JPH11170902A - Floor mat and manufacturing method thereof - Google Patents

Abstract

(57) [Summary] [Problem] It has excellent adhesion to the floor wall, can prevent earth and sand from entering the floor, and is excellent in design,
Provided are a floor mat having a sufficient peel strength and a method for producing the same. SOLUTION: A flat portion 4 and a peripheral portion surrounding the flat portion, at least a part of the peripheral portion includes a band-shaped protruding portion 5 extending continuously substantially in parallel with a peripheral edge 51, and the flat portion of the band-shaped protruding portion. The side edge and the peripheral side edge are substantially parallel, the band-shaped ridge includes a groove extending on the lower surface in the length direction of the band-shaped ridge, and the band-shaped ridge has a deformable region 61 and a shape holding region 62. And the deformable region has a concave structure 10 on the groove side of the band-shaped ridge.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a floor mat and a method for manufacturing the same. In particular, the floor mat is brought into contact with a wall, and in some cases, a force is applied to the periphery to bend the floor mat so that the floor mat is placed in contact with the wall, for example, an automobile floor mat, or a store or home entrance. For floor mats.

[0002]

2. Description of the Related Art For example, in a floor mat for an automobile, the floor is prevented from being stained,
In order to prevent soil, sand, mud, gravel, etc. from scattering to the outside of the floor mat, a floor mat with a band-shaped ridge on the periphery and a periphery higher than the central flat part is used. Are known. The most common method of manufacturing a floor mat of this type is a method of press-molding a sheet-like material. Therefore, the wall thickness of the central flat portion and the wall thickness of the peripheral band-shaped ridge are generally substantially the same. become. Therefore, a groove corresponding to the shape of the band-shaped ridge is formed on the lower surface side of the band-shaped ridge at the periphery. As described above, since the lower surface side of the band-shaped protruding portion has a groove-shaped hollow portion, when the band-shaped protruding portion is pressed with shoes or the like, or when the periphery is pressed against a wall surface, the band-shaped protruding portion is formed. However, there is a disadvantage that the floor mat is deformed, the position of the floor mat is displaced, and earth and sand enters under the floor mat.

In order to improve the shape stability of such a band-shaped ridge, Japanese Patent Application Laid-Open No. 6-24265 discloses that a linear rib portion traversing a hollow groove portion in a transverse direction (width direction) is provided inside the groove. Is disclosed. According to this floor mat, the shape stability of the band-shaped ridge is enhanced, but the provision of the linear rib traversing the groove ceiling of the band-shaped ridge in the transverse direction conversely causes the groove-shaped part (ie, , The band-shaped ridges) can be easily deformed by pushing and spreading or narrowing. Therefore, by changing the shape of the groove-shaped molded portion, for example, it is difficult to make the floor mat and the floor wall adhere to each other. There was a problem of intrusion.

Further, a part of the band-shaped protruding portion is partially projected from the upper surface side of the floor mat toward the lower surface side, and discontinuous independent projections are periodically provided inside the groove-shaped formed portion. By doing so, it is conceivable to improve the shape stability of the band-shaped ridge. However, on the upper surface side of the projection, a dent in which a part of the band-shaped ridge is depressed toward the lower surface side is formed, and the smooth surface shape of the band-shaped ridge is impaired, so design In some cases, it gave an unnatural impression. Therefore, a solution from another viewpoint has been required.

On the other hand, as the above-mentioned floor mats for automobiles and the like, a base layer made of a molded elastic soft material sheet;
Floor mats made of a laminate with a surface material layer made of a carpet or the like have been widely used. As the base layer, a thermoplastic elastomer is preferable in that it is relatively soft and can contribute to the adhesion to the floor wall, and the thermoplastic elastomer is recyclable and can be used in a normal molding machine. In addition, there are also advantages such as the ability to perform molding with a short time, and the possibility of continuous molding. However, in a floor mat made of a laminate of a base layer made of a thermoplastic elastomer and a surface material layer made of a carpet or the like, in the manufacturing process, when bonding the thermoplastic elastomer sheet and the carpet,
It is necessary to heat the thermoplastic elastomer sheet to adhere them. If the contact time is lengthened, a sufficient peel strength can be obtained. However, if the contact time is long, heat causes damage to the carpet layer. Therefore, there is a drawback that a sufficient peeling strength cannot be obtained because a short contact time is required.

[0006]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to solve the above-mentioned drawbacks of the prior art, to have appropriate shape retention and deformability, and to adhere to a wall surface in contact with the periphery of a floor mat. It is possible to install it, it is hard to cause misalignment, and it is hard for soil etc to penetrate under the floor mat, and it is also excellent in design without damaging the smooth surface shape of the belt-shaped ridge. , And a method of manufacturing the same. It is still another object of the present invention to provide a floor mat having no damage to the surface layer and having a sufficient peel strength, even if the floor mat is made of a laminate of the base layer and the surface layer. .

[0007]

According to the present invention, there is provided a flat part and a peripheral part surrounding the flat part, at least a part of the peripheral part being continuous substantially parallel to the peripheral part. A floor mat comprising a band-like ridge extending in the upper direction, wherein an edge of the band-like ridge on a flat portion side and a peripheral edge of the band-like ridge are substantially formed. Parallel; on the underside of said floor mat,
The ridge includes a groove extending the length of the ridge; the ridge is deformable in response to a change in pressure and is continuous along the length of the ridge. The deformable region extending in the shape of the band-shaped ridge and the shape holding region continuously extending in the length direction of the band-shaped ridge can be held in parallel with each other in a state of being parallel to each other. The above-mentioned floor mat, wherein the deformable region has a concave structure on the groove side of the band-shaped ridge.

Further, the present invention provides a pair of molds capable of press-molding a floor mat having the above-mentioned shape,
The present invention also relates to a method for manufacturing the floor mat, comprising feeding a sheet material maintained at a press-moldable temperature, pressing the sheet by the forming die, and cutting the sheet into individual floor mats.

[0009] In the present specification, the "recess structure" means a continuous concave portion locally depressed from the surface on the groove side surface and / or the bottom surface of the band-shaped ridge in the direction of the upper surface of the band-shaped ridge. Target or discontinuous depression (ie, depression)
One or more structures. By providing the concave structure in the groove of the band-shaped raised portion, the region provided with the concave structure is easily deformed in response to a pressure change as compared with other regions, and becomes a deformable region. That is,
Since the wall pressure in the concave portion of the deformable region becomes thinner than the wall pressure of the shape holding region, deformation occurs in the concave portion.

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, a floor mat of the present invention will be described.
A description will be given mainly with reference to FIGS. FIG. 1 is a perspective view of a floor mat 1 of the present invention as viewed from above, and FIG. 2 is an enlarged view of a corner 1a (broken line portion of FIG. 1) of the floor mat 1 as viewed from above. FIG. 3 is a partial perspective view, and FIG.
FIG. 4 is an enlarged partial perspective view of the corner portion 1a as viewed from the lower surface side. Floor mat 1
Is a base layer 2 made of a molded elastic soft material sheet,
It is a laminate with a surface material layer 3 made of a carpet or the like. Further, a floor mat (not shown) consisting only of a formed elastic soft material sheet without carrying a surface material layer can also be used in the present invention. The underlayer 2 has a non-slip projection 21
Is preferably provided. As shown in FIG. 1, the floor mat 1 of the present invention includes a flat portion 4 at a central portion and a peripheral portion 4 a surrounding the flat portion 4, and the peripheral portion 4 a
1 includes a band-shaped ridge 5 extending continuously substantially parallel thereto and protruding in the upper direction. In addition, as shown in FIGS. 2 to 4, on the lower surface of the floor mat 1, a portion corresponding to the band-shaped ridge 5, that is, a groove 6 is provided on the back side of the band-shaped ridge 5.
Are formed.

As shown in FIG. 1, on the upper surface of the floor mat 1 according to the present invention, an edge 5a on the flat portion 4 side of the band-shaped protruding portion 5 and an end on the peripheral edge 51 side of the band-shaped protruding portion 5 are provided. The edge 5b is substantially parallel. Floor mat 1
Generally, since at least one side is used in contact with a wall surface, as shown in FIG. 1, except that the corner portion may be arcuate (an arc shape having a center on the flat portion side) in some cases, The other sides are substantially straight. Therefore, on the upper surface of the floor mat 1 according to the present invention, generally, the edge 5a on the flat portion 4 side of the band-like ridge 5 described above.
Is composed of substantially straight edges only (the corners form corners), and substantially straight edges,
In some cases, the flat portion has an arc-shaped edge having a center on the side of the flat portion. That is, in general, the boundary between the flat portion 4 and the edge 5a on the flat portion 4 side of the band-shaped ridge 5 is
There is no zigzag or wavy border.

On the upper surface side of the band-shaped protruding portion 5, not only a projection protruding further from the upper surface side toward the upper surface of the floor mat 1 is provided, but also from the upper surface side to the lower surface of the floor mat 1 in reverse. It is preferable not to form a depressed dent, and it is preferable that the upper surface side of the band-shaped ridge 5 is formed of a smooth surface. Further, the width and the depth of the groove 6 formed on the lower surface side of the band-shaped raised portion 5 are not particularly limited, and
The wall thickness of the band-shaped ridge 5 is determined in the longitudinal direction of the band-shaped ridge 5 and / or
Alternatively, in the width direction, it can be substantially constant, can be continuously reduced, or can be continuously increased. In the present specification, “the wall thickness of the band-shaped ridge 5” refers to the thickness of the band-shaped ridge 5 of the base layer when the floor mat of the present invention is formed of a laminate of the base layer and the surface material layer. In the case where the floor mat of the present invention consists of only a molded sheet without carrying a surface material layer, it means the thickness of the molded sheet at the band-shaped ridge 5. In addition, since the manufacturing process is further facilitated, the entire wall thickness of the band-shaped ridge 5 is substantially the same as the wall thickness of the flat portion 4 except for the portion where the concave structure 10 is provided. Is more preferred. However, in the band-shaped protruding portion 5, a wall portion (for example, one of the side wall portions 6) forming a shape holding region 62 described later along FIGS.
By making the wall thickness of 3) thicker than the wall thickness of the other wall portion (for example, the other wall measurement portion 63), the shape holding function can be adjusted. Therefore, it is preferable to change the wall thickness. There is also.

The band-like ridge 5 has a side wall 63 and a ceiling 64.
And a region that can be easily deformed in response to a pressure change, that is, a deformable region 61 and a region that can maintain the shape of the band-shaped ridge 5 at the position where the pressure acts on the pressure change. That is, the shape holding region 62
Consists of In the embodiment shown in FIGS. 1 to 4, the portion provided with the concave structure 10, that is, the side wall 63 a corresponds to the deformable region 61, and the other portions correspond to the shape holding region 62.
Is equivalent to Deformable area 61 and shape holding area 6
2 extend continuously in the length direction of the band-shaped ridge 5 and are parallel to each other, so that the deformable region 61 and the shape holding region 62 are respectively parallel to the length direction of the band-shaped ridge 5. Is provided.

In the embodiment shown in FIGS. 1 to 4, the concave structure 10 provided in the deformable region 61 has three band-shaped concave portions 10 a and 10 extending continuously in the longitudinal direction of the band-shaped raised portion 5.
b, 10c. In the embodiment shown in FIGS. 1 to 4, the concave structure 10 continuously extending in the length direction of the band-shaped ridge 5 is provided.
One side surface of the groove 6, that is, the peripheral edge 51 of the band-shaped ridge 5
However, in the floor mat of the present invention, the position of the deformable region having the concave structure, that is, the concave structure, is set in the floor mat of the present invention, as long as the band-shaped ridge includes the deformable region and the shape holding region. The position to be provided is not limited,
One or more of the recess structures may be provided on at least a part of the side surface and / or the bottom surface of the groove. Therefore,
One or more concave structures 10 can be provided on at least one of the side surface 65 of the groove 6, that is, the side surface 65a on the peripheral edge 51 side, the side surface 65b on the flat portion 4 side, and the bottom surface 66 of the band-shaped ridge 5.

The shape of each of the concave portions constituting the concave structure is not particularly limited. For example, the shape when viewed from a direction perpendicular to the wall surface including the concave structure is, for example, a continuous shape. It can be a band-shaped recess, a discontinuous band-shaped recess, or an independent spot-shaped recess. The continuous band-shaped recess is a recess continuously extending from one end to the other end of the deformable region, and the extending direction is the length direction of the band-shaped ridge or a direction deflected therefrom (in the length direction). Vertical direction, that is, including the width direction). The above-mentioned continuous band-shaped recess extending from one end to the other end of the deformable region in the length direction of the band-shaped ridge may be constituted by a single continuous band-shaped depression alone. It is preferable that a plurality of continuous strip-shaped recesses 10a, 10b, and 10c form a recess structure as shown in FIGS. When the continuous band-shaped recess extends in a direction (preferably the width direction) deviated from the length direction of the band-shaped ridge, a plurality of continuous band-shaped recesses are provided in the entire deformable region to form a recess structure. The continuous band-shaped recess preferably extends continuously in the length direction of the band-shaped ridge, because the continuous band-shaped recess is easily deformed when pressure is applied to the band-shaped ridge 5 and absorbs force.

The discontinuous band-shaped concave portion can be provided so as to extend in the length direction of the band-shaped protruding portion or in a direction deviated therefrom (including the width direction). In the case where a plurality of discontinuous band-shaped recesses are provided, it is not necessary to make their extending directions coincide with each other, but it is preferable to provide them substantially parallel to each other. In addition, it is preferable that the discontinuous band-shaped concave portion also extends continuously in the length direction of the band-shaped protruding portion in terms of curl prevention. The shape of the independent spot-shaped concave portion is not particularly limited, and examples thereof include a circle, an ellipse, a sector that is a part of a circle or an ellipse, or a polygon, or a combination thereof. . The concave structure may be configured by combining the continuous band-shaped concave portion, the discontinuous band-shaped concave portion, or the independent spot-shaped concave portion alone or in an appropriate combination.

The cross-sectional shape of the concave portion (cross-sectional shape of the concave portion in the width direction) is not particularly limited, and examples thereof include a semicircle, a semi-ellipse, a polygon, and a combination thereof. it can. When the cross-sectional shape is a polygon, particularly a triangle, the deformability of the deformable region can be enhanced.

In the embodiment shown in FIGS. 3 and 4, that is, in the embodiment in which the shape of each of the concave portions constituting the concave structure is a continuous band-shaped concave portion extending in the longitudinal direction of the band-shaped ridge, each of the band-shaped concave portions 10a, 10a, 10b, 10c in the width direction (W
₁ ) is preferably about 0.5 to 20 mm, and the depth (D ₁ ) of each of the band-shaped recesses 10a, 10b, 10c.
Is preferably about 0.5 to 1.5 mm. If desired, each band-shaped concave portion can be provided at an appropriate interval. In this case, the interval between adjacent concave portions is preferably about 10 to 25 mm.

FIG. 5 is an enlarged partial perspective view of another embodiment of the present invention, that is, an embodiment in which the shape of each of the recesses constituting the recess structure is a continuous band-shaped recess extending in the width direction of the band-shaped ridge. It is shown in FIG. In the embodiment shown in FIG. 5, the concave structure 10 provided in the deformable region 61 is composed of a plurality of continuous band-shaped concave portions 10d extending in the width direction of the band-shaped ridge. In the embodiment shown in FIG. 5, the continuous band-shaped recess 10d is provided only on one side surface of the groove 6, that is, on the side surface 65a on the peripheral edge 51 side of the band-shaped protrusion 5 along the length direction of the band-shaped protrusion. Therefore, the concave structure 10 continuously extending in the longitudinal direction of the band-shaped ridge 5 is provided only on one of the side surfaces of the groove 6. However, in the floor mat of the present invention, the band-shaped ridge can be deformed. The position of the deformable region having the concave structure, that is, the position where the concave structure is provided is not limited as long as the region and the shape holding region are included, and at least a part of the side surface of the groove is not limited to one.
One or more of the recess structures may be provided.

In the embodiment shown in FIG. 5, a groove 6 having a height (depth: H ₂ ) of about 5 to 40 mm has a length direction (width direction of the band-shaped ridge) of each recess 10d. preferably the dimension (L ₂₎ is about 8~50mm of), the dimensions of the width direction of each of the recesses 10d (the length direction of the strip-shaped ridges) (W ₂₎ is preferably of about 1~5mm . Also,
Wall thickness (T ₂₎ relative to the side 65a of approximately 1 to 3 mm, each of the recesses 10d depth (D ₂₎ is from about 0.5
Is preferably 1.5 mm, distance between the adjacent recess (S ₂₎ is preferably about 5 to 25 mm.

FIG. 6 is an enlarged partial perspective view of still another embodiment of the present invention, that is, an embodiment in which the shape of each of the recesses constituting the recess structure is an independent spot-shaped recess as viewed from the lower surface side.
In the embodiment shown in FIG. 6, the concave structure 10 provided in the deformable region 61 is provided in a lattice shape on the side surface 65 a on the peripheral edge 51 side of the band-shaped ridge 5 in two directions of the length direction and the width direction of the band-shaped ridge. And a plurality of independent spot-shaped concave portions 10e. In the embodiment shown in FIG. 6, the concave structure 10 continuously extending in the length direction of the band-shaped ridge 5 is provided on one side surface of the groove 6,
Although it is provided only on the side surface 65a on the peripheral edge 51 side of the band-shaped ridge 5, in the floor mat of the present invention, as long as the band-shaped ridge is composed of the deformable region and the shape holding region, the deformable region having the concave structure is formed. The position, that is, the position where the concave structure is provided is not limited, and one or more concave structures can be provided on at least a part of the side surface and / or the bottom surface of the groove.

In the embodiment shown in FIG. 6, a groove 6 having a height (depth: H ₃ ) of about 5 to 40 mm is provided in the longitudinal direction of each recess 10 e (the length of the band-shaped ridge). Direction (L ₃ ) is preferably about 15 to 20 mm,
It is preferable dimensions of width direction of each of the recesses 10e (the width direction of the belt-like ridges) (W ₃₎ is about 1 to 2 mm. The interval (S ₃ ) between adjacent concave portions in the length direction of the band-shaped ridge is preferably about 5 to 15 mm, and the interval (S ₃ ^′ ) between adjacent concave portions in the width direction of the band-shaped ridge is preferable.
Is preferably about 5 to 20 mm. Further, the depth of each recess 10e is preferably about 0.5 to 1.5 mm with respect to the side surface 65a having a wall thickness (T3) of about 1 to ₃ mm.

The floor mat 1 of the present invention is generally used so as to be in close contact with the wall surface at the peripheral edge 51 of the peripheral portion 4a. Therefore, the floor mat 1 generally has a pressure in the direction of pushing against the wall surface (direction indicated by arrow B in FIG. 4) or the pressure in the direction of pulling from the wall surface (direction indicated by arrow C in FIG. 4). ) Works. For example, when pressure is applied to the band-shaped ridge 5 from the direction of the flat portion 4 in the pushing direction (the direction of arrow B), the wall (for example, In the embodiment of FIG.
a) is bent, and the width of the groove 6 can be reduced. On the other hand, when pressure is applied to the strip-shaped protruding portion 5 in the direction of pulling in the direction of the flat portion 4 (in the direction of arrow C), the bent wall portion (for example, the side wall portion 63 in the embodiment of FIG. 4).
By expanding a), the width of the groove 6 can be returned to the original length. The deformable area 61 is an area where such deformation is possible.

In the floor mat 1 of the present invention, the position where the concave structure is provided is, as described above, the side surface 65 of the groove 6.
It is not limited as long as it is (the side surface 65a on the peripheral edge 51 side and / or the side surface 65b on the flat portion 4 side of the strip-shaped protruding portion 5) and / or the bottom surface 66, and the concave structure 10 may be provided on any surface of the groove 6. Although the displacement of the floor mat 1 can be effectively prevented, the degree of deformation of the entire band-shaped ridge 5 when pressure is applied to the band-shaped ridge 5 is small, and as a result, the floor mat 1 It is preferable to provide a concave structure on the side surface 65a on the side of the peripheral edge 51 of the belt-shaped raised portion 5 in terms of excellent adhesion to the wall surface.

Further, the floor mat 1 of the present invention is
In the case of a laminate of the base material and the surface material layer 3, the peel strength between the base layer and the surface material layer can be increased by providing the concave structure 10 as described later in connection with a manufacturing method described later. it can. Considering that the separation between the base layer and the surface material layer is likely to occur at the peripheral edge of the floor mat, it is preferable to provide a concave structure on the side surface 65a on the peripheral edge 51 side of the belt-shaped raised portion 5.

In the floor mat 1 of the present invention, the concave structure 10 is provided on the inner wall surface of the hollow groove 6. That is, the groove 6 is formed in such a manner as not to affect the shape of the upper surface side of the band-shaped ridge 5.
The concave structure 10 is provided on the inner wall surface of the. Therefore, when observing from the upper surface side of the band-shaped ridge 5, the position where the concave structure 10 is provided and the position where the concave structure 10 is not provided cannot be distinguished at least on the shape. Thus, the floor mat 1 according to the present invention can satisfy the design requirements for the floor mat.

In the embodiment shown in FIGS. 1 to 4, the ceiling portion 64 of the groove 6 and the side wall portion 63 b on the flat portion 4 side correspond to the shape holding region 62. As described above, the floor mat 1 of the present invention is generally a laminate sheet of the base layer 2 made of an elastic soft material sheet and the surface material layer 3 made of a carpet or the like, or carries the surface material layer. Although it is not an elastic soft material sheet, in the embodiment shown in FIGS.
The shape holding region 62 has a wall thickness capable of holding the shape of the band-shaped ridge portion against a pressure change.

The embodiment shown in FIGS. 1 to 4 is an embodiment in which the shape holding region 62 has a wall thickness capable of holding the shape of the band-shaped ridge 5 against a pressure change. The mat can include various shape retaining regions that can retain the shape of the band-shaped ridge at the location where the pressure acts on the pressure change. Such a shape holding region is not particularly limited. For example, (1) A wall thickness larger than a minimum wall thickness necessary to hold the shape of the band-shaped ridge portion against a pressure change is set. (2) a shape holding region having a waist portion continuously extending in the length direction of the band-shaped ridge (hereinafter, referred to as a waist portion holding type shape holding region). Or (3) shape retention that includes a plurality of groove-inside projecting pieces that protrude from the part of the groove (in the width direction) toward the lower surface of the floor mat and that are discontinuous and independent of each other in the length direction of the groove. A region (hereinafter, referred to as a projecting piece carrying type shape holding region) and the like can be mentioned.

In the present specification, the "wall thickness of the shape holding region" is also the same as the "wall thickness of the band-shaped ridge", and the floor mat of the present invention comprises a laminate of a base layer and a surface material layer. In the case, it means the thickness of the base layer in the shape holding area, and when the floor mat of the present invention does not support the surface material layer and is composed of only the formed sheet, the thickness in the shape holding area of the formed sheet is Shall mean thickness. Less than,
The (1) thick-wall-type shape holding area, (2) the undulation-portion-holding-type shape holding area, and (3) the projecting-piece-holding-type shape holding area will be described in order.

The wall thickness of the thick-walled shape holding region [for example, FIG.
In the floor mat 1 shown in FIG.
4 (T ₁ ) or the thickness (T ₁ ^′ ) of the side wall 63b on the side of the flat portion 4] is generally thicker than the wall thickness of the deformable region 61 in the base layer 2, and moreover, the pressure change is less. On the other hand, the thickness is not particularly limited as long as the shape can maintain the shape of the band-shaped ridge. The wall thickness of the thick-walled shape holding region 62 is equal to the thickness of the entire side wall 63b and / or the entire ceiling 64 of the flat portion 4 corresponding to the thick-walled shape holding region 62.
With respect to the length direction and / or the width direction of the band-shaped ridge 5, it can be substantially constant, can be continuously reduced, or can be continuously increased. Note that, even in the case where the wall thickness of the deformable region is larger than the wall thickness of the thick-walled shape holding region, the deformable region is deformable in response to a pressure change. As long as the wall-shaped shape retaining region can retain the shape of the band-shaped ridge against pressure change, it is included in the scope of the present invention.

The wall thickness of the thick-walled shape holding region 62 is appropriately set according to, for example, the size and material of the floor mat 1, the size of the band-shaped ridge 5, or the wall thickness of the deformable region 61. For example, when the underlying layer is made of a thermoplastic resin, the thickness is usually 1 to
It is preferably 3 mm. In the case where the wall thickness of the thick-walled shape holding region 62 changes, the above-mentioned value indicates the value of the portion where the wall thickness is the largest.

The side wall 63b on the flat portion 4 side of the band-shaped ridge 5
[For example, the angle (θ) in the floor mat 1 shown in FIG. 4] between the groove side surface 65b and the lower surface extension surface of the flat portion 4
Is based on the state of the deformable area 61 at the time of molding (that is, the state in which the floor mat 1 according to the present invention is simply laid on the floor surface and no particular force is applied).
Preferably it is 90 °. If the angle is less than 45 °, curl linking may not be sufficiently prevented, and the pressure from the vertical direction may deform the thick wall type shape holding region 62.

Since the band-shaped ridge 5 including the thick-walled shape holding region 62 has the thick-walled shape holding region 62 extending continuously in the length direction of the band-shaped ridge, a sufficient shape for a force in various directions can be obtained. Shows holding action. For example, even when the band-shaped ridge is pressed with shoes or the like, or when the periphery is pressed against a wall surface, the shape holding region 62 exhibits an excellent shape holding effect.

Next, a description will be given, with reference to FIG. 7 and FIG. In the embodiment shown in FIG. 7 and FIG.
Is a undulation 8 extending continuously in the longitudinal direction of the band-shaped ridge 5.
Having. The undulation portion 8 is formed on a part (in the width direction) of the bottom surface side of one side surface (the side surface on the flat portion 4 side) 65b of the groove 6 and a bottom surface (that is, a ceiling surface inside the groove) 66 continuous therewith. In this embodiment, the shape of the floor mat protrudes from the bottom (in the width direction) in the direction of the lower surface of the floor mat. According to the above, the undulation portion 8 can be provided so as to protrude from a part (in the width direction) of the side surfaces 65a and 65b of the groove 6 toward the lower surface of the floor mat, or the bottom surface of the groove 6 (that is, the inside of the groove). (A ceiling surface) 66 (in the width direction) so as to protrude toward the lower surface of the floor mat.

That is, in the present specification, the “une part”
Is a part of one side of the groove of the band-shaped ridge, a part of the bottom of the groove (the ceiling surface inside the groove), or a part of one side of the groove of the band-shaped ridge and the bottom of the groove continuous with the groove. And a protrusion that protrudes from the groove and continuously extends in a band shape in the length direction of the band-shaped ridge. Since the undulation portion is supported on a part of the side wall surface and / or the bottom surface (ceiling surface) of the groove of the band-shaped ridge, the projection of the undulation portion from the side wall surface or the bottom surface is formed on the side wall surface or the bottom surface. In a part of the bottom surface (in the width direction), it continuously or intermittently increases, reaches a maximum projecting point, and then decreases continuously or intermittently. The degree of protrusion of the undulation from the side wall surface or bottom surface is not particularly limited, but is preferably substantially constant in the length direction.

Another aspect of the undulating portion holding shape retaining region 62b is schematically shown in the schematic enlarged partial sectional views of FIGS. In the floor mat 1 according to the present invention, when the undulation portion 8 is provided on a part of the side surface 65a, 65b of the groove 6, a part (in the width direction) of the side surface 65a, 65b on the bottom surface 66 side, the side surface A portion (with respect to the width direction) near the central portion of each of 65a and 65b (for example, the mode shown in FIG. 9);
Alternatively, it can be provided on any part of the part (in the width direction) on the lower surface direction side (including the end part) of the side surfaces 65a and 65b (for example, the mode shown in FIG. 10).

FIG. 9 shows a concave structure 1 on the side surface 65a on the peripheral side.
0 is provided, and an undulation portion 8 is provided at a part (in the width direction) of a central portion of the side surface 65b on the flat portion 4 side. In this embodiment, the area in which the concave structure 10 is provided becomes the deformable area 61.
The other region becomes a shape holding region, and in the shape holding region, the vicinity of the central portion of the side surface 65b becomes a undulating portion holding type shape holding region 62b. FIG. 10 shows an embodiment in which the concave portion structure 10 is provided on the side surface 65a, and the undulation portion 8 is provided on a part (in the width direction) of the groove 6 on the lower surface side (including the end portion) of the side surface 65b. In this embodiment, the area where the concave structure 10 is provided becomes the deformable area 61, and the other area becomes the shape holding area. In the shape holding area, the area on the lower surface direction side (including the end) of the side surface 65b is
It becomes the undulation part holding type shape holding area 62b.

FIG. 11 shows a concave structure 10 on the side surface 65a.
The part of the side surface 65b of the groove 6 (in the width direction) and the part of the bottom surface of the groove (that is, the ceiling surface inside the groove) 66 (in the width direction) which is continuous with the side surface 65b have a projecting distance from the bottom surface. And a mode in which the intermittently increasing drain portion 8 is provided. In this embodiment, the area where the concave structure 10 is provided becomes the deformable area 61, and the other area becomes the shape holding area. It becomes the part-carrying type shape holding region 62b. 9 to 11,
Although a description has been given of the floor mat having no surface layer made of a carpet or the like, the description of FIGS. 9 to 11 is also applicable to a laminated sheet type floor mat having a surface layer.

The cross-sectional shape of the undulation (cross-sectional shape in the width direction of the groove) is not particularly limited, and may be appropriately determined according to the cross-sectional shape of the groove and the shape stability to be imparted to the shape holding region. it can. Specifically, for example, an approximate sector, an approximate triangle, or an approximate square, which is a part of an approximate circle or an approximate ellipse, can be given. Further, the cross-sectional shape of the undulation portion is preferably the same and the same in size in the longitudinal direction of the band-shaped ridge portion, but the shape and / or size is changed continuously and / or intermittently. You can also.

For example, in the floor mat 1 shown in FIG. 8, the distance (g) between the edge 5a of the band-shaped ridge 5 on the flat portion 4 side and the edge 5b of the band-shaped ridge 5 on the peripheral edge 51 side. Is about 10 to 50 mm, and the height (depth:
For grooves 6 where h) is about 5-35 mm, the vertical dimension (d) of the undulations 8 is preferably about 4-34 mm, and the horizontal dimension (f) of the undulations 8 is about 5-25
mm, and a dimension (e) in the width direction of a region where the undulation portion 8 is not provided in the bottom surface 66 of the groove is about 2 to 20 m.
m is preferable.

In the shape holding region 62b for holding the undulation portion, the undulation portion 8 is provided in such a shape that the projection is carried on the inner wall surface of the hollow groove 6. That is, the protrusion is provided on the inner wall surface of the groove 6 in such a manner as not to affect the shape of the upper surface side of the band-shaped protrusion 5. Therefore, when observing from the upper surface side of the belt-shaped ridge 5, the position where the undulation portion 8 is provided and the position where the undulation portion 8 is not provided cannot be distinguished at least on the shape. Thus, in the floor mat 1 according to the present invention, even when the undulation portion 8 is provided, the design requirements for the floor mat can be satisfied.

Since the undulation-supporting shape retaining region 62b has the undulations 8 extending continuously in the longitudinal direction of the band-shaped ridge, the undulation retaining shape 62b exhibits a sufficient shape retaining action against forces in various directions. For example, even when the band-shaped ridge is pressed with shoes or the like, or when the rim is pressed against a wall surface, the undulation portion 8 exhibits an excellent shape retaining action.

Next, the projecting piece holding type shape holding area will be described with reference to FIGS. The projecting piece holding shape holding area 62c has a plurality of groove inside projecting pieces 7 which are mutually independent. The groove inner protruding piece 7 is provided so as to protrude from a part (in the width direction) of the groove 6 included in the shape holding region in the lower surface direction of the floor mat. In the floor mat of the present invention, the deformable region 61 and the shape holding region 62 are parallel to each other and extend continuously in the longitudinal direction of the band-shaped ridge 5, so that the band-shaped ridge 5 ( A deformable region 61 always exists in the transverse direction of the groove 6). Since the deformable region 61 does not have the groove inner projecting piece 7, the groove inner projecting piece 7 is formed on the entire surface of the groove 6 (in the width direction), that is, on one side surface of the groove 6 (the flat portion 4). Side surface) 65b (in the width direction), a continuous bottom surface (that is, the ceiling surface inside the groove) 66 (in the width direction), and another continuous side surface (in the peripheral edge 51 side) Is not provided continuously across the entire surface (in the width direction) of the side surface 65a.

In the embodiment shown in FIGS. 12 and 13,
The groove-inside protruding piece 7 is formed on one side surface (side surface on the flat portion 4 side) 65b of the groove 6 (in the width direction) and a part of a bottom surface (that is, a ceiling surface inside the groove) 66 continuous therewith. (With respect to the width direction) toward the lower surface of the floor mat. Further, the groove inside protruding piece 7 is, for example, as shown in FIG.
As shown in FIG. 13, a plurality of grooves 6 are discontinuously provided in the longitudinal direction of the groove 6 and are provided independently of each other at intervals in the longitudinal direction of the groove 6.

The lower surface of the groove inner protruding piece 7 (that is,
When the floor mat 1 according to the present invention is laid on the floor surface, the bottom surface in contact with or facing the floor surface is such that the deformable region 61 is in a state at the time of molding (that is, the floor mat 1 according to the present invention is simply placed on the floor surface). It is preferable to reach the lower surface extension surface of the flat portion 4 on the basis of only the laying down and no particular force is applied) (FIG. 13). You can also not. However,
In the latter case, when a force is applied to the floor mat 1 laid on the floor surface and the deformable area 61 is deformed, the lower surface side of the groove inner projecting piece 7 comes into contact with the floor surface and the groove inner projecting piece 7 It is preferable that the shape of the protruding piece-carrying shape holding region 62c having the shape can be held. Further, the lower surface of the groove inner protruding piece 7 protrudes further to the lower surface than the lower surface extension surface of the flat portion 4, so that the same effect as the above-mentioned anti-slip projection 21 can be obtained. However, if the floor mat 1 is laid on the floor surface when the floor mat 1 is to be protruded further to the lower surface side than the lower surface extension surface of the flat portion 4, the band-shaped raised portion 5 is
It is necessary to adjust the protruding length so that the height does not become too high, and conversely, the position shift is easily caused.
If the projection 21 exists on the lower surface of the flat portion 4, the projection 2
It is preferable that the degree of protrusion of the lower surface of the groove-inside protruding piece 7 be equal to or less than the degree of protrusion of the protrusion 21 so as not to reduce the anti-slip effect of 1.

Another aspect of the projecting piece-carrying shape holding area 62c is schematically shown in FIGS. 14 to 16
5A shows the arrangement state of the groove inside protruding pieces 7 in the groove 6, the edge 67 of the groove 6 on the peripheral edge 51 side, the edge 68 on the flat portion 4 side, and the groove internal protrusion therebetween. FIG. 17 is a schematic bottom view as viewed from the lower surface of the floor mat 1, schematically shown only by showing only the piece 7 (therefore, the recess structure is not shown), and FIGS. FIG. 2B is a schematic cross-sectional view showing the concave structure 10 provided in the deformable region 61 in addition to the cross section taken along the line bb in FIG.

FIG. 14 shows that the groove-inside projecting piece 7 is inclined at a predetermined angle (θ ₁ ) to project from the side wall surface of the groove 6 [FIG.
4 (a)], and the lower surface 71 of the groove inner protruding piece 7.
To the lower surface extension surface of the flat portion 4 [FIG.
(See (b)]]. The embodiment shown in FIG.
Except that the lower surface 71 of the groove inner protrusion 7 does not reach the lower surface extension surface of the flat portion 4, the groove inner protrusion 7
Are the same as those shown in FIG. 12 and FIG. 13 with respect to the direction (vertical) projecting from the side wall surface of the groove 6. Similarly, in the embodiment shown in FIG. 16, except that the lower surface 71 of the groove inner projecting piece 7 does not reach the lower surface extension surface of the flat portion 4, the groove inner projecting piece 7 has a predetermined angle ( It is the same as the embodiment shown in FIG. 14 in that it is inclined by θ ₁ ) and projects from the side wall surface of the groove 6.

FIGS. 12 to 16 show an embodiment in which the groove inner protruding pieces 7 are provided on the entire surface (in the width direction) of one side surface of the groove 6 and a part (in the width direction) of the bottom surface 66 continuous therewith. 12 to FIG. 14), or an embodiment in which the groove inner protruding piece 7 is provided on a part of one side surface of the groove 6 (in the width direction) and a part of the bottom surface 66 (in the width direction) continuous therewith (FIG. 15 or FIG. Although FIG. 16) is shown, the groove inside protruding piece 7 may be provided on the entire surface or a part of one side surface of the groove 6 and the entire surface (in the width direction) of the bottom surface 66 continuous therewith.
12 to 16 show the side surface 6 on the peripheral edge 51 side of the groove 6.
5a, a concave structure 10 is provided, and the side surface 6 of the groove 6 on the flat portion 4 side is provided.
Although the mode in which the groove inside protruding piece 7 is provided in 5b is shown, the groove inside protruding piece 7 can be provided according to the position of the deformable area. For example, a concave structure is provided on the side surface 65b of the groove 6 on the flat portion 4 side, and the groove inner projecting piece 7 is formed on the side surface 65a of the peripheral edge 51 side.
And the side surfaces 65a and / or 6
A concave structure may be provided in 5b so as to project from a part of the bottom surface 66 toward the lower surface.

FIG. 17 schematically shows still another embodiment of the protruding piece-carrying shape holding area 62c. FIGS. 17A and 17B are a schematic bottom view and a schematic sectional view, respectively, as in FIGS. 14 to 16.
In the embodiment shown in FIG. 17, the band-shaped ridge 5 is provided with the concave structure 10.
And a protruding piece-carrying shape holding area 62c having a plurality of groove-inside protruding pieces 7 independent of each other. In the embodiment shown in FIG.
0 is provided on a part (in the width direction) of the lower surface side (including the end) of one side surface (side surface on the side of the peripheral edge 51) 65a, and the groove internal protruding piece 7 is provided in the groove 6 included in the shape holding region. Of the one side surface (side surface on the flat portion 4 side) 65b on the bottom surface 66 side (in the width direction), the entire bottom surface (ceiling surface inside the groove) 66 continuous therewith (in the width direction), and continuous with it A part of the other side surface (side surface on the side of the peripheral edge 51) 65a is provided so as to protrude toward the lower surface of the floor mat (in the width direction). From the entire surface (in the width direction) and a part (in the width direction) of the other side surface (side surface on the side of the peripheral edge 51) 65a that is continuous with the entire surface (in the width direction). Further, the recess structure 10 may be provided on a part (in the width direction) of the side surface 65b on the lower surface direction side (including the end portion). In this case, the groove inner projecting piece 7 is Part of the side surface 65a on the bottom surface 66 side (with respect to the width direction) or the entire surface of the side surface 65a (with respect to the width direction), the entire continuous bottom surface (the ceiling surface inside the groove) 66 (with respect to the width direction), and continuous with it A portion (in the width direction) of the side surface 65b may be provided so as to protrude toward the lower surface of the floor mat.

The shape of the groove inner protruding piece 7 is not particularly limited, and can be appropriately determined according to the cross-sectional shape of the groove and the shape stability to be provided to the shape holding region. Specifically, for example, a substantially rectangular parallelepiped, a substantially cubic body, a substantially semi-cylindrical body, a quadrangular prism having a trapezoidal cross section, a columnar body having a sectoral cross section, or a columnar body having a triangular cross section can be given. Furthermore,
It is preferable to arrange the groove internal protrusions of the same shape periodically at the same interval, but it is preferable to combine groove internal protrusions of different shapes or combine groove internal protrusions of different sizes,
The arrangement interval can be changed.

For example, in the floor mat 1 shown in FIG. 12, the width (f ') of the bottom surface in the width direction is about 3 to 50 mm, and the height (depth) of the groove is about 3 to 50 mm. On the other hand, the distance (a ') between the groove inner projecting piece 7 and the adjacent groove inner projecting piece 7 is preferably about 10 to 100 mm. The size of the groove inner protruding piece 7 is, for example, about 2 to 50 mm in thickness (b ′) and about 3 to 45 m in width (c ′).
m, the height (d ′) is about 3 to 50 mm, and the dimension (e ′) of the ceiling 66 without the groove internal projection 7 is, for example,
It is about 3-48 mm.

In the protruding piece holding type shape holding area 62c, the groove inner protruding piece 7 is provided in a shape in which a protruding portion is supported on the inner wall surface of the hollow groove 6. That is, the protrusion is provided on the inner wall surface of the groove 6 in such a manner as not to affect the shape of the upper surface side of the band-shaped protrusion 5. Therefore, when viewed from the upper surface side of the strip-shaped protruding portion 5, at least on the shape, the groove inner projecting piece 7
The position where is provided is not distinguished from the position where it is not provided. Thus, in the floor mat 1 according to the present invention, even when the groove inner protruding piece 7 is provided,
The design requirements for floor mats can be satisfied.

In the protruding piece holding type shape holding area 62c, the groove inner protruding piece 7 is placed in the shape holding area 62c.
Install discontinuously in a direction parallel to the periphery. Since the groove-inside protruding pieces 7 are disposed discontinuously in the shape holding region 62c, the shape holding region 62c has a side wall portion 6 having a wall surface parallel to the length direction of the band-shaped ridge 5 (shape holding region 62c).
In addition to the 3 and / or ceiling 64, there is a groove-inside protruding piece 7 having a wall surface at a predetermined angle to the wall surface. Therefore, for example, the shape holding region 62 of the band-shaped ridge 5
Even if a force is applied to c from the direction of the flat portion 4 in the horizontal direction or from the vertical direction to the band-shaped ridge 5, the shape holding ability is excellent. In addition, the portion in which the groove inner protruding piece 7 is not arranged in the shape holding region 62c is combined with the groove inner protruding piece 7 adjacent thereto, and the portion itself in which the groove inner protruding piece 7 is not arranged,
It has a shape-retaining action against forces in various directions. That is, the shape holding region 62c is
The interaction between the portion where the groove is arranged and the portion where the groove inner protruding piece 7 is not arranged exhibits an excellent shape retaining action.

In the floor mat 1 of the present invention, at least a part of the shape holding region is provided with a thick-wall shape holding region, a undulation holding shape holding region, a projecting piece holding type shape holding region, or a combination thereof. Can be included.

As is apparent from the above description, the "groove" in the floor mat according to the present invention is a depression formed in the strip-shaped protruding portion and composed of the ceiling portion and the side wall portion continuous therewith. The recess structure and / or
Alternatively, in the case where the entire inside of the groove is in a hollow state without providing any protruding portion (for example, the undulation portion or the protruding piece), the wall thickness is band-like in the entire side wall portion and / or the entire ceiling portion. Whether it is substantially constant or continuously decreasing with respect to the length and / or width of the ridge,
Alternatively, it means a continuously increasing depression. Accordingly, the cross-sectional shape of the groove 6 (cross-sectional shape in the width direction of the groove) is not particularly limited, and is, for example, a semicircle, a semi-ellipse, or a polygon [for example, a trapezoid (see FIGS. 2 to 4), a square, and a ceiling]. Rectangle or triangle having a long side or a short side as a part], or a combination thereof.

It is to be noted that the “ceiling” and the “side wall” in this specification are necessarily included in the groove, and the “ceiling” in the groove is defined as the lower surface of the flat part of the floor mat. The height (depth) from the extension surface indicates the maximum value, or the maximum value and a value corresponding thereto, and the “side wall portion” in the groove is continuous with the ceiling portion, Means a portion extending to the edge of When the cross-sectional shape of the groove is, for example, trapezoidal, square, or rectangular, a horizontal portion (corresponding to the upper side of the trapezoid, square, or rectangle) located substantially at the center of the groove (in the width direction of the groove) A portion (corresponding to a side in a trapezoid, a square, or a rectangle) corresponding to the “ceiling portion” and corresponding thereto corresponds to the “side wall portion”. Further, when the cross-sectional shape of the groove is, for example, a semicircle or a semi-ellipse,
A substantially horizontal portion located substantially at the center of the groove (with respect to the width direction of the groove) corresponds to the “ceiling portion”, and a portion continuous thereto corresponds to the “sidewall portion”. When the cross-sectional shape of the groove is, for example, a triangle, the height (depth)
Is the maximum value (corresponding to the vertex in the triangle)
The vicinity located on both sides thereof corresponds to the “ceiling portion”, and a portion continuous therewith corresponds to the “side wall portion”.

In the floor mat 1 of the present invention, FIGS.
As shown in (1), it is preferable to provide the band-shaped ridge 5 on the entire periphery 4a. However, the band-shaped ridge 5 can be provided on at least a part of the periphery 4a. For example, the floor mat 1 [side (a), (b), (c),
(D), (e) and (f)] is used as a floor mat for a driver's seat of an automobile when the pressure from the driver's feet is mainly in the traveling direction (the direction of arrow A in FIG. 1). Often joins. Therefore, if the band-shaped ridges 5 are provided on the sides (a), (c), and (e), the displacement due to the pressure can be effectively prevented. In addition, when the band-shaped ridges 5 are provided on the sides (b), (d), and (f), it is possible to effectively prevent the displacement due to the pedaling force when getting on and off the driver's seat.

When the floor mat of the present invention comprises a laminate of an underlayer and a surface layer, the floor mat comprises only a molded sheet as a molding material for the underlayer or without carrying the surface layer. In such a case, the molding material may be a thermoplastic resin, for example, a thermoformable polyvinyl chloride, an ethylene-vinyl acetate copolymer, or polyethylene, as in the case of a conventional floor mat; a thermoplastic elastomer, for example, a styrene-based thermosetting resin. Thermoplastic elastomer, polyolefin-based thermoplastic elastomer, or polyvinyl chloride-based thermoplastic elastomer; thermosetting resin, for example, phenolic resin, polyurethane, or unsaturated polyester resin; or, natural rubber or synthetic rubber, for example, styrene-butadiene rubber , Butadiene rubber, isoprene rubber, or nitrile
It can be made of butadiene rubber or the like. The hardness (Shore A hardness) of the thermoformable material is preferably 50
~ 90, more preferably 65-80.

Among them, the thermoplastic elastomer is relatively soft and contributes to the adhesion to the floor wall, so that it can be suitably used. Further, the thermoplastic elastomer has advantages that it can be recycled, can be molded by a usual molding machine, has a short molding time, and can be continuously molded. Examples of the styrene-based thermoplastic elastomer include a polystyrene-polybutadiene-polystyrene (SBS) thermoplastic elastomer and a polystyrene-polyisoprene-polystyrene (SIS).
A thermoplastic elastomer can be used, and as the polyolefin-based thermoplastic elastomer, for example,
EPDM (ethylene-propylene-diene copolymer)
A blend of an olefin rubber such as an olefin rubber and an olefin resin such as a polypropylene, an alloy or a block copolymer can be used. Examples of the polyvinyl chloride elastomer include a blend of a nitrile rubber and a polyvinyl chloride. Can be suitably used. When a thermoplastic elastomer is used, a crosslinking treatment can be performed. Among these thermoplastic elastomers, olefin-based thermoplastic elastomers are lightweight,
Since it has excellent weather resistance, it can be suitably used.

When the floor mat of the present invention is composed of a laminate of a base layer and a surface layer, for example,
A tufted carpet, a needle punch carpet, a woven fabric, or the like can be used.

The floor mat of the present invention can be manufactured by various methods. For example, when the molding material is a thermoplastic resin, the floor mat is manufactured by the following method shown in FIGS. Is preferred. That is, FIG.
As shown in FIG. 8, a thermoplastic elastomer sheet 13 is placed on a surface material carpet 12 (supplied from a supply roll not shown) conveyed on a belt conveyor 11a.
Is supplied from the extrusion molding nozzle 14. In addition, the thermoplastic elastomer sheet 13 can be directly supplied from the extrusion molding nozzle 14 onto the belt conveyor 11a, and the carpet 12 can be placed thereon and sent to the next step. continue,
The belt conveyor 1 is passed through a buffer 15 provided in some cases.
It is sent to the auxiliary heater 17 by 1b. In the auxiliary heater 17, the elastomer sheet 13 is heated to a temperature at which cold pressing is possible in the next pressing step. However, when the elastomer sheet 13 is conveyed while being maintained at the molding temperature, it is not necessary to heat the sheet with the auxiliary heater 17.

Subsequently, the laminate is conveyed to the cold press device 18 by the belt conveyor 11b, the belt conveyor 11b is temporarily stopped, and the pair of forming dies 18a and 18b are sequentially moved by the cold press device 18. The stack is moved up and down to form a flat portion 4, a band-shaped ridge 5 at a position corresponding to a peripheral portion 4 a surrounding the flat portion 4, a concave structure 10, and optionally a surface of the flat portion 4 on the lower surface side. Anti-slip projections 21 (and, depending on the case, undulations 8 or projecting pieces 7 inside the groove)
Is formed, and at the same time, the carpet 12 and the elastomer sheet 13 are bonded. The molding die 18a is provided with molding projections for forming the concave structure 10 on the floor mat 1 of the present invention. In the press molding step, a larger pressure is applied to the laminate through the molding projections. As a result, the surface layer (the carpet 12 for the surface material) and the base layer (the thermoplastic elastomer sheet 13) can be strongly bonded to each other, and as a result, the peel strength between the surface layer and the base layer can be increased. . In addition, since sufficient peel strength can be obtained in a short time, damage to the surface layer does not occur.

Next, the press-formed laminate is transported to the cutting device 19, and cut at the individual peripheral edges 51 to produce the floor mat 1 of the present invention, which can be transported by the belt conveyor 11c. The cold press device 18 may be provided with a cutting means, and the press forming step and the cutting step may be performed simultaneously. Further, the cold press device 18 and the cutting device 1
It is preferable to synchronize the processing by 9 with the temporary stop of the belt conveyor 11b. In addition, the said buffer part 15 is
It is preferable to provide a buffer for adjusting the generally continuous conveyance by the belt conveyor 11a and the generally intermittent conveyance by the belt conveyor 11b.

Alternatively, as shown in FIG. 19, the thermoplastic elastomer sheet 13 is supplied from the extrusion molding nozzle 14 onto the belt conveyor 11a and sent to the auxiliary heater 17 by the belt conveyor 11a. The carpet 12 (supplied from the supply roll 12a). In the auxiliary heater 17, the elastomer sheet 13
Is heated to a temperature at which cold pressing is possible in the next pressing step using the emboss rollers 20a and 20b. However, when the temperature of the elastomer sheet 13 is maintained at the molding temperature, there is no need to heat the sheet with the auxiliary heater 17. In the process shown in FIG.
An elastomer sheet 13 can be supplied from an extrusion nozzle 14 onto the carpet 12 conveyed on 1a.

Subsequently, the sheet is sent to the embossing press device 20 by the belt conveyor 11a. In the embossing press device 20, the laminate is passed between the embossing rollers 20a and 20b, and a flat portion 4, a band-like ridge 5 at a position corresponding to a peripheral portion 4a surrounding the flat portion 4, The structure 10 and, if necessary, anti-slip projections 21 (and, in some cases, undulations 8 or groove-inside protruding pieces 7) formed on the lower surface side of the flat portion 4,
2 and the elastomer sheet 13 are adhered. The embossing roller 20b is provided with a molding projection for forming the concave structure 10 in the floor mat 1 of the present invention,
In the press forming step, since a larger pressure is applied to the laminate through the forming protrusions, the surface material layer (the surface material carpet 12) and the base layer (the thermoplastic elastomer sheet 13) are strongly bonded. As a result, the peel strength between the surface material layer and the base layer can be increased. Also,
Since sufficient peel strength can be obtained in a short time, damage to the surface material layer does not occur.

Next, the press-formed laminated body is conveyed to the cutting device 19 by the belt conveyor 11c via the belt conveyor 11b and the buffer part 15 provided as the case may be, and the belt conveyor 11c is temporarily stopped. The floor mat 1 of the present invention is manufactured by cutting at individual peripheral edges 51,
It can be conveyed by the belt conveyor 11d. In addition, the said buffer part 15 is the said belt conveyor 11
It is preferable to provide a buffer for adjusting the generally continuous conveyance by the belt conveyors 11a and 11b and the generally intermittent conveyance by the belt conveyor 11c.

Further, as shown in FIG. 20, the carpet 12 for the surface material and the thermoplastic elastomer sheet 13 are directly applied to the embossing rollers 20a and 20b arranged in parallel from the supply roll 12a and the extrusion molding nozzle 14, respectively. It can also be supplied. In this case, since the elastomer sheet 13 is supplied at a temperature at which cold pressing by the embossing device 20 is possible, there is no need to provide an auxiliary heater. In the embossing press device 20, the laminate of the carpet 12 for the front material and the thermoplastic elastomer sheet 13 is passed between the embossing rollers 20a and 20b, and the flat portion 4 and the peripheral portion surrounding the flat portion 4 are passed through the laminate. 4a, a band-shaped ridge 5, a concave structure 10, and possibly a non-slip projection 21 on the surface on the lower surface side of the flat portion 4 (and, in some cases, the undulation 8 or the protruding piece 7 in the groove). Is formed, and at the same time, the carpet 12 and the elastomer sheet 13 are bonded. The emboss roller 20
b is provided with a forming protrusion for forming the concave structure 10 in the floor mat 1 of the present invention, and in the press forming step, a larger pressure is applied to the laminate through the forming protrusion. Surface material layer (Carpet for surface material 1
2) and the underlying layer (thermoplastic elastomer sheet 13) can be strongly bonded, and as a result, the peel strength between the surface layer and the underlying layer can be increased. In addition, since sufficient peel strength can be obtained in a short time, damage to the surface layer does not occur.

Next, the press-formed laminated body is conveyed to the cutting device 19 by the belt conveyor 11b via the belt conveyor 11a and the buffer part 15 which is optionally provided, and the belt conveyor 11b is temporarily stopped. The floor mat 1 of the present invention is manufactured by cutting at individual peripheral edges 51,
It can be conveyed by the belt conveyor 11c. In addition, the said buffer part 15 is the said belt conveyor 11a.
Is preferably provided as a buffer for adjusting the generally continuous conveyance by the belt conveyor and the generally intermittent conveyance by the belt conveyor 11b.

As described above, the case where the molding material is a thermoplastic resin has been described as an example of the method for manufacturing the floor mat according to the present invention with reference to FIGS. 18 to 20, but the molding material is a thermosetting resin or an uncured resin. When rubber is used, the floor mat of the present invention can be manufactured using a heating press instead of the cold press 18.

The floor mat of the present invention is used for applications in which the periphery of the floor mat is brought into contact with a wall and, in some cases, is closely adhered to the extent that the periphery is bent, for example, an automobile floor mat, a store entrance floor mat, It can be used as a floor mat for home entrance.

[0071]

The floor mat according to the present invention has band-shaped ridges exhibiting appropriate deformability and shape retention, and thus exhibits various excellent characteristics. That is, since the belt-shaped ridge has flexibility, it has excellent adhesion to the floor wall, and can prevent earth and sand from entering between the floor mat and the floor. In addition, since the shape is excellent in shape retention, earth and sand can be held on the floor mat. In addition, since it has a band-like raised portion, it is difficult to slip and wrinkle. In addition, since the shape of a structure (for example, a concave structure, a ridge portion, a projecting piece, or the like) that imparts shape retention or deformability to the band-shaped ridge does not appear on the upper surface of the band-shaped ridge, the design is excellent. . Further, since the adhesiveness to the floor wall is excellent, the processing with a tape and the overlock processing which have been conventionally required become unnecessary, and the manufacturing process is simplified, and the manufacturing cost is reduced.

Further, even in the case of a floor mat composed of a laminate of a base layer and a surface material layer, when a molding die or an embossing roller is used to form a concave structure in the press molding step, the molding die is used. Or, through a molding protrusion provided on the embossing roller, a larger pressure is applied to the laminate, so that even with an underlayer made of a thermoplastic resin, the underlayer and the surface material layer can be strongly bonded to each other. As a result, the peel strength between the surface material layer and the base layer can be increased. Further, even if the contact time between the surface material layer and the base layer in the press molding is short, sufficient peel strength can be obtained, so that the contact time does not need to be lengthened. For example, damage to the carpet layer) can be minimized.

[Brief description of the drawings]

FIG. 1 is a perspective view of a floor mat according to one embodiment of the present invention as viewed from above.

FIG. 2 is an enlarged partial perspective view of a corner of the floor mat of FIG. 1 as viewed from above.

FIG. 3 is an enlarged partial perspective view of a corner portion of the floor mat of FIG. 1 viewed from a lower surface side.

FIG. 4 is an enlarged partial sectional view of the floor mat of FIG. 1;

FIG. 5 is an enlarged partial perspective view of another embodiment of a floor mat according to the present invention.

FIG. 6 is an enlarged partial perspective view of still another embodiment of a floor mat according to the present invention.

FIG. 7 is an enlarged partial perspective view of still another embodiment of a floor mat according to the present invention.

FIG. 8 is an enlarged partial sectional view of the floor mat of FIG. 7;

FIG. 9 is a schematic enlarged partial sectional view of a floor mat according to still another embodiment of the present invention.

FIG. 10 is a schematic enlarged partial sectional view of a floor mat according to still another embodiment of the present invention.

FIG. 11 is a schematic enlarged partial sectional view of a floor mat according to still another embodiment of the present invention.

FIG. 12 is an enlarged partial perspective view of still another embodiment of a floor mat according to the present invention.

13 is an enlarged partial cross-sectional view of the floor mat of FIG.

14 is an explanatory view schematically showing a floor mat of still another embodiment according to the present invention, FIG. 14 (a) is a schematic bottom view, and FIG. 14 (b) is a schematic sectional view.

FIG. 15 is an explanatory view schematically showing a floor mat of still another embodiment according to the present invention, wherein FIG. 15 (a) is a schematic bottom view and FIG. 15 (b) is a schematic sectional view.

FIG. 16 is an explanatory view schematically showing a floor mat according to still another embodiment of the present invention, wherein FIG. 16 (a) is a schematic bottom view, and FIG. 16 (b) is a schematic sectional view.

FIG. 17 is an explanatory view schematically showing a floor mat of still another embodiment according to the present invention. FIG. 17 (a) is a schematic bottom view, and FIG. 17 (b) is a schematic sectional view.

FIG. 18 is an explanatory view schematically showing a manufacturing process of the floor mat according to the present invention.

FIG. 19 is an explanatory view schematically showing another manufacturing process of the floor mat according to the present invention.

FIG. 20 is an explanatory view schematically showing still another manufacturing process of the floor mat according to the present invention.

[Explanation of symbols]

1. Floor mat; 2. Underlayer; 3. Surface layer; 4
..Flat portions; 4a.
・ Groove; 8 ・ ・ Under part; 10 ・ ・ Recess structure; 11a, 11
b, 11c · belt conveyor; 12 · carpet;
13. Elastomer sheet; 14. Extrusion nozzle; 15 Buffer section; 17 Auxiliary heater; 18 Cold press machine; 18a, 18b Mold; 19 Cutting machine;・ Embossing press device; 20a, 20b
..Emboss rollers; 21. Projections;
1 .. Deformable area; 62 .. Shape holding area; 63 ..
Side wall portion; 64 ceiling portion; 65a, 65b side surface of groove; 66 bottom surface of groove.

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Kazuhisa Taya 2-1-1, Matsuhamacho, Fukuyama City, Hiroshima Prefecture Inside Hiroshima Kasei Co., Ltd. (72) Inventor Seiichi Nakanishi 1128 Katsumecho, Moriyama City, Shiga Prefecture Japan Vilean (72) Inventor Motofumi Kikuchi 1128 Katsube-cho, Moriyama, Shiga

Claims (2)

[Claims] 1. A flat portion and a peripheral portion surrounding the flat portion, and at least a part of the peripheral portion extends continuously substantially in parallel with the peripheral edge and extends from a band-shaped protruding portion protruding in an upper surface direction. An edge on the flat portion side of the band-shaped ridge and a peripheral edge on the peripheral side of the band-shaped ridge are substantially parallel to each other; Includes a groove extending the length of the ridge; wherein the ridge is deformable in response to a change in pressure and is continuous along the length of the ridge. An elongated deformable region and a shape-retaining region capable of retaining the shape of the band-shaped ridge against a pressure change and continuously extending in the length direction of the band-shaped ridge, in a state parallel to each other. The deformable region has a concave structure on the groove side of the band-shaped ridge. The floor mat as described above. 2. A sheet material maintained at a press-moldable temperature is sent to a pair of molds capable of press-molding the floor mat having the shape according to claim 1, and the sheet is pressed by the mold. The method for manufacturing a floor mat according to claim 1, wherein the floor mat is processed and cut into individual floor mats.