, as shown in FIG. 8, the initial mat member 1A is placed on the table 11 of the pretreatment device 10 with the pile layer 3A on the lower side. At this time, the initial mat member 1A is positioned in the up and down direction and the left and right direction while the protrusion 4aA of the back sheet layer 4A is guided by the guide member 23 and the side surface side of the base material 2A is guided by the guide member 35. Has been.

Next, the rotation shaft 28 is rotated by the operation of the drive motor 26, and the first and second rotary cutters 33 and 34 and the rotary brush 36 are rotated in the rotation direction R. Further, the suction air flow is generated in the waste shooter 21 by the operation of the intake source. Moreover, the air is jetted obliquely downward from the first to third jet nozzles 38 to 40 by the operation of the air supply source. At this time, as shown in FIG. 5, the air jetted from the first jet nozzle 38 is applied to the outer surface side of the pile layer 3A before the cutting of the initial mat member 1A on the table 11, and the pile layer 3A stands upright. Aligned to state. Further, the air applied to the outer surface side of the pile layer 3 </ b> A before the cutting flows in the feeding direction S along the recovery passage 20. Furthermore, the air sprayed from the third spray nozzle 40 is applied to the outer surface side of the pile layer 3A after the initial mat member 1A on the table 11 is cut.
In addition, the air injected from the 2nd injection nozzle 39 is applied to the inner side part of the pile layer 3A.

  From the state described above, the initial mat member 1A is fed in the feeding direction by the feeding operation of the feed dog 16 and the operator's feeding operation. Then, the first rotating cutter 33 cuts the pile layer 3A provided at the end of the surface of the base material 2A in the pile layer 3A of the initial mat member 1A on the table 11, and the pile layer 3A is cut into the pile layer 3A. Part 6 is formed. Simultaneously with the cutting of the pile layer 3A, the back surface of the substrate 2A among the plurality of protrusions 4aA provided on the back surface of the back sheet layer 4A of the initial mat member 1A on the table 11 by the second rotating cutter 34. The protrusion 4aA provided at the end of the sheet is cut, and the cut portion 7 is formed in the back sheet layer 4A. Further, the rotary brush 36 separates the cutting waste cut by the first rotary cutter 33 and the pile waste gathered when the product shape is extracted from the carpet raw fabric from the end portion of the pile layer 3A.

  Then, as shown in FIG. 5, the cutting waste cut by the first and second rotary cutters 33 and 34, and the cutting waste and pile waste separated by the rotary brush 36 are jetted air from the first jet nozzle 38. Is collected by being driven into the waste shooter 21 through the recovery passage 20 along the airflow in the recovery passage 20. Further, the air sprayed from the third spray nozzle 40 is applied to the outer surface side of the pile layer 3A after cutting the initial mat member 1A on the table 11, and the debris remaining on the cut portion 6 of the pile layer 3A It is dropped into the waste shooter 21.

  In addition, although the above-mentioned effect | action demonstrated the form which cut | disconnects the pile layer 3A of the linear part of the peripheral part of the initial mat material 1A, the pile layer 3A of the corner part (R part) of the peripheral part of the initial mat material 1A is demonstrated. In the case of cutting, as shown in FIG. 6, the air sprayed from the second spray nozzle 39 is applied to the outer surface side of the pile layer 3A before cutting at the corner portion, and the pile layer 3A is aligned in an upright state. Is cut off.

  Thereafter, as shown in FIG. 9, sewing is performed on the peripheral portion of the initial mat member 1 </ b> A in which the cutting portions 6 and 7 are formed over the entire circumference by a known sewing device. That is, the initial mat member 1A placed on the table 50 is fed in the feeding direction by the operator's feeding operation together with the feed dog feeding operation. At this time, air is blown from the air nozzle 42 toward the end of the pile layer 3A of the initial mat member 1A in a direction substantially orthogonal to the feed direction, and the end of the pile layer 3A is aligned in an upright state. Further, the intermediate portion in the height direction of the pile layer 3 </ b> A to which air is blown is pressed by the presser plate 43. From this state, the sewing needle 44 is reciprocated from the front surface side to the back surface side of the base material 2A of the initial mat member 1A and sewn. Then, overlock stitching (edge stitching) is applied to the peripheral edge portion of the initial mat material 1A by the decorative yarn 8 and the sewing yarn 9, and both end portions on the front and back sides of the base material of the decorative yarn 8 as the covering portion are sewn. Connected with thread 9. Then, the above mat material 1 is obtained by performing overlock sewing on the entire periphery of the initial mat material 1A.

(4) Effects of the Example According to the mat material 1 of the present example, the pile layer 3 is provided with the cutting portion 6 formed by cutting the portion provided on the end portion of the surface of the base material 2, and the decorative yarn 8, Since the cut portion 6 of the pile layer 3, the side portion of the base material 2, and the end portion of the back surface side of the base material 2 are covered, it is possible to suppress the pile layer 3 from being caught inside the decorative yarn 8, It can suppress that the terminal part of the pile layer 3 is visible from the clearance gap between the decoration yarns 8. FIG. In particular, it is possible to use a single hook that has been used to hang two decorative yarns 8 (pitch yarns) in general, and it is possible to ensure a linear appearance without the decorative yarns 8 overlapping each other. Further, the basis weight of the pile layer 3 is 800 g / m ² or more, and the end portion of the pile layer 3 is formed in a fan shape so as to cover the upper end portion of the surface of the substrate 2. The decorative yarn 8 is difficult to see due to the end portion of the layer 3, and the peripheral portion of the mat material 1 can be integrated with the central portion of the mat material 1. As a result, the appearance of the product can be improved even when the basis weight of the pile layer 3 is large.

  In this embodiment, the back sheet layer 4 is further provided, and the decorative yarn 8 covers the end portion including the cut portion 6 of the pile layer 3, the side portion of the base material 2, and the cut portion 7 of the back sheet layer 4. Since it did in this way, it can suppress that the protrusion part 4a for slip prevention protrudes and is visible from the clearance gap between the decoration yarns 8. FIG.

  In this embodiment, since the height of the pile layer 3 is 10 mm or more, the end portion of the pile layer 3 is easily formed in a fan shape, and the peripheral portion of the mat member 1 is integrated with the central portion. Furthermore, it can be reliably provided.

  According to the mat material pre-processing apparatus 10 of the present embodiment, the first rotary cutter 33 is provided at the end of the surface of the base material 2 in the pile layer 3 of the initial mat material 1A placed on the table 11. Since the pile layer 3 to be cut is cut, the pre-processed initial mat material 1A is cut with the decorative yarn 8 by the cutting portion 6 of the pile layer 3, the side portion of the base material 2, and the end of the back surface side of the base material. If the portion is covered, the pile layer 3 can be prevented from being caught inside the decorative yarn 8, and the pile layer 3 can be suppressed from being seen through the gap of the decorative yarn 8. In particular, it is possible to use a single hook that has been used to hang two decorative yarns 8 (pitch yarns) in general, and it is possible to ensure a linear appearance without the decorative yarns 8 overlapping each other. Moreover, since the end part of the pile layer 3 can be formed in a fan shape so as to cover the upper part of the end part of the surface of the base material 2, the decorative yarn 8 is not easily seen by the end part of the pile layer 3, The unity with the central part can be provided. As a result, even when the weight of the pile layer 3 is large, the mat member 1 with improved appearance of the product can be provided.

  In the present embodiment, the second rotating cutter 34 cuts the protrusion 4a provided at the end of the back surface of the base member 2 among the plurality of protrusions 4a for preventing slipping. In the treated initial mat material 1A, if the decorative yarn 8 covers the end portion including the cut portion 6 of the pile layer 3, the side portion of the base material 2, and the cut portion 7 of the back sheet layer 4, the decorative yarn 8 It can suppress that the protrusion part 4a for slip prevention protrudes from the clearance gap, and it is visible.

  In the present embodiment, the pile layer 3A before cutting at the straight portion of the initial mat member 1A is aligned in an upright state by the air jetted from the first jet nozzle 38. The pile layer 3A can be cut more accurately. Further, since the pile layer 3A before cutting at the corner portion of the initial mat member 1A is aligned in an upright state by the air jetted from the second jet nozzle 39, the pile layer 3A is arranged by the first rotary cutter 33. Can be cut more accurately. That is, the pile layer 3A can be cut more accurately at the straight and corner portions of the entire peripheral edge of the initial mat member 1A.

  In this embodiment, the table 11 is provided with a recovery passage 20 extending along the feed direction S, and the jet air from the first and second injection nozzles 38 and 39 flows in the feed direction S along the recovery passage 20. Since it did in this way, the cutting waste cut | disconnected by the 1st and 2nd rotation cutters 33 and 34 can be collect | recovered via the collection | recovery channel | path 20, without being scattered around. In addition, since the cutting waste is collected by using the jet air of the first and second jet nozzles 38 and 39 having the function of aligning the pile layer 3A, it can be configured more simply and inexpensively.

  In the present embodiment, since the rotary brush 36 is provided at a position close to the first rotary cutter 33 of the rotary shaft 28, the cutting scraps cut by the first rotary cutter 33 by the rotary brush 36 are removed from the pile layer 3A. Can be forcibly separated from the end of each. In addition, the rotary brush 36 can forcibly separate pile scraps gathered when the product shape is extracted from the carpet original fabric from the end portion of the pile layer 3A. Do not need.

  In the present invention, the present invention is not limited to the above embodiment, and various modifications can be made within the scope of the present invention depending on the purpose and application. That is, in the above-described embodiment, the sewing thread 9 is moved to the side portion of the base material 2B using the sewing needle 44 that reciprocates in the direction orthogonal to the plane of the initial mat material 1A that has been pre-processed (cut processing) on the table 50. However, the present invention is not limited to this. For example, as shown by an imaginary line in FIG. 9, the sewing machine reciprocates in a direction that obliquely intersects the plane of the initial mat member 1B on the table 50. You may make it sew so that the sewing thread | yarn 9 may leave | separate from the side part of the base material 2B as it goes to the back surface side from the surface side of the base material 2B using the moving sewing needle 44 '.

  Further, in the present embodiment, the mat material 1 (initial mat material 1A) including the base material 2, the pile layer 3, and the back sheet layer 4 is exemplified, but the present invention is not limited thereto, and for example, the base material 2 and the pile layer 3 A mat material (initial mat material) may be used.

  It is suitably used as a vehicle floor mat.

It is a principal part front view of the pre-processing apparatus which concerns on an Example. It is a principal part expanded sectional view of FIG. FIG. 3 is an enlarged view of a main part of FIG. 2. It is IV arrow line view of FIG. FIG. 4 is a view taken in the direction of arrow V in FIG. FIG. 4 is a view taken in the direction of the arrow V in FIG. 3 (showing a state of cutting a pile layer at a corner portion). It is a longitudinal cross-sectional view of the initial mat material which concerns on an Example. It is explanatory drawing for demonstrating the cutting process of the said initial mat material. It is explanatory drawing for demonstrating the said sewing process of the initial mat material. It is a longitudinal cross-sectional view of the mat material which concerns on an Example. It is a perspective view of the mat material which concerns on an Example. It is a XII arrow line view of FIG. It is a perspective view of the conventional mat material. It is a perspective view of the conventional mat material.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1; Mat material, 1A; Initial mat material, 2, 2A; Base material, 3, 3A; Pile layer, 4, 4A; Back sheet layer, 4a, 4aA; Protrusion part, 6: Cutting part, 7: Cutting part, 8; decorative yarn, 10; pretreatment device, 11; table, 13; rotating cutter mechanism, 20; recovery passageway, 28; rotating shaft, 33; first rotating cutter, 34; second rotating cutter, 36; 38; 1st injection nozzle, 39; 2nd injection nozzle.

Claims (7)

A substrate;
A fibrous skin layer having a cut portion formed by cutting a portion provided on the entire surface of the base material and provided at a terminal portion of the surface of the base material;
An end protection means having a covering portion that covers a cut portion of the skin layer, a side portion of the base material, and a terminal portion on the back surface side of the base material;
The basis weight of the skin layer is 800 g / m ² or more, and the end portion of the skin layer is formed in a fan shape so as to cover the upper end portion of the surface of the base material ,
Provided on the entire back surface of the base material, and has a plurality of anti-slip protrusions, and further cuts the protrusion provided at the end of the back surface of the base material among the plurality of protrusions. Further comprising a back sheet layer having a cut portion formed by
The mat member according to claim 1, wherein the covering portion of the end protection means covers a terminal portion including a cut portion of the skin layer, a side portion of the base material, and a cut portion of the back sheet layer . The mat material according to claim 1 , wherein the skin layer has a height of 10 mm or more . A table on which an initial mat material provided with a fibrous skin layer over the entire surface of the substrate is placed;
Cutting means for cutting a skin layer provided at a terminal portion of the surface of the base material of the skin layer of the initial mat material placed on the table,
The initial mat member includes a back sheet layer provided on the entire back surface of the base material and having a plurality of anti-slip protrusions, and the cutting means is the initial mat placed on the table. A mat material pre-processing apparatus, characterized in that a projection provided at the end of the back surface of the base material among the plurality of projections of the material can be cut . A table on which an initial mat material provided with a fibrous skin layer over the entire surface of the substrate is placed;
Cutting means for cutting a skin layer provided at a terminal portion of the surface of the base material of the skin layer of the initial mat material placed on the table ,
The cutting means includes a rotary shaft that is rotatably provided around an axis that intersects the upper surface of the table, a rotary cutter that is provided on the rotary shaft and that cuts the skin layer, and is provided on the rotary shaft and that rotates. A mat material pretreatment device , comprising: a rotating brush that separates cutting waste cut by a cutter from an end portion of the skin layer . The mat material pre-processing apparatus according to claim 3 , further comprising air injection means for injecting air toward an outer surface side of the skin layer cut by the cutting means . The table is provided with a recovery passage for recovering the cutting waste cut by the cutting means, and the air injection means is configured such that air injected toward the outer surface side of the skin layer enters the recovery passage. 6. The mat material pre-processing apparatus according to claim 5, wherein the mat material pre-processing apparatus is arranged to flow along . Cutting the skin layer provided at the end portion of the surface of the base material of the initial mat material provided with a fibrous skin layer over the entire surface of the base material;
Covering the cut portion of the skin layer, the side portion of the base material, and the end portion of the back surface side of the base material by the covering portion of the end protection means,
The method for producing a mat material, wherein the step of cutting the skin layer is a step of cutting the skin layer using the mat material pretreatment device according to any one of claims 3 to 6 .

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