JP7634355B2 - Vehicle floor installation structure - Google Patents

Description

The present invention relates to a vehicle floor installation structure, and in particular to a vehicle floor installation structure on which a carpet is laid on the floor surface.

In general, in vehicles such as automobiles, fiber floor carpets such as tufted carpets and needle punch carpets are used as floor carpets laid on the floor surface inside the vehicle. These are formed three-dimensionally by, for example, heating a carpet roll with a thermoplastic resin backing (laminated) on the back side and press-molding it to a shape that conforms to the floor shape. On the other hand, resin floor carpets made only of resin are used in products with a nearly flat shape such as floor carpets and floor mats (accessory mats, piece mats, option mats) formed by vacuum molding, but there are no examples of floor carpets that are laid on the floor surface inside the vehicle and formed by injection molding to have a three-dimensional shape that conforms to the unevenness of the floor surface. For example, Patent Document 1 discloses a resin floor carpet. By laying these floor carpets on the floor surface, it is expected that the floor surface of the vehicle will be protected and the design and comfort of the floor will be improved.

The floor surface of a vehicle has unevenness due to the physical structure of the vehicle. Therefore, if a floor carpet is laid on the floor surface, when the vehicle occupants step on the floor carpet, the floor carpet will conform to the unevenness of the floor surface and become deformed or so-called bumpy, which will make it uncomfortable to step on, reduce safety and comfort, and significantly reduce marketability.

Therefore, it is conceivable that, even if the floor surface is uneven, the loss of safety and comfort as described above can be avoided by placing molded urethane foam of different thicknesses between the vehicle floor and the floor carpet, by placing felt layers of different thicknesses between the vehicle floor and the floor carpet, or by overlapping flat felt on the back side of the floor carpet.

JP 2001-315562 A

However, it is preferable to provide vehicles with functional parts such as heel pads to prevent wear on the floor surface and hooks for attaching equipment mats, but in that case, there is a problem that the manufacturing cost of the entire vehicle, the labor hours for assembling the parts, and the management labor hours increase.

As mentioned above, when a resin molded body such as urethane foam is interposed between the floor surface of the vehicle and the floor carpet, a resin molded body such as urethane foam having a thickness corresponding to the unevenness must be prepared for each area where the unevenness exists. This requires dedicated equipment for preparing resin molded bodies such as urethane foam, and the quality control and process become complicated, which is one of the causes of increased costs. In addition, when a felt layer having a partially different thickness and/or a partially different basis weight is interposed between the floor surface of the vehicle and the floor carpet, or when flat felt, chip urethane molded products, foam bead molded products, etc. are layered on the back surface of the floor carpet, a felt layer having a thickness corresponding to the unevenness must be prepared for each area where the unevenness exists on the floor surface, and the number of flat felt layers must be adjusted. Therefore, in this case as well, the quality control and process become complicated, and it is feared that this will be one of the causes of increased costs.

The present invention was made in consideration of the problems with the conventional technology described above, and aims to provide a vehicle floor installation structure that can reduce manufacturing costs and labor, and that can clean and disinfect more easily and reliably.

In order to achieve the above object, the present invention provides
A floor installation structure for a vehicle having a floor surface with projections and recesses and having functional parts installed or extended on the floor surface, comprising:
A resin carpet is formed by injection molding and laid on the floor surface,
At least a portion of the functional component is integrated into the carpet.

In the present invention configured as described above, the carpet is made of resin, which allows cleaning and sterilization to be performed more easily and reliably, improving cleaning properties, stain resistance, and a clean feeling. This is particularly suitable for vehicles with frequent occupant changes, such as shared cars, taxis, and commercial vehicles, because cleaning and sterilization can be performed more easily and reliably. In addition, at least a portion of the functional parts installed or extended on the floor surface as the functional parts of the present invention are integrated into the carpet, which reduces the number of parts, thereby reducing manufacturing costs, labor hours for part assembly, and management labor hours, and also reduces the mold investment costs for the entire vehicle.

In addition, if the carpet has a height adjustment member on the surface facing the floor that corresponds to the unevenness and that creates the required space at that height, the height adjustment member constitutes a functional part or a part of the functional part, and the carpet achieves the height from the floor surface by the height adjustment member, when the carpet is laid on a floor surface with unevenness, the carpet will not feel uncomfortable when the vehicle occupant steps on it, and safety and comfort will not be compromised. In this way, with a simple configuration in which a height adjustment member that has a height corresponding to the unevenness is provided on the surface of the carpet facing the floor surface, it is possible to avoid the safety and comfort being compromised according to the unevenness present on the floor surface. In addition, by creating the required space by the height adjustment member, conventional resin molded bodies such as urethane foam and felt layers are replaced with structures that contain many spaces, which is expected to reduce weight, and a double wall is formed, which is expected to improve sound absorption and sound insulation. Furthermore, even if the functional part integrated with the carpet has a predetermined height from the floor surface, it is not necessary to use a separate part to achieve that height. In addition, the height adjustment members create a floor-laying structure with space inside, which not only reduces weight, but also provides insulation and sound absorption, and the space created provides insulation.

Furthermore, if felt or other cushioning material is placed between the floor surface and the carpet, or in at least part of the space inside the carpet, the sound-absorbing and cushioning properties of the felt or other cushioning material can provide quietness inside the vehicle and a carpet that is comfortable to walk on, which is equal to or better than conventional performance.

In addition, if a resin material is applied to the top or bottom surface of the felt, it is possible to provide the necessary amount of sound insulation in the required areas.

In addition, if the number, thickness or diameter of the height adjustment members are set according to the position of the vehicle, the comfort can be adjusted to the required level at any time by adjusting them to the optimum value according to the vehicle requirements and location. For example, if the number, thickness or diameter of the height adjustment members in the area corresponding to the passenger's riding position of the vehicle is larger than in other areas, the comfort of the carpet will be improved.

In addition, if the floor surface is provided with an engaging member that engages with a vehicle part installed inside the vehicle, the floor installation structure can be configured so that a hole that exposes part of the engaging member is opened in the area facing the engaging member, and the opening edge of the hole has a canopy that covers part of the engaging member, allowing the vehicle part to engage with the engaging member without looking bad or causing tripping.

According to the present invention, because the carpet is made of resin, cleaning and disinfection can be performed more easily and reliably, improving cleaning properties, stain resistance, and a clean feeling. In addition, by integrating at least a portion of the functional parts installed or extended on the floor surface into the carpet, the number of parts can be reduced, which reduces manufacturing costs, labor hours for part assembly, and management labor hours, and also reduces mold investment costs for the entire vehicle.

In addition, a height adjustment member is provided on the surface of the carpet facing the floor surface, which has a height corresponding to the unevenness present on the floor surface and creates the required space at that height, and the height adjustment member constitutes a functional part or a part of a functional part, and the carpet achieves the height from the floor surface by the height adjustment member, so that a configuration that does not impair safety or comfort can be realized with a simple configuration even when the carpet is laid on a floor surface with unevenness. In addition, by creating the required space using the height adjustment member, conventional resin molded bodies such as urethane foam and felt layers are replaced with structures containing many spaces, and weight reduction can be expected, and a double wall is formed, and the effect of improving sound absorption and sound insulation can be expected. Furthermore, even if the functional part integrated with the carpet has a predetermined height from the floor surface, the height of the functional part can be realized without using a separate part. In addition, the height adjustment member creates a floor laying structure with an internal space, so weight reduction can be achieved, insulation and sound absorption properties can be imparted, and insulation can also be imparted due to the effect of the created space.

In addition, when felt or other cushioning material is placed between the floor surface and the carpet, or in at least part of the space inside the carpet, the sound-absorbing and cushioning properties of the felt or other cushioning material can achieve quietness inside the vehicle and carpet comfort equal to or better than conventional performance.

In addition, when a resin material is applied to the top or bottom surface of the felt, sound insulation can be provided in the required areas.

In addition, in cases where the number, thickness or diameter of height adjustment members are set according to the position of the vehicle, the comfort can be adjusted to the required level at any time by adjusting to the optimum value according to the vehicle requirements and location. For example, if the number, thickness or diameter of height adjustment members in the area corresponding to the passenger's riding position of the vehicle is larger than in other areas, the comfort of the carpet can be improved.

In addition, when an engaging member that engages with a vehicle part installed inside the vehicle is provided on the floor surface, if the floor installation structure has a hole that exposes part of the engaging member in the area facing the engaging member and has a canopy on the opening edge of the hole that covers part of the engaging member, it is possible to realize a configuration in which the vehicle part can be engaged with the engaging member without spoiling the appearance or causing tripping.

1 is a diagram showing an example of a vehicle in which the floor laying structure of the present invention is used. FIG. 2 is a diagram showing the configuration of the feet of the driver's seat and the passenger seat among the three rows of seats of the vehicle shown in FIG. 1 . 3A and 3B are diagrams showing the A-A' cross section of the floor laying structure shown in FIG. 2, in which (a) shows a conventional structure and (b) shows the structure of the present invention. FIG. 2 is a diagram showing the configuration of a foot space of a second seat among the three rows of seats of the vehicle shown in FIG. 1 . 5A and 5B are diagrams showing the A-A' cross section of the floor installation structure shown in FIG. 4, in which (a) shows a conventional structure, and (b) shows the structure of the present invention. FIG. 2 is a diagram showing a so-called foot pool area in the vehicle shown in FIG. 1 where a vehicle occupant steps on the carpet with their feet.

Below, an embodiment of the present invention will be described with reference to the drawings.

Figure 1 shows an example of a vehicle in which the floor installation structure of the present invention is used.

As shown in FIG. 1, in a vehicle 1 in which the floor installation structure of the present invention is used, seats 4 are installed on the floor surface 2 inside the vehicle, and a carpet 3 is laid down. In this embodiment, the seats 4 are arranged in three rows, and a configuration in which the second and third seats of the three rows of seats 4 can slide back and forth will be described as an example.

In the vehicle floor installation structure of the present invention, the carpet 3 laid on the floor surface 2 has a shape different from that of conventional carpets. Below, the configuration of the carpet 3 at the feet of the driver's seat and passenger seat among the three rows of seats 4, and the configuration of the carpet 3 at the feet of the second seat among the three rows of seats 4 will be described.

Figure 2 shows the configuration of the foot space of the driver's seat and passenger seat among the three rows of seats 4 of the vehicle 1 shown in Figure 1.

As shown in FIG. 2, at the foot of the driver's seat and the passenger seat of the three rows of seats 4 of the vehicle 1 shown in FIG. 1, a tunnel-shaped protrusion 11 for installing a center console between the driver's seat and the passenger seat, or for arranging a drive shaft in the case of a rear-wheel drive vehicle, protrudes toward the inside of the vehicle. In addition, a floor mat fixing device 14 for fixing a floor mat placed on the carpet protrudes toward the inside of the vehicle, and a side step 13 made of resin is installed on a side sill 12 extending from the floor surface 2 and located directly below the door. In addition, a VIN lid 15 for checking the VIN (vehicle identification number) engraved on the floor surface 2, etc. is provided at the driver's seat, and a heel pad 16 is provided in the area that comes into contact with the heel when the driver steps on the accelerator pedal (not shown). In addition, a protrusion 17 (see FIG. 3) exists on the floor surface 2 to avoid interference with parts (not shown) installed under the floor surface 2.

Figure 3 shows the A-A' cross section of the floor installation structure shown in Figure 2, where (a) shows the conventional structure and (b) shows the structure of the present invention.

When placing the carpet 3 on the area having the above-mentioned configuration as shown in FIG. 1, conventionally, as shown in FIG. 3(a), a fiber-based carpet 103 is placed on the floor surface 2. Here, the carpet 103 is formed by cutting a roll (fiber structure) which is a flat material in which fiber layers and backing resin layers are laminated, to a fixed length and press-molding it, so it is difficult to mold it into a shape that perfectly matches the shape of the floor surface. For example, since it is flat, if there are convex parts 17 on the floor surface 2, when the occupant of the vehicle 1 steps on the carpet 103 with his/her foot, the carpet 103 follows the unevenness caused by the convex parts 17 on the floor surface, and is deformed or so-called bumpy, which makes it difficult to step on. Therefore, between the floor surface 2 and the carpet 103, urethane foam 106 molded from urethane is interposed with different thicknesses, or a floor spacer or floor silencer (functional part) made of separately molded felt or foam is interposed. In addition, a shock absorbing material called a tibia pad, which is made by heating and foaming foaming resin particles, is also used. The floor mat fixing device 14 and the VIN lid 15 are attached so that they are exposed from holes provided in the carpet 103. The side step 13 is also provided with an integrated rib on the back surface, which realizes the height of the surface of the side step 13 from the side sill 12. Furthermore, a harness protector 18 is provided on the side sill 12. The harness protector 18 is configured, for example, by forming a space between the side sill 12 and the carpet 103 using a rib or the like to house the harness.

In contrast, in the floor installation structure of this embodiment, as shown in FIG. 3(b), a resin carpet 203 is placed on the floor surface 2. A rib 208 serving as a height adjustment member is provided on the back surface of the carpet 203 in an area not facing the tunnel-shaped convex portion 11. The height of the rib 208 differs between the area facing the convex portion 17 and the other areas at the driver's foot and the passenger's foot. The height of the rib 208 in the area facing the convex portion 17 is a value obtained by subtracting the protruding height of the convex portion 17 from the height of the rib in the other areas. In addition, the carpet 203 is integrated with a floor mat fixing device 214, a VIN lid 215, a side step 213, and a heel pad 16 (FIG. 2). This is realized by manufacturing the carpet 203 by injection molding of resin. The side step 213 needs to be installed so that its surface has a predetermined height from the side sill 12. The carpet 203 also has a rib 208 on its back surface in the area facing the side sill 12, and the height of the rib 208 corresponds to the height of the surface of the side step 213 from the side sill 12. This allows the side step 213 to have a predetermined height from the side sill 12. The floor mat fixing device 214 and the VIN lid 215 also achieve the required height by the height of the rib 208 on the back surface of the carpet 203. On the side sill 13, the rib 208 creates a space between the side sill 13 and the area of the carpet 203 that will become the side step 213, and this space forms the harness protector 218. Felt 207 is interposed between the carpet 203 and the floor surface 2, which is configured in this way.

In this embodiment, the rib 208 having a height corresponding to the unevenness present on the floor surface 2 of the carpet 203 laid on the floor surface 2 of the vehicle 1 is provided on the surface facing the floor surface 2, and the carpet 203 expresses the necessary space at the height of the rib 208. As a result, when the carpet 203 is laid on the floor surface 2 with unevenness, the occupant of the vehicle does not feel uncomfortable when stepping on the carpet 203 with his/her feet, and safety and comfort are not impaired. In this case, with the simple configuration in which the rib 208 having a height corresponding to the unevenness is provided on the surface facing the floor surface of the carpet 203, it is possible to avoid the safety and comfort being impaired according to the unevenness present on the floor surface 2 without making the urethane foam 106 or stacking felt so that the thickness varies from area to area. In addition, since the carpet 203 is made of resin, cleaning and sterilization can be performed more easily and reliably, improving cleaning ability and cleanliness. In addition, the ribs 208 create the necessary space, forming a double wall, improving sound absorption and sound insulation, and reducing weight. In this case, the carpet 203 does not have any holes for fixing the carpet 203 to the floor surface or for ensuring breathability, so sound leakage can be prevented as much as possible, resulting in excellent sound insulation. In addition, the floor mat fixing device 214 and the VIN lid 215, which are functional parts installed on the floor surface 2, and the side step 213, which is a functional part extended from the floor surface 2, are integrated into the carpet 203, reducing the number of parts, thereby reducing manufacturing costs, labor hours for assembling parts, and management labor hours, and reducing the mold investment cost for the entire vehicle.

In addition, the height of the ribs 208 of the carpet 203 determines the height of the surface of the side step 213 from the side sill 12 and the height of the floor mat fixture 214 and VIN lid 215 from the floor surface 2, so there is no need to use separate parts to achieve the height of the side step 213, floor mat fixture 214, or VIN lid 215.

In addition, by interposing the felt 207 between the floor surface 2 and the carpet 203, the sound absorbing and cushioning properties of the felt 207 allow the felt 207 to act as a silencer or cushion, improving the quietness inside the vehicle and the comfort of the carpet 203. The felt 207 does not need to be interposed over the entire surface between the floor surface 2 and the carpet 203, and the above effect can be obtained if it is interposed at least partially. Furthermore, the felt 207 may be inserted into the space inside the carpet 203, rather than between the floor surface 2 and the carpet 203. However, unlike the conventional urethane foam 106, the felt 207 can be interposed in a narrow area, and can be easily interposed over the entire surface between the carpet 203 and the floor surface 2, so that effective improvement in sound absorbing properties and quietness can be expected. In terms of quietness, a sound absorbing effect due to Helmholtz resonance is expected not only by the felt 207 but also by the closed space formed between the area between the ribs 208 of the carpet 203 and the felt 207. In addition, the closed space formed between the area between the ribs 208 of the carpet 203 and the felt 207 can provide weight reduction and heat insulation effects. Furthermore, there is no need to use different weights and different plate thicknesses to adjust the height and comfort for each part as in the conventional technology, and performance can be specialized to satisfy, for example, the minimum required cushioning and quietness. For example, it is possible to use a simple felt with a constant weight and flat plate thickness. Furthermore, by placing felt 207 between floor surface 2 and carpet 203, not only can noise caused by interference between floor surface 2 and carpet 203 be prevented, but various components installed in the vehicle, such as cooling ducts and harnesses for various electrical components, can be laid on this felt, which plays an important role in eliminating the nonwoven fabric, protectors, and cushioning materials that are conventionally attached to these components for the purpose of preventing noise. In addition, functional components that have the function of positioning and holding these components may be integrated into the floor carpet. For example, the rib shape and the distance between the ribs can be designed to accommodate harnesses.

Furthermore, a resin material may be applied by providing a resin packing on the entire upper or lower surface of the felt 207, by partially attaching a resin sheet, or by providing a resin-coated portion. In this case, sound insulation can be improved.

Figure 4 is a diagram showing the configuration of the foot space of the second seat, one of the three rows of seats 4 of the vehicle 1 shown in Figure 1. Note that what is shown in Figure 4 shows the configuration of a vehicle 1 with a typical three-row seat configuration, and therefore does not have a configuration corresponding to the tunnel-shaped protrusion 11 shown in Figure 2.

As shown in FIG. 4, in addition to the side step 13 shown in FIG. 2, a slide rail 19 is provided at the foot of the second seat, one of the three rows of seats 4 of the vehicle 1 shown in FIG. 1, and serves as an engagement member for engaging with the second seat, which is a vehicle component, to slide the second seat forward and backward in the vehicle 1.

Figure 5 shows the A-A' cross section of the floor installation structure shown in Figure 4, where (a) shows the conventional structure and (b) shows the structure of the present invention.

When placing the carpet 3 on the area having the above-mentioned configuration as shown in FIG. 1, conventionally, a fiber-based carpet 103 is placed on the floor surface 2 as shown in FIG. 5(a). Here, the carpet 103 is formed by cutting a roll of fabric (a fiber structure) which is a flat material in which fiber layers and backing resin layers are laminated, to a fixed length, and press-molding it, so it is difficult to mold it into a shape that perfectly matches the shape of the floor surface. For example, since it is a flat surface, if there are irregularities on the floor surface 2, as shown in FIG. 3(a), when an occupant of the vehicle 1 steps on the carpet 103 with his/her foot, the carpet 103 follows the irregularities on the floor surface, and is deformed or so-called bumpy, which makes it difficult to step on. In addition, since the slide rail 19 has a certain height, if the surface of the carpet 103 is to be flat, the height of the carpet 103 from the floor surface 2 in the area where the slide rail 19 is not arranged must be set according to the height of the slide rail 19. Therefore, between the floor surface 2 and the carpet 103, urethane foam 106 made by molding urethane is placed with different thicknesses. Also, on the slide rail 19, a resin slide rail cover 118 is attached, which has a hole 119 for the connector provided at the bottom of the second seat to fit into, and caps (not shown) are fitted into the front and rear ends of the slide rail cover 118.

In contrast, in the floor installation structure of this embodiment, as shown in FIG. 5(b), a resin carpet 203 is placed on the floor surface 2. The back surface of the carpet 203 is provided with a rib 208 that serves as a height adjustment member, as shown in FIG. 3(b). The height of the rib 208 corresponds to the height of the slide rail 19. This makes the surface of the carpet 203 flat. The carpet 203 also extends over the slide rail 19, and is integrated with the slide rail cover 118 shown in FIG. 5(a). In the area of the carpet 203 facing the slide rail 19, a hole 221 is opened for the connector provided at the bottom of the second seat to enter, and a visor 222 that covers a part of the slide rail 19 is provided at the opening edge of the hole 221. A felt 207 is interposed between the carpet 203 configured in this way and the floor surface 2, as shown in FIG. 3(b).

In this embodiment, the surface of the carpet 203 laid on the floor surface 2 of the vehicle 1 facing the floor surface 2 has a height corresponding to the unevenness present on the floor surface 2, and the rib 208 that creates the necessary space by this height is provided. Therefore, when the carpet 203 is laid on the floor surface 2 having unevenness as shown in FIG. 3(b), the passenger of the vehicle does not feel uncomfortable when stepping on the carpet 203 with his/her foot, and safety and comfort are not compromised. In this case, the simple configuration in which the rib 208 having a height corresponding to the unevenness is provided on the surface of the carpet 203 facing the floor surface, without making the urethane foam 106 or laminating felt so that the thickness varies from area to area, prevents the safety and comfort from being compromised according to the unevenness present on the floor surface 2. In addition, the height of the rib 208 corresponds to the height of the slide rail 19 arranged on the floor surface 2, so that the surface of the carpet 203 can be flattened. Furthermore, the carpet 203 has a hole 221 that exposes the slide rail 19 in the area facing the slide rail 19, and the opening edge of the hole 221 has a visor 222 that covers part of the slide rail 19. This allows the carpet 203 to be integrated with the conventional slide rail cover 118 that covers the slide rail 19, making it possible to realize a configuration in which the joint of the second seat engages with the slide rail 19 without spoiling the appearance or causing feet to get caught. Furthermore, the slide rail cover itself can be eliminated. Some vehicles have eight or more slide rails, so eliminating the slide rail cover can reduce the number of parts and assembly processes.

In this embodiment, the floor mat fixing device 214, VIN lid 215, side step 213, and slide rail cover 118 are given as examples of functional parts integrated with the carpet 203, but the functional parts to be integrated are not limited to these, and it is sufficient that at least some of the functional parts of the vehicle are integrated. For example, functional parts such as a tibia pad with shock absorbing function and a footrest arranged for the passenger's feet to rest on may be integrated with the carpet 203. In addition, functional parts such as a storage pocket, a handle to be held when carrying, a grip, etc. may be integrated with the carpet 203.

The ribs 208 provided on the carpet 203 of this embodiment are described in detail below.

As described above, the carpet 203 of this embodiment has a height that corresponds to the unevenness present on the floor surface 2 of the vehicle 1, so that when a vehicle occupant steps on the carpet 203, the carpet 203 conforms to the unevenness of the floor surface and deforms or becomes so-called bumpy, making it uncomfortable to step on and reducing safety and comfort. Therefore, it is preferable that the ribs 208 provided on the back surface of the carpet 203 are configured to be less likely to deform when a vehicle occupant steps on the carpet 203 with their feet.

Figure 6 is a diagram showing the so-called foot pool area where the vehicle occupant steps on the carpet 203 in the vehicle 1 shown in Figure 1. Note that in the configuration shown in Figure 6, the tunnel-shaped protrusion 11 is not for arranging a drive shaft, but for installing a center console, and therefore exists only between the driver's seat and the passenger seat, and does not extend to the area between the rear wheels (not shown).

As shown in FIG. 6, in the vehicle 1 shown in FIG. 1, the area other than the shielded area 31 where the seats 4 are installed, the luggage compartment area 32, and the tunnel-shaped protrusion 11 forms a so-called foot pool area 33 where the vehicle occupant steps on the carpet 203 with their feet. This foot pool area corresponds to the riding position of the vehicle 1 occupant in the present invention. In addition to the tunnel-shaped protrusion 11 shown in FIG. 6, other protrusions include cross members formed to cross the width direction midway in the front-rear direction of the floor surface 2, and rocker panels formed on both left and right ends, and the carpet is formed with protrusions that cover these protrusions.

Since the footwell area 33 is an area where the vehicle occupant steps on the carpet 203, it is preferable to make the number and thickness of the ribs 208 larger than in other areas. This can improve the comfort and strength of the carpet 203. In this embodiment, the ribs 208 are used as an example of the height adjustment member, but the ribs 208 may be formed in a lattice or line shape. Furthermore, the height adjustment member is not limited to the ribs 208, and may be a convex or cylindrical boss as long as it functions as a spacer that is a functional part. In addition, the ribs 208 are not limited to the footwell area 33, and as long as the number, thickness, or diameter are set according to the position of the vehicle, they can be adjusted to the optimal value according to the vehicle requirements and part, allowing the necessary comfort to be adjusted at any time and weight reduction to be achieved.

As described above, the carpet 203 is manufactured by injection molding of resin. Therefore, in addition to the effect of improving the cleaning property and feeling of cleanliness, unlike a fiber carpet, it is possible to form a pattern or groove in a line extending in the front-rear direction of the vehicle, or to print a metal or wood grain pattern according to the color of the seat or door panel. This makes it possible to provide a variety of carpet variations according to the vehicle model, its color, and grade. For example, a black carpet can be standard equipment, and a metal or wood grain carpet can be selected as an option. In addition, various known technologies that are conventionally used for door trims formed by resin molding can also be easily diverted to this floor part. For example, it is possible to partially attach a skin at the same time as molding the fabric at the same time (HPM), or to change the color or material using a two-color molding technique. In addition, when attaching a skin partially, it is possible to use a wood grain technique, an illumination technique, or a plating technique.

In addition, the carpet 203 is not limited to being placed on the floor surface 2 as a single structure. For example, the carpet placed in the driver's seat and passenger seat area, the carpet placed in the second seat area, and the carpet placed in the third seat area may be separate. This makes it easy for the user to change the carpets, and allows carpets with different designs to be used depending on the season, etc. In that case, it is possible to prevent the carpets placed on the floor surface 2 from shifting by providing each carpet with a boss and a hole into which the boss fits and engaging these, but since the carpets are manufactured by injection molding of resin, the engaging parts such as the boss and hole can be easily made.

In addition, by making part of the carpet 203 bellows-shaped or using an elastic material for part of the carpet 203, the carpet 203 can be made stretchable, thereby absorbing variations in size and shape caused by injection molding.

REFERENCE SIGNS LIST 1 vehicle 2 floor surface 3, 103, 203 carpet 4 seat 11 tunnel-shaped convex portion 12 side sill 13, 213 side step 14, 214 floor mat fixing device 15, 215 VIN lid 16 heel pad 17 convex portion 18, 218 harness protector 19 slide rail 31 shielding area 32 luggage compartment area 33 footwell area 106 urethane foam 118 slide rail cover 119, 221 hole portion 207 felt 208 rib 222 eaves portion

Claims (4)

A floor installation structure for a vehicle having a floor surface with projections and recesses, and a functional part different from the projections and recesses being installed or extended on the floor surface,
A resin carpet is laid on the floor surface,
The carpet is an integral resin molding, and has a plurality of ribs on a surface facing the floor surface, the ribs having heights corresponding to the irregularities, and a height adjustment member that creates a required space by adjusting the height of the plurality of ribs;
the height adjustment member constitutes the functional component or a part of the functional component,
the plurality of ribs are provided in an area facing the convex portion of the floor surface and an adjacent area adjacent to the area, and a height of the rib provided in the area facing the convex portion is a value obtained by subtracting a height of the convex portion from the floor surface from a height of the rib provided in the adjacent area ,
A vehicle floor installation structure , wherein a felt is interposed between the floor surface and the carpet, and the plurality of ribs abut against the felt . 2. The vehicle floor installation structure according to claim 1 ,
A vehicle floor laying structure, in which a resin material is applied to the upper or lower surface of the felt. The vehicle floor installation structure according to claim 1 or 2 ,
A floor installation structure for a vehicle, in which the number, thickness or diameter of the ribs varies depending on the position of the vehicle. The vehicle floor installation structure according to any one of claims 1 to 3 ,
an engagement member that engages with a vehicle component installed in the vehicle is provided on the floor surface;
A vehicle floor installation structure having a hole opening in an area facing the engaging member to expose a portion of the engaging member, and a canopy portion covering a portion of the engaging member at the opening edge of the hole.

Images