Glutinous floor mat for vehicle and method for manufacturing same

Abstract

The present invention relates to a glossy floor mat for a vehicle and a method for manufacturing the same, and more particularly, to a floor mat for a vehicle, the color tone or the gloss of which differs depending on the viewing angle, so as to exhibit a more brand-new design. This floor mat (1) for a vehicle is provided with: a base fabric (20); cut pile yarns (10) implanted in the base fabric; and a pre-coating layer (31) provided on the back surface of the base fabric. The cut pile yarn includes: a glossy yarn (11) relatively glossy; and a matt line (12) which is relatively matt and has greater crinkling properties than the glossy line. On the surface side of the base fabric, the height of the glossy lines (11) is higher than the height of the matt lines (12).

Description

TECHNICAL FIELD

[0001] The present application relates to a floor mat for a vehicle to be placed under the feet of a driver or a passenger of the vehicle, and more particularly to a floor mat for a vehicle having a gloss. BACKGROUND

[0002] As a floor mat for a vehicle, a tufted carpet type in which pile yarns are tufted into a base cloth and a backing layer of synthetic resin or rubber is provided on the back surface of the base cloth is known.

[0003] The color tone of the surface of such a floor mat for a vehicle is set variously by dyeing after tufting or coloring of the pile yarns used as such, but there is a problem of lack of design.

[0004] Japanese Patent Application Publication No. 2005-323950 (Patent Document 1) discloses a light-reflecting floor mat having a lighting function and a display function. The light-reflecting floor mat disclosed in this document uses a glossy thread for a portion of the threads constituting the fabric of the base cloth in a specific area so as to reflect light in the specific area.

[0005] Japanese Utility Model Registration No. 3015364 (Patent Document 2) discloses a car mat in which pile yarns containing gold and silver threads are tufted on the surface side of a base cloth, and a backing layer of rubber or synthetic resin is formed on the back surface side of the base cloth. According to this structure, since the color tone of the pile yarns is added with the shining metallic gloss of the gold and silver threads, the surface of the car mat displays a unique metallic gloss that has never been seen before, and the design is improved.

[0006] [Related Art Documents]

[0007] [Patent Documents]

[0008] Patent Document 1: Japanese Patent Application Publication No. 2005-323950

[0009] Patent Document 2: Japanese Utility Model Registration No. 3015364 SUMMARY

[0010] [Problems to be Solved by the Invention]

[0011] In the floor mat or car mat disclosed in Japanese Patent Application Publication No. 2005-323950 (Patent Document 1) or Japanese Utility Model Registration No. 3015364 (Patent Document 2), although a gloss is presented by tufting a thread having a gloss into a base cloth, the gloss does not change, and there is no change in the color tone or the gloss even when the floor mat or car mat is viewed from any angle.

[0012] An object of the present application is to provide a vehicle floor mat in which the color tone or the glossiness varies depending on the angle of view, thereby achieving a more novel design.

[0013] [Means for solving the technical problem]

[0014] The vehicle floor mat of the present application includes a base fabric, cut pile yarns implanted in the base fabric, and a precoat layer provided on the back surface of the base fabric. The cut pile yarns include a glossy yarn having gloss and a matte yarn having no gloss and having greater crimp than the glossy yarn. The height of the glossy yarn is higher than the height of the matte yarn on the surface side of the base fabric.

[0015] The material of the glossy yarn is, for example, polyester or polyamide, and the material of the matte yarn is, for example, polypropylene or polyamide.

[0016] In one embodiment, the glossy yarn is a glossy twisted yarn twisted from a plurality of fiber yarns having gloss, and the matte yarn is a matte straight yarn that is not twisted.

[0017] In another embodiment, the glossy yarn is a glossy twisted yarn twisted from a plurality of fiber yarns having gloss, and the matte yarn is a matte twisted yarn twisted from a plurality of fiber yarns having no gloss. In this case, the number of twists of the glossy twisted yarn is greater than the number of twists of the matte twisted yarn.

[0018] In still another embodiment, the glossy yarn is a glossy twisted yarn twisted from a plurality of fiber yarns having gloss, and the matte yarn is a matte twisted yarn twisted from a plurality of fiber yarns having no gloss. In this case, the heat setting temperature of the glossy twisted yarn is higher than the heat setting temperature of the matte twisted yarn.

[0019] The protruding length of the leading end of the glossy yarn upward from the matte yarn is, for example, in the range of 1 to 3 mm.

[0020] The area occupied by the glossy yarn when the cut pile yarns implanted in the base fabric are viewed from above is, for example, in the range of 5 to 20%.

[0021] The method for manufacturing the vehicle floor mat of the present application includes the following steps.

[0022] (a) a step of preparing a glossy yarn having gloss and a matte yarn having no gloss and having greater crimp than the glossy yarn.

[0023] (b) a step of implanting the glossy yarn and the matte yarn in a base fabric.

[0024] (c) a pre-coating layer is provided on the back of the base fabric to prevent the shedding of the lustrous threads and the non-lustrous threads, and a heating step is performed at a predetermined heating temperature.

[0025] (d) a step of making the non-lustrous threads curl by the heating in the heating step, and making the leading ends of the lustrous threads more protrude upward than the non-lustrous threads.

[0026] In one embodiment, the lustrous threads are lustrous twisted threads made by twisting a plurality of polyester or polyamide fibers having luster, and heat setting at 130 to 160°C. Further, the heating temperature in the heating step is 100°C or higher and less than 130°C.

[0027] The non-lustrous threads are, for example, non-lustrous twisted threads made by twisting a plurality of polypropylene or polyamide fibers having no luster, and not performing heat setting thereafter. In another embodiment, the non-lustrous threads are non-lustrous twisted threads made by twisting a plurality of polypropylene or polyamide fibers having no luster, and heat setting at 110 to 130°C thereafter.

[0028] [Effects of the Invention]

[0029] In the vehicle floor mat of the present application, the leading ends of the lustrous threads protrude upward from the non-lustrous threads around them, so that the presence of the lustrous threads protruding upward is particularly noticeable when the surface of the vehicle floor mat is viewed from an oblique direction, and the surface of the cut pile yarns as a whole appears to have a lustrous appearance. On the other hand, when the surface of the vehicle floor mat is viewed from a vertical direction, the presence of the lustrous threads is hidden in the non-lustrous threads around them, and the color tone of the non-lustrous threads as a whole is noticeable, and no lustrous appearance is present.

[0030] As described above, according to the vehicle floor mat of the present application, the color tone or the lustrous appearance differs depending on the viewing angle. BRIEF DESCRIPTION OF DRAWINGS

[0031] Figure 1 A diagrammatic cross-sectional view showing one embodiment of the vehicle floor mat of the present application.

[0032] Figure 2 A diagrammatic view showing lustrous threads and non-lustrous threads.

[0033] Figure 3 A diagram showing one embodiment of the manufacturing method of the vehicle floor mat of the present application.

[0034] Figure 4 A diagrammatic view of the state of the cut pile yarns after being implanted in the base fabric, without heating in the heating step.

[0035] Figure 5 A diagrammatic view showing the difference in height of the cut pile yarns after heating in the heating step.

[0036] Reference Signs List

[0037] 1 Floor mat for vehicle

[0038] 10 Cut-pile yarn

[0039] 11 Glossy yarn

[0040] 12 Matt yarn

[0041] 12a Matt straight yarn

[0042] 12b Matt twisted yarn

[0043] 20 Base fabric

[0044] 31 Pre-coating layer

[0045] 32 Substrate layer DETAILED DESCRIPTION

[0046] Reference Signs List Figure 1 An embodiment of a floor mat for vehicle according to the present application is described. The floor mat for vehicle 1 is provided with a base fabric 20, a cut-pile yarn 10 implanted in the base fabric 20, a pre-coating layer 31 provided on the back surface of the base fabric 20, and a substrate layer 32 attached to the back surface of the pre-coating layer 31.

[0047] The base fabric 20 is, for example, a sheet of a resin material that is hard and has a high melting point. The cut-pile yarn 10 is a yarn obtained by cutting the loop portion on the surface of the base fabric 20 at the same time as the implantation (tufting) of pile yarns, and each of the yarns is dispersed and stands on the base fabric 20. The material of the cut-pile yarn 10 is, for example, polyester, polypropylene, polyamide, nylon, or the like.

[0048] The pre-coating layer 31 is mainly a rubber layer or an SBR resin layer applied to the back surface of the base fabric 20 to prevent the cut-pile yarn 10 implanted in the base fabric 20 from falling off. The material of the substrate layer 32 attached to the back surface of the pre-coating layer 31 is, for example, polyethylene, thermoplastic rubber, or thermoplastic elastomer. The back surface of the substrate layer 32 can also be subjected to slip-preventing processing. In addition, a secondary base fabric (non-woven fabric) can also be attached to the back surface of the substrate layer 32.

[0049] The embodiment is characterized in that the cut-pile yarn 10 includes a glossy yarn 11 that has gloss and a matt yarn 12 that has no gloss and has greater crimping than the glossy yarn 11, and the height of the glossy yarn 11 is higher than the height of the matt yarn 12 on the surface side of the base fabric 20.

[0050] The term "shrinkage" refers to the degree of thermal shrinkage of the thread before and after heating. Even if the glossy thread 11 and the matte thread 12 erected on the base fabric 20 have the same length (height) before heating, the matte thread 12 will shrink significantly due to the heating during the formation of the pre-coating layer 31, causing the leading edge of the glossy thread 11 to protrude above the surrounding matte thread 12. This state is as follows: Figure 1 As shown.

[0051] The material of the glossy thread 11 is, for example, polyester with a softening point temperature of approximately 230 to 240°C. The material of the matte thread 12 is, for example, polypropylene with a softening point temperature of approximately 140 to 160°C. In order to reduce the shrinkage of the glossy thread 11 (to minimize the degree of thermal shrinkage before and after heating), in a preferred embodiment, the glossy thread 11 is a glossy twisted thread formed by twisting together multiple glossy fiber threads, and more preferably, a glossy twisted thread formed by heat setting at a temperature range higher than the heating temperature range (above 100°C and below 130°C) during the formation of the pre-coating layer (e.g., 130°C to 160°C). The glossy thread 11 formed by heat setting at a temperature range of 130°C to 160°C will not revert to its twisted state even under the heating state during the formation of the pre-coating layer, thus minimizing the degree of shrinkage (thermal shrinkage).

[0052] The glossy thread 11 is a thread that has been dyed to a glossy color (e.g., gold or silver). In the case of glossy twisted thread, each twisted fiber has been dyed to a glossy color.

[0053] In one embodiment, for example, the matte yarn 12 made of polypropylene is a matte twisted yarn formed by twisting together multiple matte fiber yarns. It is more preferably a matte twisted yarn formed by heat setting at a temperature range lower than the softening point temperature (140 to 160°C) (e.g., 110 to 130°C). Since the matte twisted yarn 12 will recover from the twisting under the heating state (above 100°C but below 130°C) during the formation of the pre-coating layer, the degree of shrinkage (heat shrinkage) is relatively large.

[0054] Therefore, as Figure 1 As shown, in the completed vehicle floor mat 1 with the pre-coating layer 31 applied and the substrate layer 32 adhered, the height of the matte yarns 12, which have greater shrinkage, is reduced, and the leading edge of the glossy yarns 11 protrudes above the surrounding matte yarns 12. The upward protrusion length of the glossy yarns 11 above the surrounding matte yarns 12 is, for example, in the range of 1 to 3 mm. Furthermore, when viewed from above (directly above), the area occupied by the glossy yarns 10 embedded in the base fabric 20 is, for example, in the range of 5 to 20%.

[0055] Although some parts of the explanation above are repeated, the following references... Figures 2 to 5 This describes the manufacturing method of vehicle floor mat 1.Figure 3 Each step of the manufacturing method is shown.

[0056] First, in step S1, a lustrous thread 11 and a matte thread 12 are prepared. The lustrous thread 11 has relatively small crimping, and the matte thread 12 has relatively large crimping when compared in terms of crimping. Hereinafter, several combinations of the types of the lustrous thread 11 and the matte thread 12 that produce such a difference in crimping are described.

[0057] [Combination Example 1]

[0058] As shown in (a) of FIG. 10, the lustrous thread 11 is provided as a lustrous twisted thread in which a plurality of lustrous fiber threads are twisted. On the other hand, as shown in (b) of FIG. 10, the matte thread 12 is provided as a matte straight thread 12a that is not twisted. The lustrous thread 11 hardly crimps even in a heated state during formation of the pre-coat layer, but the matte straight thread 12a greatly crimps in the heated state during formation of the pre-coat layer. Figure 2 Figure 2 [Combination Example 2]

[0059] As shown in (a) of FIG. 11, the lustrous thread 11 is provided as a lustrous twisted thread in which a plurality of lustrous fiber threads are twisted. On the other hand, as shown in (c) of FIG. 11, the matte thread 12 is provided as a matte twisted thread 12b in which a plurality of matte fiber threads are twisted. The number of twists of the lustrous twisted thread 11 is set to be larger than the number of twists of the matte twisted thread 12b. Therefore, even if recovery of twisting occurs in a heated state during formation of the pre-coat layer, the crimping of the matte twisted thread 12b having a small number of twists is greater than the crimping of the lustrous twisted thread 11 having a large number of twists.

[0060] [Combination Example 3] Figure 2 Figure 2 Although both the lustrous thread 11 and the matte thread 12 are provided as twisted threads, the material of the lustrous thread is provided as a resin having a relatively high melting point, and the material of the matte thread is provided as a resin having a relatively low melting point. Therefore, if the temperature of heat setting that fixes the twisting is compared, the temperature of heat setting of the lustrous thread is higher than the temperature of heat setting of the matte thread. Due to the difference in the temperature of heat setting, the lustrous thread hardly crimps even in a heated state during formation of the pre-coat layer, but the matte thread greatly crimps in the heated state during formation of the pre-coat layer.

[0061] [Combination Example 4]

[0062] Although both the lustrous thread 11 and the matte thread 12 are provided as twisted threads, the material of the lustrous thread is provided as a resin having a relatively high melting point, and the material of the matte thread is provided as a resin having a relatively low melting point. Therefore, if the temperature of heat setting that fixes the twisting is compared, the temperature of heat setting of the lustrous thread is higher than the temperature of heat setting of the matte thread. Due to the difference in the temperature of heat setting, the lustrous thread hardly crimps even in a heated state during formation of the pre-coat layer, but the matte thread greatly crimps in the heated state during formation of the pre-coat layer.

[0063] [Combination Example 4]

[0064] ​​Although both the glossy thread 11 and the matte thread 12 are provided as straight threads without twist, the material of the glossy thread 11 is provided as a resin with a small coefficient of linear expansion, and the material of the matte thread 12 is provided as a resin with a large coefficient of linear expansion. Due to this difference in the coefficient of linear expansion, the heating state during the formation of the pre-coat layer causes the matte thread 12 to shrink more than the glossy thread 11, and as a result, the leading end of the glossy thread 11 protrudes more upward than the surrounding matte thread 12.

[0065] Next, in step S2, the glossy thread 11 and the matte thread 12 are implanted in the base fabric 20. Specifically, the glossy thread 11 and the matte thread 12 are threaded, and tufted through the needle holes of a tufting machine, while cutting the loops of the pile yarns on the surface of the base fabric 20 to become the cut pile yarns 10. At this point, the heights of the respective cut pile yarns standing on the base fabric 20 are the same.

[0066] Next, in step S3, in order to prevent the cut pile yarns 10 from falling off, SBR resin 31 is applied to the back surface of the base fabric 20, and dried in a dryer at a temperature of 100 to 130°C.

[0067] Next, in step S4, a backing layer 32 is attached to the back surface of the dried pre-coat layer 31. At this time, pressure can be applied to the attached backing layer 32.

[0068] Figure 4 A state before heating during the formation of the pre-coat layer is shown, Figure 5 A state after heating during the formation of the pre-coat layer is shown. In the state before heating, the glossy thread 11 and the matte thread 12 standing on the base fabric 20 have the same height, but in the state after heating, the matte thread 12 is greatly shrunk, and as a result, the leading end of the glossy thread 11 protrudes to a position above the surrounding matte thread 12.

[0069] The glossy thread 11 is dispersed substantially uniformly over the entire surface of the cut pile yarns 10, and occupies an area of about 5 to 20% of the entire surface. In addition, the protruding length of the leading end of the glossy thread 11 upward is about 1 to 3 mm.

[0070] Therefore, if the finished vehicle floor mat 1 is viewed from above (directly above), the glossy thread 11 is hidden in the surrounding matte thread 12, and the presence of the glossy thread 11 is not conspicuous. Therefore, the entire surface of the cut pile yarns 10 appears to have a matte color, and does not exhibit a glossy appearance.

[0071] On the other hand, if the finished vehicle floor mat 1 is viewed from an oblique direction slightly above the horizontal, the presence of the glossy thread 11 protruding above the surrounding matte thread 12 is particularly conspicuous, and the entire surface of the cut pile yarns 10 appears to exhibit a glossy appearance.

[0072] As described above, the vehicle floor mat 1 in which the color tone and the glossiness are different depending on the angle of view has a more novel design, and is more likely to arouse the interest of a demander.

[0073] The above has described the embodiments of the present application with reference to the drawings, but the present application is not limited to the illustrated embodiments. The illustrated embodiments can be variously modified or changed within the same range or equivalent range as the present application.

[0074] [Industrial applicability]

[0075] The present application is advantageous in utilizing the vehicle floor mat having high design.

Claims

1. A vehicle floor mat, comprising: Base fabric; Cut pile yarns are embedded in the aforementioned base fabric; and A pre-coated layer is provided on the back side of the aforementioned base fabric; The aforementioned cut pile yarn includes: lustrous yarn, which is relatively lustrous; and matte yarn, which is relatively matte and has greater crimp than the aforementioned lustrous yarn; On the surface side of the aforementioned base fabric, the height of the aforementioned glossy line is higher than the height of the aforementioned matte line.

2. The vehicle floor mat according to claim 1, wherein, The aforementioned glossy lines are made of polyester or polyamide, while the aforementioned matte lines are made of polypropylene or polyamide.

3. The vehicle floor mat according to claim 1, wherein, The aforementioned lustrous yarn is a lustrous twisted yarn made by twisting together multiple lustrous fiber threads; The aforementioned matte line is an untwisted, matte straight line.

4. The vehicle floor mat according to claim 1, wherein, The aforementioned lustrous yarn is a lustrous twisted yarn made by twisting together multiple lustrous fiber threads; The aforementioned matte yarn is a matte twisted yarn made by twisting together multiple matte fiber yarns; The aforementioned glossy twisted yarn has a higher number of twists than the aforementioned matte twisted yarn.

5. The vehicle floor mat according to claim 1, wherein, The aforementioned lustrous yarn is a lustrous twisted yarn made by twisting together multiple lustrous fiber threads; The aforementioned matte yarn is a matte twisted yarn made by twisting together multiple matte fiber yarns; The heat setting temperature of the aforementioned glossy twisted yarn is higher than that of the aforementioned matte twisted yarn.

6. The vehicle floor mat according to claim 1, wherein, The upward protrusion of the aforementioned glossy line above the aforementioned matte line is in the range of 1 to 3 mm.

7. The vehicle floor mat according to claim 1, wherein, When viewed from above, the area occupied by the cut pile yarn implanted in the aforementioned base fabric ranges from 5% to 20%.

8. A method for manufacturing a vehicle floor mat, comprising the following steps: The steps of preparing glossy lines and matte lines, wherein the glossy lines are relatively glossy and the matte lines are relatively matte, and have greater curlability than the aforementioned glossy lines; The step of implanting the aforementioned glossy lines and the aforementioned matte lines into the base fabric; To prevent the aforementioned glossy and matte lines from peeling off, a pre-coating layer is applied to the back of the aforementioned base fabric, and a heating step is maintained at a predetermined heating temperature; and The heating process described above causes the matte line to curl up, while the leading edge of the glossy line protrudes further upwards than the matte line.

9. The method for manufacturing a vehicle floor mat according to claim 8, wherein, The aforementioned glossy yarn is a glossy twisted yarn made by twisting multiple glossy polyester or polyamide fiber threads together and heat-setting them at 130 to 160°C. The heating temperature during the aforementioned heating step is above 100°C but below 130°C.

10. The method for manufacturing a vehicle floor mat according to claim 9, wherein, The aforementioned matte yarn is a matte twisted yarn made by twisting together multiple matte polypropylene or polyamide fibers and then not heat-setting it.

11. The method for manufacturing a vehicle floor mat according to claim 9, wherein, The aforementioned matte yarn is a matte twisted yarn made by twisting multiple matte polypropylene or polyamide fiber threads together and then heat-setting them at 110 to 130°C.

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