JPH1111202A - Car floor mat and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve the durability of a car floor mat. SOLUTION: The whole is molded integrally by increasing the hardness of the matrix inside of the car floor mat of a place, where the load loaded to the car floor mat is large, than that of the other place, while maintaining the flatness of an entire car floor mat upper surface. The mixture with a high hardness and the mixture with a low hardness for producing the car floor mat are thrown from a separate extrusion molding machine into the prescribed metal mold cavity for producing the car floor mat and pressurized and molded.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a car floor mat and a method for manufacturing the same. More specifically, the present invention relates to a portion where a driver's heel abuts when a driver operates an accelerator pedal, a brake pedal, or a clutch pedal, or a region where a passenger's seat in a front passenger seat or a rear seat abuts. The present invention relates to a car floor mat characterized in that the hardness of the internal matrix of the car floor mat at a point is higher than that of the other parts, and a method of manufacturing the same.

[0002]

2. Description of the Related Art A so-called car floor mat to be laid on an automobile floor is a solid mat consisting only of an edge and a main body made of a thermoplastic synthetic resin or rubber, and a carpet adhered to the main body of the solid mat. There are two types integrated. The term "car floor mat" as used in the present invention encompasses both of these.

[0003] The load applied to the car floor mat from the upper surface of the car floor mat is not uniformly applied to the whole,
Limited to specific locations. That is, in the case of a car floor mat laid on the floor of the driver's seat, it is a place where the driver's heel abuts when the driver operates an accelerator pedal, a brake pedal, or a clutch pedal. In the case of a car floor mat laid on a floor, a large load is applied to a peripheral portion where a passenger's foot abuts.

In particular, when a driver operates an accelerator pedal, a brake pedal, or a clutch pedal, not only a static load but also a dynamic load or a repetitive load is applied to the car floor mat. Therefore, the portion of the car floor mat where the driver's heel abuts is significantly worn or damaged as compared with other portions.

[0005] Conventional car floor mats are manufactured so that the hardness or density in the matrix of the car floor mat is substantially uniform at places where a large load is applied and at places where a large load is not applied. Therefore, even though the parts that do not receive a large load that occupy most of the entire area of the car floor mat are sound and are not damaged, the parts that apply a large load that is only a small part of the entire area of the car floor mat are damaged. The drawback is that the car floor mats must be discarded and renewed because of this.

In order to solve this drawback, the heel pad of the car floor mat corresponding to the driver's heel is applied to prevent the driver's heel from directly contacting the car floor mat. A method of buffering or dispersing a load applied to the device is adopted.

[0007] However, this improvement method is a troublesome method for the driver, and is not a method for essentially improving the durability of a place where the load applied to the car floor mat is high.

[0008]

SUMMARY OF THE INVENTION Accordingly, the problem to be solved by the present invention is to change the hardness of the matrix of the car floor mat in the conventional car floor mat in accordance with the magnitude of the load applied to the car floor mat. That was not possible.

Another problem to be solved by the present invention is a car floor mat to be laid on the floor of a driver's seat, and when the driver operates an accelerator pedal, a brake pedal, or a clutch pedal, the driver of the car floor mat is required. The hardness of the inside of the matrix of the car floor mat corresponding to the place where the heel abuts cannot be changed from the hardness of other places.

Another problem to be solved by the present invention is a car floor mat to be laid on the floor of a passenger seat or a backseat, wherein a car floor mat inside a matrix of a car floor mat at a peripheral position where a passenger's foot abuts. That is, the hardness could not be made higher than the hardness of other parts. Further problems and advantages to be solved by the invention will be clarified one by one below.

[0011]

SUMMARY OF THE INVENTION The present invention, which is a means for solving the above problems, is made of a thermoplastic synthetic resin or rubber, and comes into contact with the floor of an automobile to improve the followability of the floor. Therefore, in a car floor mat having an arbitrary designed bottom surface and a flat upper surface with which the driver and the passenger's feet contact directly or indirectly, the car floor mat is loaded while maintaining the flatness of the upper surface. A car floor mat characterized in that the hardness inside the matrix of the car floor mat at a place where the load is large is higher than the hardness inside the matrix of the car floor mat at other places.

In one embodiment of the present invention, it is preferable that an edge is integrally formed with the car floor mat on the outer periphery of the upper end of the car floor mat.

Further, as another aspect of the present invention,
It is preferable that a carpet is covered and adhered to the upper surface and the edge of the car floor mat.

Another aspect of the present invention, which is a means for solving the above-mentioned problems, is an arbitrary design which is made of a thermoplastic synthetic resin or rubber and which comes into contact with the floor of an automobile to improve floor followability and the like. In a car floor mat having a bottom surface provided with a flat top surface with which a driver and a passenger's foot contact directly or indirectly, a large load is applied to the car floor mat while maintaining the flatness of the top surface. A method of manufacturing a car floor mat in which the hardness inside the matrix of a car floor mat at a location is higher than the hardness inside the matrix of the car floor mat at other locations, wherein the car floor mat has a predetermined design on a bottom surface. A manufacturing die is prepared in advance, a position where a large load is applied to the car floor mat is positioned, and a large load is applied to the car floor mat. A mixture of a thermoplastic synthetic resin or rubber having a high hardness corresponding to various places and a compound of a thermoplastic synthetic resin or rubber having a low hardness corresponding to the other places are prepared and loaded on the car floor mat. The composition of the thermoplastic synthetic resin or rubber having a high hardness corresponding to the location where the load is large and the composition of the thermoplastic synthetic resin or rubber having a low hardness corresponding to the other places are respectively put into separate extruders, The load applied to the car floor mat positioned on the mold is filled with a high thermoplastic synthetic resin or rubber compound having a high hardness corresponding to the point where the load applied to the car floor mat is large. A load applied to a car floor mat in which a thermoplastic synthetic resin or rubber compound having a low hardness corresponding to the other portions is positioned in the mold. Filled to a place other than a large portion, and a combination of the mold is a method of manufacturing a car floor mat comprising a pressurizing at a predetermined condition.

In another embodiment of the present invention, the separate extruders are connected by a single nozzle, and the high-hardness compound and the low-hardness compound are each intermittently formed in the mold from the nozzle. It is preferable to fill a predetermined portion of the sheet.

In another aspect of the present invention, it is preferable that an edge is formed integrally with the car floor mat on an outer periphery of an upper end of the car floor mat.

In still another embodiment of the present invention,
It is preferable that a carpet is covered and adhered to the upper surface and the edge of the car floor mat.

A feature of the car floor mat of the present invention is that a material manufactured separately from the car floor mat is attached to a place where the load applied to the car floor mat is large, or a place where the load is large is separated from other places. A car floor mat that is not thickly manufactured but has a higher hardness, density, or specific gravity than the other parts to be filled in a place where a heavy load is applied, thereby keeping the entire upper surface of the car floor mat flat. The hardness inside the matrix was changed.

Since the car floor mat of the present invention has the above-described internal structure, the performance originally required of the car floor mat, such as followability to the floor surface and adhesion, is not impaired.
In addition, the high-hardness segment and the low-hardness segment of the car floor mat are integrally formed of the same material with a different mixing ratio of the plasticizer, so that a crack is generated or deformed at each boundary portion. Never.

Hereinafter, the present invention will be described in detail with reference to examples. Preparation of Compounds A compound having a high hardness and a compound having a low hardness were manufactured according to the following compounding ratios. High hardness formulation Component Parts by weight PVC (polymerization degree 1300) 100 filler (calcium carbonate) 100 stabilizer 5 plasticizer (DOP) 40 Pigment qs

The low hardness formulation Component Parts by weight PVC (polymerization degree 1300) 100 Filler (calcium carbonate) 50 Stabilizer 5 plasticizer (DOP) 80 Pigment qs

Preparation of Extruders Two extruders having a screw diameter of 50 mm and an L / D of 25 were prepared. These extruders were connected by one T-shaped nozzle having a diameter of about 50 mm.

Preparation of mold 600 mm (W) × 800 mm (L) × 15 mm (T)
A press die having a predetermined design was prepared such that a rib for maintaining strength and a projection for imparting floor followability were formed on the back surface of the car floor mat having the shape shown in FIG. On the other hand, the position where the driver's heel abuts on the car floor mat by the driver's pedal operation was accurately positioned.

The above two types of compounds are supplied from separate extruder hoppers, and the high hardness compounds are supplied to the heel of the driver by the pedal operation of the driver of the mold according to a pre-programmed trajectory. Filling the cavity corresponding to the place where the floor mat touches, while applying the low hardness compound to the place other than where the driver's heel touches the car floor mat by the pedal operation of the driver of the mold. Into the cavity. Then, the male mold and the female mold were combined and pressed at 200 tons to produce a desired car floor mat.

[0025]

As described above, according to the car floor mat of the present invention, the flatness of the entire upper surface of the car floor mat is maintained and, at the same time, the place where the load applied to the car floor mat is large, for example, when the driver operates the accelerator, The hardness of the matrix inside the matrix of the car floor mat with which the driver's heel abuts when operating the brake and clutch pedal is higher than the hardness of other parts, so it is required for the car floor mat including the ability to follow the floor surface. This has the effect of improving the durability without impairing the performance.

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Akinori Matsui 2-2-1-11 Matsuhama-cho, Fukuyama City, Hiroshima Prefecture Inside Hiroshima Kasei Co., Ltd. (72) Inventor Seiichi Nakanishi 1128 Katsume-cho, Moriyama City, Shiga Prefecture Inside the corporation

Claims (7)

[Claims] 1. A car having a bottom surface that comes into contact with the floor surface of an automobile and has an arbitrary design for improving floor followability and the like, and a flat upper surface that directly or indirectly contacts feet of a driver and a passenger. In the floor mat, while maintaining the flatness of the upper surface, the load applied to the car floor mat is the hardness of the matrix inside the matrix of the car floor mat at a large point,
A car floor mat characterized by being higher than the hardness inside the matrix of the car floor mat in other places. 2. The car floor mat according to claim 1, wherein an edge is integrally formed on an outer periphery of an upper end of the car floor mat with the car floor mat. 3. The car floor mat according to claim 2, wherein a carpet is covered and adhered to an upper surface and an edge of the car floor mat. 4. A car having a bottom surface which is in contact with the floor surface of an automobile and has an arbitrary design for improving the floor followability and the like, and a flat upper surface where the feet of the driver and the passenger directly or indirectly contact. In the floor mat, while maintaining the flatness of the upper surface, the load applied to the car floor mat is the hardness of the matrix inside the matrix of the car floor mat at a large point,
A method of manufacturing a car floor mat characterized by having a hardness higher than the inside of the matrix of the car floor mat in other places, wherein a mold for manufacturing a car floor mat having a predetermined design on a bottom surface is prepared in advance. And positioning a location where the load applied to the car floor mat is large; and a thermoplastic synthetic resin or rubber compound having a high hardness corresponding to the location where the load applied to the car floor mat is large, and Preparing a thermoplastic synthetic resin or rubber compound having a low hardness corresponding to other portions; compounding a thermoplastic synthetic resin or rubber having a high hardness corresponding to a portion where a large load is applied to the car floor mat; The compound and the compound of the thermoplastic synthetic resin or rubber having low hardness corresponding to the above-mentioned other parts are put into separate extruders. The load applied to the car floor mat positioned on the mold is filled with a high thermoplastic synthetic resin or rubber compound having a high hardness corresponding to the point where the load applied to the car floor mat is large. Filling a portion other than the portion where the load applied to the car floor mat positioned on the mold with a low hardness thermoplastic synthetic resin or rubber corresponding to the other portion is other than a large portion; and A method for producing a car floor mat comprising combining a mold and pressing under predetermined conditions. 5. The method according to claim 5, wherein the separate extruders are connected by a single nozzle, and the high-hardness compound and the low-hardness compound are intermittently filled from the nozzle into predetermined portions of a mold. A method for manufacturing a car floor mat according to claim 4, characterized in that: 6. The method of manufacturing a car floor mat according to claim 4, wherein an edge is integrally formed on an outer periphery of an upper end of the car floor mat with the car floor mat. 7. The method for manufacturing a car floor mat according to claim 5, wherein a carpet is coated and adhered to an upper surface and an edge of the car floor mat.