JPH0414859B2 - - Google Patents

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a method for forming a floor carpet for a vehicle.
The present invention relates to a method for forming a vehicle floor carpet comprising a buffer layer laminated on the back side of the carpet layer.

[Conventional technology]

Conventionally, floor carpets have been installed on the floors of vehicles, etc., and these floor carpets consist of a carpet layer to improve the feel and appearance of the surface side, and a buffer layer to improve cushioning and cushioning properties. These carpet layers and buffer layers are press-molded to correspond to the shape of the floor.

The carpet layer and the buffer layer are press-molded separately and then joined into a laminated state.The carpet layer is molded, the carpet layer is placed in a foam mold, and the buffer layer is placed on the back side of the carpet layer. There is one in which a foamed synthetic resin stock solution is injected to form a buffer layer.

[Problem that the invention seeks to solve]

However, in any conventional method of molding a floor carpet for a vehicle, a press mold for forming the carpet layer and a foam mold for forming the buffer layer are required, which increases the mold manufacturing cost. This resulted in a significant lack of economic efficiency, and it was not possible to improve the working efficiency for forming the carpet layer and the buffer layer.

An object of the present invention is to provide a method for molding a floor carpet for a vehicle, which is extremely economical with low mold production costs, significantly improves work efficiency, and shortens the manufacturing time of the floor carpet. .

[Means for solving problems]

The present invention has been made in view of the above-mentioned problems, and includes a lower mold and an upper mold that is matched with the lower mold, and the upper mold is an outer mold that is moved up and down by a first vertical lifting means. and an inner mold that is moved up and down with respect to the outer mold by a second vertical elevating means, an injection port for the stock solution of the foamed synthetic resin is formed in the inner mold, and an injection port is formed between the lower mold and the upper mold. A carpet original fabric on which a carpet layer is to be formed is placed, and the first and second up-and-down lifting means are operated to lower the outer mold and lower the inner mold relative to the outer mold. is press-molded to form a carpet layer, and then the second vertical elevating means is operated to raise the inner mold,
Injecting an undiluted solution of foamed synthetic resin through an injection port formed in the inner mold into the space formed by the rise of the inner mold, and curing the foam to integrally form a buffer layer on the back side of the carpet layer. It is characterized by

[Effect]

According to the present invention, a carpet material is press-molded by a lower mold and an upper mold consisting of an outer mold and an inner mold,
The inner mold of the upper mold is raised by a second vertical elevating means, and the foamed synthetic resin stock solution is injected into the space formed between the inner mold and the carpet layer while the carpet layer is pressed by the outer mold. It is possible to form a buffer layer integrally on the back side of the carpet layer from the foamed synthetic resin stock solution, and when forming the buffer layer, it is not necessary to perform work such as rearranging the carpet layer in a different mold. There is no such thing.

〔Example〕

DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the method for molding a vehicle floor carpet according to the present invention will be described in detail below with reference to the drawings.

FIG. 1 schematically shows an embodiment of a mold for carrying out the method of molding a vehicle floor carpet according to the present invention, and this mold 1 includes a lower mold 2.
and an upper mold 3 that is mold-matched to the lower mold 2. The upper mold 3 is mounted on a mounting board 4 so as to be movable up and down by a first up and down means 5. The first vertical elevating means 5 can be formed using a member that moves up and down mechanically, as well as one that uses fluid such as a hydraulic cylinder or an air cylinder.

The upper mold 3 has an outer mold 6 and an inner mold 7, and a first movable member 8 of the first vertical elevating means 5 is connected to the outside of the outer mold 6. This outer mold 6 has a pressing part 9 that can come into contact with the mold matching part 11 of the lower mold 2 while holding the outer peripheral edge 32 of the carpet original fabric 31, and has A recessed groove portion 10 is formed in which the inner mold 7 can be housed in a vertically movable manner.

A second vertical elevating means 12 is provided on the upper part of the outer mold 6, and a second movable member 13 of the second vertical elevating means 12 is moved inside the outer mold 6 through a through hole 15 formed in the outer mold 6. The inner mold 7 is attached to one end of the second movable member 13 so as to be movable up and down. A concave portion 17 and a convex portion 18 for molding the carpet original fabric 31 are formed at mutually opposing positions of the lower mold 3 and the inner mold 7, respectively. Furthermore, an injection port 2 is provided at a position where the outer mold 6 and the inner mold 7 of the upper mold 3 face each other.
1 and 22 are formed respectively, and the injection port 2 of this outer mold 6
1, the foamed synthetic resin stock solution 35 can be injected between the inner mold 7 and the lower mold 2 through the injection port 22 of the inner mold 7.

Next, an embodiment of the method for forming a vehicle floor carpet according to the present invention will be described with reference to FIGS. 1 to 5.

First, as shown in FIG. 1, a carpet original fabric 31 for forming a carpet layer 33 is placed between a lower mold 2 and an upper mold 3.

Next, as shown in FIG.
The first and second movable members 8 and 13 of No. 2 are lowered and press-molded onto the original carpet 31 using the concave portions 17 of the lower die 2 and the convex portions 18 of the inner die 7, etc., thereby forming the carpet layer 33. At this time, the inner mold 7 is moved below the groove portion 10 of the outer mold 6.

Next, as shown in FIG.
After the formation of the carpet layer 33, the outer peripheral edge 32 of the carpet layer 33 is pressed and held by the pressing part 9, and the second vertical elevating means 12 is operated to raise the second movable member 13, and the inner mold 7 is removed from the outside. The mold 6 is moved above the groove 10 to form a space 37 for forming a buffer layer 36 between the lower part of the inner mold 7 and the carpet layer 33.

Next, as shown in FIG. 4, a foamed synthetic resin stock solution 35 for the backing layer 36 is injected into the space 37 using an injection machine 40 such as a foamed urethane injection machine. A nozzle 41 of an injection machine or the like is formed to have a length extending from the injection port 21 of the outer mold 6 to the injection port 22 of the inner mold 7. In this embodiment, the injection port 2 of the inner mold 7
2 was provided at the convex portion 18 position, but the injection port 2 of the outer mold 6
Nozzle 41 is provided at an appropriate position on the side adjacent to 1.
can be formed short. Further, the injection machine 40 is arranged on the side of the upper mold 3, and the nozzle 41 of the injection machine 40 is
from between the outer mold 6 and the inner mold 7 to the injection port 22 of the inner mold 7.
If the injection port 21 is configured to be inserted into the outer mold 21, the injection port 21 of the outer mold 21 can be omitted.

As shown in FIG. 5, by foaming and curing the foamed synthetic resin stock solution 35, a buffer layer 36 integrally molded with the carpet layer 33 is formed, and a floor carpet 38 having a desired shape is obtained.

Next, when the first movable member 8 of the first up/down lifting means 5 is raised to raise the outer mold 6, that is, the entire upper mold 3, the inner mold 7 also rises as the outer mold 6 rises, and the upper mold 3 Floor carpet 3 from between and lower mold 2
8, a floor carpet 38 can be obtained as a molded product.

In the embodiment described above, the second vertically lifting means 12 is provided on the outer mold 6, but it is attached to the mounting board 4 in the same way as the first vertically lifting means 5, and the second vertically lifting means 12 is attached to the mounting board 4. The movable member 13 may be moved up and down while passing through the through hole 15.

〔Effect of the invention〕

The above is an embodiment of the method for molding a vehicle floor carpet according to the present invention. According to this method, the upper mold is formed by an outer mold and an inner mold, and the upper mold is formed by the outer mold and the inner mold. are moved up and down by the first and second up-and-down means to press-form the original carpet, and then apply a buffer layer to the back side of the carpet layer without moving the molded carpet layer to another mold. It can be integrally molded, and the buffer layer can also be formed by raising the inner mold of the upper mold using the second up-and-down means, forming a space between the carpet layer and the inner mold, and filling the space with foaming compound. As it is only necessary to inject the resin stock solution through the injection port, work efficiency can be significantly improved, and there is no need to prepare multiple molds, mold production costs are low, and this is an extremely economical vehicle floor. You can learn how to mold carpets.

[Brief explanation of drawings]

1 to 5 show one embodiment of the method for molding a vehicle floor carpet according to the present invention, and FIG. 1 is an explanatory cross-sectional view of a mold used in carrying out the invention, 5 through 5 are cross-sectional explanatory views of molds showing the floor carpet molding process, respectively. In the figure, 1... Molding die, 2... Lower die, 3... Upper die, 4... Mounting board, 5... First vertical lifting means, 6... Outer die, 7... Inner die, 8 ...First movable member, 9...Press portion, 10...Concave groove portion, 12...
Second vertical elevating means, 13... second movable member,
15...Through hole, 17...Concave portion, 18...Convex portion, 2
1, 22...Injection port, 31...Carpet material,
33... Carpet layer, 35... Stock solution of foamed synthetic resin, 36... Buffer layer, 37... Space, 38...
...Floor carpet.

Claims (1)

[Claims] 1. A method for molding a vehicle floor carpet comprising a carpet layer and a buffer layer laminated on the back side of the carpet layer, comprising a lower mold and an upper mold to be molded to the lower mold, The mold has an outer mold that is moved up and down by a first up-and-down means, and an inner mold that is moved up and down with respect to the outer mold by a second up-and-down means, and the inner mold is made of foamed synthetic resin. A carpet material having an inlet for the stock solution formed therein and forming a carpet layer between the lower mold and the upper mold is arranged, and
and lowering the outer mold by operating a second vertical elevating means, and lowering the inner mold with respect to the outer mold,
The carpet material is press-molded to form a carpet layer, and then the second up-and-down means is operated to raise the inner mold, and the carpet layer is formed in the inner mold in the space formed by the rise of the inner mold. A method for molding a floor carpet for a vehicle, comprising injecting a stock solution of a foamed synthetic resin through an injection port and curing the foam to integrally form a buffer layer on the back side of the carpet layer.