Automobile carpet and manufacturing method thereof

Abstract

The present invention discloses a method for manufacturing a car carpet, comprising the following manufacturing steps: S1, raw material manufacturing; S2, compression molding; S3, cutting and edging; S4, combined installation; The present invention also proposes a car carpet, comprising a PE middle layer, a wear-resistant layer is installed on the top of the PE middle layer, and a bottom protective layer is installed on the bottom of the PE middle layer, a first through hole is provided on the top of the wear-resistant layer, and a finger groove is reserved on the top of one side inside the first through hole, a first installation groove is provided on the top of the PE middle layer, and a second installation groove is reserved on the bottom inside the first installation groove. The present invention separates the carpet body and the rubber pedal board, making maintenance and replacement convenient and quick, while reducing maintenance costs, being stable to use, and ensuring anti-slip function, increasing comfort during use, and collecting dust and water stains to avoid diffusion and affecting the interior environment of the car.

Description

Technical Field

[0001] The invention relates to the technical field of automobile accessories, and in particular to an automobile carpet and a manufacturing method thereof. Background Art

[0002] With the continuous progress of society, people's living standards are constantly improving, and the popularity of cars is also increasing, making people's travel more convenient. The production process of cars needs to go through many steps and is composed of multiple main parts, including the main support part, the drive part, the interior part, etc. The car carpet belongs to the interior part of the car, which can fully protect the bottom part of the car's interior, while increasing the beauty of the car's interior, making people more comfortable when driving.

[0003] When existing car carpets are used, they are generally of integrated design. During the installation process, they can fully wrap and protect the bottom of the car interior except for the seats and other necessary exposed parts, thereby ensuring their protective effect. However, in actual use, the part where people step on is worn and aged much faster than other parts due to long-term trampling by people, affecting its subsequent protective effect and overall aesthetics. However, since it is generally of integrated design, it is extremely troublesome to disassemble it for replacement or maintenance. The seats and other parts in the car need to be disassembled as a whole, and the cost is high. Therefore, many people choose to add an extra set of pedals to the carpet, but slippage is likely to occur between the pedals and the carpet, especially at the driver's position. The slippage has a greater impact on driving and is likely to cause certain safety hazards. At the same time, the existing carpets only have a protective effect against dust and water stains. The dust and water stains on the soles of the users' feet can easily enter the car and further spread in the car, affecting the interior environment. Summary of the invention

[0004] The purpose of the present invention is to solve the shortcomings of the prior art and to propose an automobile carpet and a manufacturing method thereof.

[0005] In order to achieve the above object, the present invention adopts the following technical solutions:

[0006] A method for manufacturing an automobile carpet comprises the following steps:

[0007] S1. Raw material production: the raw material of the carpet fabric is used to make the fabric into a flat plate shape, the skeleton layer material is heated to a molten state and evenly applied to the bottom of the fabric part, the base material layer is produced by a needle punching process, and the fabric layer, the skeleton layer and the base material layer are assembled up and down to form a composite material;

[0008] S2, compression molding, putting the composite material composed of the fabric layer, the skeleton layer and the bottom material layer into the compression molding equipment, heating and extruding it into a shape that fits the bottom of the car interior through the model equipment, the heating temperature is not less than 200°C, and the pressure is 7-15MPA;

[0009] S3, cutting and edge binding, using cutting and drilling equipment to cut and drill holes on the formed carpet, cut off the excess part, and make corresponding holes for installation, and finally use the edge strips to bind the cut edges to protect the exposed parts on the side;

[0010] S4. Combined installation: various accessories are installed and fixed on the carpet, and the finished carpet is finally cleaned and packaged for subsequent direct transportation and use.

[0011] The present invention also proposes an automobile carpet, comprising a PE middle layer, a wear-resistant layer is installed on the top of the PE middle layer, and a bottom protective layer is installed on the bottom of the PE middle layer, a first through hole is opened on the top of the wear-resistant layer, and a finger groove is reserved at the top of one side inside the first through hole, a first installation groove is opened on the top of the PE middle layer, and a second installation groove is reserved at the bottom inside the first installation groove, a first card groove is evenly opened at the bottom of the second installation groove, and a light metal plate is arranged inside the second installation groove, and a first elastic rubber ball is evenly installed at the bottom of the light metal plate , and the first elastic rubber ball extends to the inside of the first slot, the second slot is evenly opened on the top of the lightweight metal plate, and a collecting slot is evenly reserved on the top of the lightweight metal plate, a rubber pedal is arranged on the top of the lightweight metal plate, and a second elastic rubber ball is evenly installed on the bottom of the rubber pedal, and the second elastic rubber ball extends to the inside of the second slot, a third installation slot is evenly opened on the top of the rubber pedal, and connecting slots are reserved around the inside of the third installation slot, a movable block is arranged inside the third installation slot, and a fixed block is evenly installed on the top of the rubber pedal.

[0012] Preferably, the wear-resistant layer and the bottom protective layer are made of nylon and non-woven fabric respectively, and the wear-resistant layer and the bottom protective layer are fixedly connected by gluing with a PE intermediate layer respectively.

[0013] Preferably, the first elastic rubber ball is incompletely spherical, the center of the first elastic rubber ball is located inside the first slot, and the first elastic rubber ball is made of rubber.

[0014] Preferably, the cross-sectional shape of the collecting groove is square, and the collecting groove and the second card groove are staggered.

[0015] Preferably, the second elastic rubber ball is incompletely spherical, the center of the second elastic rubber ball is located inside the second slot, and the second elastic rubber ball is made of rubber.

[0016] Preferably, a second through hole is opened at the bottom of the connecting groove, and the second through hole is connected with the collecting groove, and the second through hole and the connecting groove form a funnel shape.

[0017] Preferably, a rubber spring is attached to the outer wall of the movable block, a rubber ring is connected between the movable block and the rubber pedal, and the top of the movable block is arc-shaped.

[0018] Preferably, the fixed block and the rubber pedal are made in one piece, and the top of the fixed block is arc-shaped. The fixed block and the connecting groove are located directly above the connecting groove, and the fixed block and the connecting groove correspond one to one, and the highest position of the top of the fixed block is lower than the highest position of the top of the movable block in the initial state.

[0019] Compared with the prior art, the present invention has the following beneficial effects:

[0020] 1. By using the rubber pedal as the footrest and separating the carpet body from the rubber pedal, when the rubber pedal is severely worn, the operator can easily disassemble and replace the rubber pedal without disassembling and replacing the entire carpet body, which is more convenient and quick and can reduce maintenance costs.

[0021] 2. Through the mutual fit between the lightweight metal plate and the second mounting groove, the mutual fit between the rubber pedal and the first mounting groove, the first elastic rubber ball and the first slot cooperate to further fix the lightweight metal plate, and the second slot and the second elastic rubber ball cooperate to further fix the rubber pedal. When there is no sufficient upward manual disassembly force, the lightweight metal plate and the rubber pedal can be fully fixed on the PE middle layer, thereby ensuring stability during use.

[0022] 3. A movable block, a rubber ring and a rubber spring are arranged inside the third mounting groove. The third mounting groove is connected with the connecting groove and the second through hole, and the second through hole is connected with the collecting groove. When the operator steps on the rubber pedal, the movable block and the rubber ring on the sole of the foot can be driven to slide downward, and the connecting groove is exposed. Most of the water stains and dust on the sole of the user's foot can enter the collecting groove through the connecting groove and the second through hole and be collected, thereby preventing dust and water stains from spreading on the surface of the vehicle for a long time and affecting the environment inside the vehicle.

[0023] 4. The movable blocks and fixed blocks are evenly arranged on the rubber pedal so that the movable blocks and fixed blocks can be used as anti-skid protrusions, thereby greatly increasing the anti-skid ability of the footrest. At the same time, when the user steps on the movable block, the movable block can slide downward by one end, thereby increasing the softness of the stepping area, thereby increasing the comfort of the carpet when used. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 This is a schematic diagram of the main cross-sectional structure of a car carpet proposed by the present invention;

[0025] Figure 2 For the present invention Figure 1 A schematic diagram of the enlarged structure at point A;

[0026] Figure 3 This is a schematic diagram of a top view and cross-sectional structure of a car carpet proposed by the present invention;

[0027] Figure 4 For the present invention Figure 3 A schematic diagram of the enlarged structure at B;

[0028] Figure 5 The figure is a schematic top view of the structure of a car carpet proposed by the present invention.

[0029] In the figure: 1 PE middle layer, 2 wear-resistant layer, 3 bottom protective layer, 4 first through hole, 5 finger groove, 6 first mounting groove, 7 second mounting groove, 8 first card slot, 9 lightweight metal plate, 10 first elastic rubber ball, 11 second card slot, 12 collecting slot, 13 rubber pedal, 14 second elastic rubber ball, 15 third mounting groove, 16 connecting groove, 17 second through hole, 18 movable block, 19 rubber ring, 20 rubber spring, 21 fixed block. DETAILED DESCRIPTION

[0030] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the specific embodiments of the present invention are described in detail below in conjunction with the accompanying drawings. In the following description, many specific details are set forth to facilitate a full understanding of the present invention. However, the present invention can be implemented in many other ways different from those described herein, and those skilled in the art can make similar improvements without violating the connotation of the present invention, so the present invention is not limited by the specific implementation disclosed below.

[0031] The present invention provides a method for manufacturing an automobile carpet, comprising the following steps:

[0032] S1. Raw material production: the raw material of the carpet fabric is used to make the fabric into a flat plate shape, the skeleton layer material is heated to a molten state and evenly applied to the bottom of the fabric part, the base material layer is produced by a needle punching process, and the fabric layer, the skeleton layer and the base material layer are assembled up and down to form a composite material;

[0033] S2, compression molding, putting the composite material composed of the fabric layer, the skeleton layer and the bottom material layer into the compression molding equipment, heating and extruding it into a shape that fits the bottom of the car interior through the model equipment, the heating temperature is not less than 200°C, and the pressure is 7-15MPA;

[0034] S3, cutting and edge binding, using cutting and drilling equipment to cut and drill holes on the formed carpet, cut off the excess part, and make corresponding holes for installation, and finally use the edge strips to bind the cut edges to protect the exposed parts on the side;

[0035] S4. Combined installation: various accessories are installed and fixed on the carpet, and the finished carpet is finally cleaned and packaged for subsequent direct transportation and use.

[0036] Reference Figure 1-5 The present invention also proposes an automobile carpet, comprising a PE middle layer, a wear-resistant layer 2 is installed on the top of the PE middle layer 1, and a bottom protective layer 3 is installed on the bottom of the PE middle layer 1, the wear-resistant layer 2 and the bottom protective layer 3 are made of nylon and non-woven fabric respectively, and the wear-resistant layer 2 and the bottom protective layer 3 are fixedly connected with the PE middle layer 1 by adhesive respectively, nylon material is a common fabric material for carpets, which can play a protective role such as wear resistance and waterproofing, and non-woven fabric is a common base material for carpets, which can slow down the molding stretching of the carpet body and increase the molding performance;

[0037] A first through hole 4 is provided at the top of the wear-resistant layer 2, and a finger groove 5 is reserved at the top of one side inside the first through hole 4. A first mounting groove 6 is provided at the top of the PE intermediate layer 1, and a second mounting groove 7 is reserved at the bottom inside the first mounting groove 6. A first card slot 8 is evenly provided at the bottom of the second mounting groove 7, and a light metal plate 9 is provided inside the second mounting groove 7. A first elastic rubber ball 10 is evenly installed at the bottom of the light metal plate 9, and the first elastic rubber ball 10 extends to the inside of the first card slot 8. The first elastic rubber ball 10 is incompletely spherical, and the center of the first elastic rubber ball 10 is located inside the first card slot 8. The first elastic rubber ball 10 is made of rubber material, so that when the operator places the light metal plate 9 in the second mounting groove 7 that fits therewith and presses it, the first elastic rubber ball 10 can be deformed to enter the inside of the first card slot 8, and cooperate with the first card slot 8 to fix the light metal plate 9. In the absence of sufficient upward external force, the light metal plate 9 can be fully stabilized inside the second mounting groove 7, thereby ensuring its stability during use;

[0038] The top of the light metal plate 9 is evenly provided with a second card slot 11, and the top of the light metal plate 9 is evenly reserved with a collection slot 12, the cross-sectional shape of the collection slot 12 is square, and the collection slot 12 and the second card slot 11 are staggered, so that when the operator cleans the collection slot 12, the light metal plate 9 can be disassembled and turned upside down to remove internal impurities, and further cleaned and disinfected with a cleaning liquid;

[0039] A rubber pedal 13 is arranged on the top of the lightweight metal plate 9, and a second elastic rubber ball 14 is evenly installed on the bottom of the rubber pedal 13, and the second elastic rubber ball 14 extends to the inside of the second card slot 11, the second elastic rubber ball 14 is incompletely spherical, and the center of the second elastic rubber ball 14 is located inside the second card slot 11, and the second elastic rubber ball 14 is made of rubber material, so that when the operator places the rubber pedal 13 in the first mounting groove 6 that matches it and presses it, the second elastic rubber ball 14 can be deformed and enter the inside of the second card slot 11, and cooperate with the second card slot 11 to fix the rubber pedal 13, and in the absence of sufficient upward external force, the rubber pedal 13 can be fully stabilized inside the first mounting groove 6, thereby ensuring its stability during use;

[0040] The top of the rubber pedal 13 is evenly provided with a third installation groove 15, and the third installation groove 15 is provided with a connecting groove 16 around it. The bottom of the connecting groove 16 is provided with a second through hole 17, and the second through hole 17 is connected with the collecting groove 12, and the second through hole 17 and the connecting groove 16 form a funnel shape, so that dust and water stains can enter the inside of the connecting groove 16 and then enter the inside of the second through hole 17, and then further fall into the inside of the collecting groove 12 for collection;

[0041] A movable block 18 is arranged inside the third installation groove 15, a rubber spring 20 is pasted on the outer wall of the movable block 18, and a rubber ring 19 is connected between the movable block 18 and the rubber stepping plate 13, and the top of the movable block 18 is arc-shaped, and the movable block 18 and the rubber ring 19 are slidably connected with the third installation groove 15, so that when the user steps on it, the movable block 18 can slide downward to a certain extent, so that the connecting groove 16 is connected with the third installation groove 15, and then the dust and water stains can be guided by the arc edge of the movable block 18 to roll or flow into the inside of the connecting groove 16, so as to complete the collection;

[0042] A fixed block 21 is evenly installed on the top of the rubber pedal 13. The fixed block 21 and the rubber pedal 13 are made as one piece, and the top of the fixed block 21 is arc-shaped. The fixed block 21 and the connecting groove 16 are located directly above the connecting groove 16, and the fixed block 21 corresponds to the connecting groove 16 one by one, and the highest position of the top of the fixed block 21 is lower than the highest position of the top of the movable block 18 in the initial state. The fixed block 21 can cooperate with the movable block 18 to play a protective role, and at the same time, the fixed block 21 will not hinder the downward movement of the movable block 18 when it is stepped on.

[0043] When the present invention is used, Figure 1-5As shown, after the carpet is manufactured according to the process, the main body consisting of the PE middle layer 1, the wear-resistant layer 2 and the bottom protective layer 3 is installed at the bottom of the car, and the second installation groove 7 is just located at the stepping point in front of the seat. The light metal plate 9 is fitted with the second installation groove 7, and the light metal plate 9 is placed inside the second installation groove 7, so that the first elastic rubber ball 10 at the bottom of the light metal plate 9 corresponds to the first card groove 8 at the bottom of the second installation groove 7. At this time, the light metal plate 9 is pressed downward with force, so that the arc edge of the first elastic rubber ball 10 and the edge of the first card groove 8 are squeezed against each other. When the squeezing force is sufficient, the first elastic rubber ball 10 can be deformed, thereby making the first elastic rubber ball 10 It can be fully inserted into the first slot 8. At this time, the lightweight metal plate 9 is completely in the second mounting slot 7. The first elastic rubber ball 10 returns to its initial state. When there is no sufficient upward separation force, the first elastic rubber ball 10 can cooperate with the first slot 8 to fix the lightweight metal plate 9 in the second mounting slot 7, thereby ensuring the stability of the lightweight metal plate 9. Through the fit of the rubber pedal 13 with the first mounting slot 6, the rubber pedal 13 is placed in the first mounting slot 6 and pressed hard. Similarly, the second elastic rubber ball 14 fully enters the second slot 11 under the action of sufficient pressing force, and cooperates with the second slot 11 to fix the rubber pedal 13, thereby ensuring To ensure the stability of the rubber pedal 13 during use, when the user steps on the rubber pedal 13, the protruding movable block 18 is provided inside the third mounting groove 15, and the fixed block 21 is provided on the rubber pedal 13, so that the movable block 18 and the fixed block 21 can act as anti-slip convex blocks to play an anti-slip role. At the same time, the movable block 18 and the rubber ring 19 are slidably connected with the third mounting groove 15, and the elasticity of the rubber spring 20 enables the movable block 18 to slide downward to a certain extent when the user steps on it, thereby increasing the softness and making the user more comfortable when stepping on it. When the soles of the user's feet are stained with water stains or dust, the dust falls on the movable block 18 and the fixed block 2 under the action of stepping. 1, and after the movable block 18 slides downward, the arc-shaped edge at the top of the movable block 18 cannot close the edge of the third installation groove 15, and the connecting groove 16 is connected with the third installation groove 15. Most of the dust or water stains on the fixed block 21 flow or roll into the inside of the connecting groove 16 along the arc, and further enter the inside of the collecting groove 12 through the second through hole 17. When the user releases the stepping, under the elastic action of the rubber spring 20, the movable block 18 and the rubber ring 19 slide upward to restore to the initial position, so that the connecting groove 16 is closed, thereby preventing the dust in the collecting groove 12 from spreading outward, and further assisting in collecting dust and water stains, and preventing them from continuing to spread in the car and affecting the interior environment of the car;

[0044] When the rubber pedal 13 is severely worn and needs to be replaced, insert a finger into the finger groove 5 on the wear-resistant layer 2 to apply force to the rubber pedal 13, lift the rubber pedal 13 upward, and through the elasticity of the second elastic rubber ball 14, under the action of a sufficiently upward external force, the second elastic rubber ball 14 can be squeezed out from the inside of the second card slot 11, so that the rubber pedal 13 can be taken out from the inside of the first mounting slot 6 for replacement. When the inside of the collecting slot 12 needs to be cleaned, after the rubber pedal 13 is taken out from the first mounting slot 6, insert a finger into the inside of the collecting slot 12 to apply force to pull out the lightweight metal plate 9 vertically upward. Through the elasticity of the first elastic rubber ball 10, under the action of a sufficiently upward external force, the first elastic rubber ball 10 can be deformed and squeezed out from the inside of the first card slot 8, so that the lightweight metal plate 9 can be taken out from the inside of the second mounting slot 7, and the lightweight metal plate 9 can be taken out for thorough cleaning.

[0045] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical scheme and inventive concept of the present invention within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.

Claims

1. An automotive carpet, comprising a PE middle layer (1), characterized in that: The top of the PE intermediate layer (1) is provided with a wear-resistant layer (2), and the bottom of the PE intermediate layer (1) is provided with a bottom protective layer (3), the top of the wear-resistant layer (2) is provided with a first through hole (4), and a finger groove (5) is reserved at the top of one side inside the first through hole (4), the top of the PE intermediate layer (1) is provided with a first installation groove (6), and a second installation groove (7) is reserved at the bottom inside the first installation groove (6), the bottom of the second installation groove (7) is evenly provided with a first card groove (8), and a light metal plate (9) is arranged inside the second installation groove (7), and the bottom of the light metal plate (9) is evenly provided with a first elastic rubber ball (10), and the first elastic rubber ball (10) extends to the first card groove (8) ), the top of the light metal plate (9) is uniformly provided with a second slot (11), and the top of the light metal plate (9) is uniformly provided with a collecting slot (12), the top of the light metal plate (9) is provided with a rubber pedal (13), and the bottom of the rubber pedal (13) is uniformly provided with a second elastic rubber ball (14), and the second elastic rubber ball (14) extends to the inside of the second slot (11), the top of the rubber pedal (13) is uniformly provided with a third installation slot (15), and the third installation slot (15) is surrounded by connecting slots (16), the inside of the third installation slot (15) is provided with a movable block (18), and the top of the rubber pedal (13) is uniformly provided with a fixed block (21); The wear-resistant layer (2) is made of nylon, the bottom protective layer (3) is made of non-woven fabric, and the wear-resistant layer (2) and the bottom protective layer (3) are respectively fixedly connected by gluing to the PE intermediate layer (1); The cross-sectional shape of the collecting groove (12) is square, and the collecting groove (12) and the second card groove (11) are arranged in a staggered manner; A second through hole (17) is provided at the bottom of the connecting groove (16), and the second through hole (17) is connected to the collecting groove (12), and the second through hole (17) and the connecting groove (16) form a funnel shape; A rubber spring (20) is adhered to the outer wall of the movable block (18), a rubber ring (19) is connected between the movable block (18) and the rubber pedal (13), and the top of the movable block (18) is arc-shaped.

2. The automotive carpet according to claim 1, characterized in that: The first elastic rubber ball (10) is incompletely spherical, the center of the first elastic rubber ball (10) is located inside the first clamping groove (8), and the first elastic rubber ball (10) is made of rubber material.

3. The automotive carpet according to claim 1, characterized in that: The second elastic rubber ball (14) is incompletely spherical, the center of the second elastic rubber ball (14) is located inside the second clamping groove (11), and the second elastic rubber ball (14) is made of rubber material.

4. The automotive carpet according to claim 1, characterized in that: The fixed block (21) and the rubber pedal (13) are integrally manufactured, and the top of the fixed block (21) is arc-shaped. The fixed block (21) is located directly above the connecting groove (16), and the fixed block (21) corresponds to the connecting groove (16) one by one, and the highest position of the top of the fixed block (21) is lower than the highest position of the top of the movable block (18) in the initial state.

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