JP6991946B2 - How to manufacture vehicle floor mats and vehicle floor mats - Google Patents

Description

The present invention relates to a vehicle floor mat laid on a floor in a vehicle and a method for manufacturing the vehicle floor mat.

A floor mat is usually laid on the floor to prevent dirt on the occupant's shoes from adhering to the floor inside the vehicle. Since the so-called genuine floor mat is manufactured according to the shape of the floor of the vehicle for each vehicle type, it fits the shape of the floor without excess or deficiency when laid on the floor.

On the other hand, floor mats with versatility that are not suitable for a specific vehicle type are also generally on the market. When such a general-purpose floor mat is laid on the floor of a vehicle, it may not partially fit the shape of the unevenness of the floor. For example, if there is a convex part on the floor where the end of the floor mat is located, the floor mat will be bent and ride on the convex part, but due to the restoring force of the floor mat itself, the floor mat There may be a gap between the floor and the floor, or the floor mat may roll up.

In order to adapt to the shape of the floor in such a case, a trunk interior material is known in which a thermoplastic resin film is used for the floor mat, the floor mat is heated, and the floor mat is molded into a desired shape by a cold compression press (for example). , Patent Document 1).

Jikkenhei 3-20143 Gazette

However, in the trunk interior material described in Patent Document 1, it is necessary to laminate a thermoplastic resin film on both sides of a mat-like material including a portion that is not bent. As a result, the thermoplastic resin film used is wasted, resulting in an increase in manufacturing cost.

Therefore, the present invention solves the above problems and provides a vehicle floor mat in which a thermoplastic resin is arranged only in a portion necessary for maintaining a bent state, and a method for manufacturing the vehicle floor mat. The purpose.

The vehicle floor mat according to the present invention is a vehicle floor mat laid on the floor in the vehicle, and the vehicle floor mat is integrated by laminating a plurality of sheet-like members and adhering them with an adhesive. It has a bent portion that is bent according to the shape of the uneven portion of the floor portion, and the thermoplastic resin is applied only to the bent portion of the lowermost layer sheet portion that is the sheet-like member of the lowermost layer. It is characterized by being impregnated.

The vehicle floor mat according to the present invention has an uneven laying portion that abuts on the uneven portion, and when the bent shape of the bent portion is arcuate, the uneven laying portion is also impregnated with the thermoplastic resin. It is characterized by being done.

The vehicle floor mat according to the present invention is a vehicle floor mat laid on the floor in the vehicle, and the vehicle floor mat is integrated by laminating a plurality of sheet-like members and adhering them with an adhesive. The bottom layer sheet portion , which is a sheet-like member of the bottom layer, has a bent portion that is bent according to the shape of the uneven portion of the floor portion and an uneven laying portion that abuts on the uneven portion. It is characterized in that the thermoplastic resin is impregnated only in the bent portion and the uneven laying portion.

The vehicle floor mat according to the present invention is characterized in that the melting point of the thermoplastic resin is lower than the temperature at which the adhesive is peeled off.

The vehicle floor mat according to the present invention is characterized in that the lowermost layer seat portion is formed of a non-woven fabric.

The method for manufacturing a floor mat for a vehicle according to the present invention includes a step of adhering the plurality of sheet-shaped members, a step of impregnating the lowermost layer sheet portion with the thermoplastic resin, and a state in which the floor mat for a vehicle is bent. It is characterized by having a step of heating the thermoplastic resin and a step of cooling the heated thermoplastic resin in a state where the floor mat for a vehicle is bent.

The method for manufacturing a floor mat for a vehicle according to the present invention is a method for manufacturing a floor mat for a vehicle laid on the floor in a vehicle, in which a plurality of sheet-like members are laminated and bonded with an adhesive to be integrated. And the step of impregnating only the bent portion of the lowermost layer sheet portion, which is the sheet-like member of the lowermost layer, which is bent corresponding to the shape of the uneven portion of the floor portion, with the thermoplastic resin, and the vehicle. It is characterized by having a step of heating the thermoplastic resin in a bent state of the floor mat for vehicles and a step of cooling the heated plastic resin in a state of bending the floor mat for vehicles.

The method for manufacturing a floor mat for a vehicle according to the present invention is a method for manufacturing a floor mat for a vehicle laid on the floor in a vehicle, in which a plurality of sheet-like members are laminated and bonded with an adhesive to be integrated. Heat is applied only to the bent portion of the lowermost sheet portion, which is the sheet-like member of the lowermost layer, which is bent according to the shape of the uneven portion of the floor portion, and the uneven laying portion which abuts on the uneven portion. A step of impregnating the plastic resin, a step of heating the thermoplastic resin with the vehicle floor mat bent, and a step of cooling the heated resin with the vehicle floor mat bent. It is characterized by having.

According to the vehicle floor mat according to the present invention, it can be laid in a bent state according to the shape of the uneven portion of the floor portion in the vehicle. Further, according to the method for manufacturing a floor mat for a vehicle according to the present invention, it is possible to manufacture a floor mat for a vehicle that can be laid in a bent state according to the shape of the uneven portion of the floor portion in the vehicle. ..

It is a perspective view of the floor mat for a vehicle laid on the floor part in the vehicle which shows Example 1 of this invention. The same is a perspective view showing the inside of the vehicle with the floor mat for the vehicle removed. It is a vertical sectional view of a part of the floor mat for a vehicle. It is the bottom view of the floor mat for a vehicle.

Hereinafter, examples of the present invention will be described with reference to FIGS. 1 to 4 attached to the invention. The examples described below do not limit the content of the invention described in the claims. Moreover, not all of the configurations described below are essential requirements of the present invention.

1 to 4 show the first embodiment of the present invention, and as shown in FIG. 1, the vehicle floor mat 1 is laid on the floor portion 3 below the driver's seat (not shown) of the vehicle 2. It is a thing. In FIGS. 1 and 2, 4 is an accelerator pedal, 5 is a brake pedal, and 6 is a footrest.

As shown in FIG. 3, the vehicle floor mat 1 has a three-layer structure of a first layer portion 11 which is a sheet-shaped member, a second layer portion 12 which is also a sheet-shaped member, and a third layer portion 13. .. The first layer portion 11 is formed of a non-woven fabric sheet, the second layer portion 12 is formed of a polyester sheet, and the third layer portion 13 is formed of a pile yarn made of polypropylene (PP) or nylon. .. The first layer portion 11, the second layer portion 12, and the third layer portion 13 are not limited to these members and may be formed of other materials.

The first layer portion 11 which is the lowest layer sheet portion is a non-woven fabric whose constituent fibers are one or more selected from, for example, polyolefin fibers, polyester fibers, polyamide fibers, acrylic fibers, and polyvinyl alcohol fibers. Sheets can be used.

The second layer portion 12 is laminated on the upper side of the first layer portion 11, and the pile yarn which is the third layer portion 13 is planted in the second layer portion 12. The first layer portion 11 and the second layer portion 12 are adhered to each other by the adhesive 14. The adhesive 14 also has the effect of fixing the pile yarn, which is the third layer portion 13, to the second layer portion 12.

As the adhesive 14, among organic adhesives, thermoplastic resin-based adhesives, thermosetting resin-based adhesives, or elastomer-based adhesives can be used. As the form of the adhesive 14, hot melt type, emulsion type, latex type, water type, and solution type can be used. As the adhesive 14, the adhesive having a peeling temperature higher than the melting point of the thermoplastic resin 15 described later is used.

The peripheral edge portion 16 of the vehicle floor mat 1 of this embodiment is piped with a bias tape 17 to prevent unraveling, but other processing such as overlock processing may be performed instead of piping. The vehicle floor mat 1 has a front surface 22 on the third layer 13 side and a back surface 23 on the first layer 11 side.

As shown in FIG. 2, the floor portion 3 in the vehicle 2 of the present embodiment is flat with a flat floor portion 31 which is a flat portion and a convex convex step portion 32 formed on the front side of the flat floor portion 31. It has a concave concave step 33 formed on the left rear side of the floor 31. Further, a convex footrest 6 is arranged on the left front side of the flat floor portion 31. The vehicle floor mat 1 is laid on the flat floor portion 31, the inclined portion 34 of the convex step portion 32, the concave step portion 33, and the foot rest portion 35 of the footrest 6.

When the floor mat 1 for a vehicle is laid on the floor portion 3, the boundary B1 between the flat floor portion 31 and the convex step portion 32, the boundary B2 between the flat floor portion 31 and the concave step portion 33, and the flat floor portion 31 It is bent at the boundary B3 with the footrest 6. Therefore, as shown in FIGS. 1 and 4, the vehicle floor mat 1 of this embodiment has three bent portions R1, R2, and R3. In this embodiment, the convex step portion 32, the concave step portion 33, and the footrest 6 are the uneven portions of the present invention.

As shown in FIGS. 1 and 4, the vehicle floor mat 1 is laid on the flat laying portion 18 laid on the flat floor portion 31, the convex laying portion 19 laid on the inclined portion 34, and the concave step portion 33. It has a concave laying portion 20 to be laid and a convex laying portion 21 laid on the foot resting portion 35. The convex laying portion 19, the concave laying portion 20, and the convex laying portion 21 are the uneven laying portions of the present invention.

As shown in FIG. 4, the bent portions R1, R2, and R3 of the first layer portion 11 are impregnated with the thermoplastic resin 15. The thermoplastic resin 15 may be impregnated into the first layer portion 11 before the first layer portion 11 and the second layer portion 12 are bonded by the adhesive 14 in the manufacturing stage of the vehicle floor mat 1. After manufacturing the vehicle floor mat 1, the first layer portion 11 may be impregnated from the back surface 22 side of the vehicle floor mat 1. Further, by impregnating not only the bent portions R1, R2, R3 but also the peripheral portions S1, S2, S3 with the thermoplastic resin 15, the effect of maintaining the vehicle floor mat 1 in a bent state is enhanced. Can be done.

When the bent shape is an arc shape or the like that is difficult to bend like the bent portion R2, the concave laying portion 20 is impregnated with the thermoplastic resin 15 in addition to the bent portion R2 and the peripheral portion S2. Therefore, the effect of maintaining the vehicle floor mat 1 in a bent state can be enhanced.

Although not particularly limited, as the thermoplastic resin 15, for example, a thermoplastic resin such as polyethylene, polystyrene, or polyamide can be used, but the melting point of the thermoplastic resin 15 is the first layer portion 11 and the second layer portion 12. And the temperature is lower than the temperature at which the adhesive 14 adhering the third layer portion 13 is peeled off. Therefore, the combination of the adhesive 14 and the thermoplastic resin 15 is selected in consideration of the peeling temperature of the adhesive 14 and the melting point of the thermoplastic resin 15.

Here, a method for manufacturing the floor mat 1 for a vehicle will be described. First, the first layer portion 11 and the second layer portion 12 are cut into desired shapes. The shape (outer shape) of the floor mat 1 for a vehicle is such that the first layer portion 11 and the second layer portion 12 are cut according to the shape of the floor portion 3, but the versatility that can be applied to a plurality of vehicle types is provided. It may be cut into a shape to have. Then, the third layer portion 13 is implanted in the second layer portion 12 (tufting). Next, the first layer portion 11 and the second layer portion 12 are bonded with the adhesive 14. Next, the thermoplastic resin 15 melted and liquefied is applied to the bent portions R1, R2, R3, the peripheral portions S1, S2, S3, and the concave laying portion 20 of the first layer portion 11 which is the back surface 22 of the vehicle floor mat 1. Impregnate. The range of impregnating the thermoplastic resin 15 is only the bent portions R1, R2, R3, the bent portions R1, R2, R3 and the peripheral portions S1, S2, S3, and the bent portions R1, R2, R3. Peripheral portion S2 and the like can be appropriately selected. Next, the floor mat 1 for a vehicle is heated to a temperature at which the thermoplastic resin 15 softens or melts, and the bent portions R1, R2, and R3 are formed on the convex step portion 32, the concave step portion 33, and the footrest 6 of the floor portion 3. Bend and press to fit. The thermoplastic resin 15 heated in a state where the bent portions R1, R2, and R3 of the vehicle floor mat 1 are bent is cooled. As a result, the thermoplastic resin 15 is solidified, and the bent portions R1, R2, and R3 are maintained in a bent state. Therefore, the floor mat 1 for a vehicle can be laid by abutting the convex step portion 32, the concave step portion 33, and the footrest 6 of the floor portion 3 without a gap. In this embodiment, the floor mat 1 for vehicles was pressed when it was bent, but if the thermoplastic resin 15 can be heated and cooled in the bent state and the bent state can be maintained, it is necessary to press using a press machine or the like. There is no.

As another method for allowing the vehicle floor mat 1 to be laid corresponding to the convex step portion 32, the concave step portion 33 and the footrest 6, the folding of the third layer portion 13 side which is the surface 22 of the vehicle floor mat 1 By heating the bent portions R1, R2 and R3, only the third layer portion 13 or the second layer portion 12 and the third layer portion 13 are partially melted or softened, and the pile yarns of the bent portions R1, R2 and R3 are formed. By shrinking, etc., it may be possible to bend it so as to fit the convex step portion 32, the concave step portion 33, and the footrest 6.

As described above, the vehicle floor mat 1 of the present embodiment is the vehicle floor mat 1 laid on the floor portion 3 in the vehicle 2, and the vehicle floor mat 1 is the first layer portion 11 and the first layer portion 11. The two-layered portion 12 is laminated and bonded and integrated with the adhesive 14, and the bent portion R1 is bent according to the shapes of the convex step portion 32, the concave step portion 33 and the footrest 6 of the floor portion 3. By impregnating the bent portions R1, R2 and R3 of the first layer portion 11 which has R2 and R3 and is the lowermost sheet-like member with the thermoplastic resin 15, the floor portion 3 in the vehicle 2 The bent portions R1, R2, and R3 can be maintained in a bent state according to the shape, and the floor mat 1 for a vehicle can be laid in contact with the floor portion 3 neatly.

Further, the vehicle floor mat 1 of the present embodiment has a convex laying portion 32, a concave step portion 33, and a convex laying portion 19 that abuts on the concave step portion 33 and the footrest 6, a concave laying portion 20 and a convex laying portion 21. Since the convex laying portion 19, the concave laying portion 20 and the convex laying portion 21 of the first layer 11 are impregnated with the thermoplastic resin 15, the convex laying portion 32, the concave laying portion 33 and the footrest 6 are more reliably fitted. The vehicle floor mat 1 can be maintained in a bent state.

Further, in the vehicle floor mat 1 of the present embodiment, the melting point of the thermoplastic resin 15 is lower than the temperature at which the adhesive 14 is peeled off, so that the vehicle floor mat 1 reaches a temperature at which the thermoplastic resin 15 is softened or melted. It is possible to prevent the adhesive 14 adhering the first layer portion 11, the second layer portion 12, and the third layer portion 13 from peeling off even when the first layer portion 11, the second layer portion 12, and the third layer portion 13 are heated.

Further, in the vehicle floor mat 1 of this embodiment, since the first layer portion 11 is made of a non-woven fabric, the thermoplastic resin 15 can be easily impregnated.

Further, the method for manufacturing the vehicle floor mat 1 of the present embodiment includes a step of adhering the first layer portion 11 and the second layer portion 12, a step of impregnating the first layer portion 11 with the thermoplastic resin 15, and a vehicle. By having a step of heating the thermoplastic resin 15 in a bent state of the floor mat 1 for a vehicle and a step of cooling the heated thermoplastic resin 15 in a state of bending the floor mat 1 for a vehicle, the inside of the vehicle 2 is provided. It is possible to manufacture a floor mat 1 for a vehicle that can be laid in accordance with the convex step portion 32, the concave step portion 33, and the footrest 6 of the floor portion 3.

The present invention is not limited to the above embodiment, and various modifications can be made within the scope of the gist of the present invention. For example, the number of laminated sheet-like members constituting the floor mat for a vehicle can be appropriately changed. Further, the floor mat for a vehicle may be for a passenger seat, a second row seat, or a third row seat.

1 Floor mat for vehicle 2 Vehicle 3 Floor part 6 Footrest (uneven part)
11 First layer (sheet-like member, lowest layer sheet)
12 Second layer part (sheet-like member)
13 Third layer part 14 Adhesive 15 Thermoplastic resin 19 Convex laying part (concave and convex laying part)
20 Concave laying part (uneven laying part)
21 Convex laying part (concave and convex laying part)
32 Convex step part (concavo-convex part)
33 Concave part (uneven part)
R1 folding part R2 folding part R3 folding part

Claims (8)

A vehicle floor mat laid on the floor inside a vehicle.
The vehicle floor mat is made by laminating a plurality of sheet-shaped members and adhering them with an adhesive to integrate them.
It has a bent portion that is bent according to the shape of the uneven portion of the floor portion.
A floor mat for a vehicle, characterized in that a thermoplastic resin is impregnated only in the bent portion of the lowermost layer sheet portion, which is the sheet-like member of the lowermost layer. It has an uneven laying portion that comes into contact with the uneven portion, and has an uneven laying portion.
The floor mat for a vehicle according to claim 1, wherein when the bent shape of the bent portion is an arc shape, the uneven laying portion is also impregnated with the thermoplastic resin. A vehicle floor mat laid on the floor inside a vehicle.
The vehicle floor mat is made by laminating a plurality of sheet-shaped members and adhering them with an adhesive to integrate them.
It has a bent portion that bends according to the shape of the uneven portion of the floor portion and an uneven laying portion that abuts on the uneven portion.
A floor mat for a vehicle , characterized in that a thermoplastic resin is impregnated only in the bent portion and the uneven laying portion of the lowermost layer sheet portion, which is the lowermost sheet-like member . The floor mat for a vehicle according to any one of claims 1 to 3 , wherein the melting point of the thermoplastic resin is lower than the temperature at which the adhesive is peeled off. The vehicle floor mat according to any one of claims 1 to 4 , wherein the lowermost layer seat portion is formed of a non-woven fabric. The process of adhering the plurality of sheet-like members and
The step of impregnating the lowermost layer sheet portion with the thermoplastic resin, and
The step of heating the thermoplastic resin in a state where the floor mat for a vehicle is bent, and
The method for manufacturing a vehicle floor mat according to any one of claims 1 to 5 , further comprising a step of cooling the thermoplastic resin heated in a bent state. It is a method of manufacturing a floor mat for vehicles to be laid on the floor inside the vehicle.
The process of laminating multiple sheet-shaped members and adhering them with an adhesive to integrate them.
A step of impregnating only the bent portion of the lowermost layer sheet portion, which is the sheet-like member of the lowermost layer, which is bent corresponding to the shape of the uneven portion of the floor portion, with the thermoplastic resin.
The step of heating the thermoplastic resin in a state where the floor mat for a vehicle is bent, and
A method for manufacturing a vehicle floor mat, which comprises a step of cooling the thermoplastic resin heated in a bent state of the vehicle floor mat. It is a method of manufacturing a floor mat for vehicles to be laid on the floor inside the vehicle.
The process of laminating multiple sheet-shaped members and adhering them with an adhesive to integrate them.
The bottom layer sheet portion, which is the sheet-like member of the bottom layer, is impregnated with the thermoplastic resin only in the bent portion that is bent according to the shape of the uneven portion of the floor portion and the uneven laying portion that abuts on the uneven portion. And the process of making
The step of heating the thermoplastic resin in a state where the floor mat for a vehicle is bent, and
A method for manufacturing a vehicle floor mat, which comprises a step of cooling the thermoplastic resin heated in a bent state of the vehicle floor mat.

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