Floor member and method for manufacturing floor member

Abstract

To provide a new structure of a floor member.SOLUTION: According to an aspect of the present invention, there is provided a floor member to be placed on a floor panel including a seat slide rail, the floor member including a floor member body having a housing portion in which the seat slide rail is housed when the floor member is placed on the floor panel, a molding member extending along the housing portion and overlapping an upper surface of the seat slide rail, and a carpet member joined to an upper surface of the floor member body, wherein a part of the carpet member is disposed above the molding member.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates to flooring members and methods of manufacturing the same. [Background technology]

[0002] BACKGROUND ART Conventionally, a floor member that is placed on a floor panel that is provided with a seat slide rail is known (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Publication No. 2015-123669 (Figs. 1, 2, etc.) Summary of the Invention [Problem to be solved by the invention]

[0004] The present disclosure provides a novel construction for this type of flooring member. [Means for solving the problem]

[0005] One aspect of the invention is a floor member that is placed on a floor panel that is equipped with a seat slide rail, and includes a floor member main body that has a storage portion in which the seat slide rail is stored when placed on the floor panel, a molding member that extends along the storage portion and is overlaid on the upper surface of the seat slide rail, and a carpet member that is joined to the upper surface of the floor member main body, and a portion of the carpet member is the floor member that is positioned above the molding member. [Brief explanation of the drawings]

[0006] [Figure 1] FIG. 1 is a cross-sectional view of a floor member placed on a floor panel. [Figure 2] FIG. 2 is a partially cutaway perspective view of the floor member. [Figure 3] FIG. 3 is a top perspective view of the floor member. [Figure 4]FIG. 4 is a partially cutaway perspective view of a molding member. [Figure 5] Figure 5 is a cross-sectional view of the mold in which the molding material and carpet material are set. [Figure 6] Figure 6 shows a cross section of the closed mold. [Figure 7] FIG. 7 is a cross-sectional view of the floor member body formed in the mold. [Figure 8] FIG. 8 is an enlarged cross-sectional view of the vicinity of a molding member in a floor member according to another embodiment. [Figure 9] FIG. 9 is a perspective view of a molding member. [Figure 10] Figure 10 is a cross-sectional view of the molding material set in the mold. [Figure 11] Figure 11 is an enlarged cross-sectional view of the molding area of ​​the floor member body formed in the mold. DETAILED DESCRIPTION OF THE INVENTION

[0007] [First embodiment] As shown in FIG. 1, a floor member 10 according to the first embodiment of the present disclosure is placed on a floor panel 90 equipped with seat slide rails 80 (hereinafter simply referred to as "slide rails 80"). The floor member 10 is for, for example, a vehicle (for example, a vehicle such as an automobile), and the seat slide rails 80 slidably support a seat in which an occupant sits (in the example of this embodiment, slidably in the front-to-rear direction). Note that the floor member 10 may also be for, for example, a building, and may be placed on a floor panel 90 that slidably supports a seat to be placed in the building.

[0008] The floor member 10 is used, for example, as a soundproofing material having sound-blocking and sound-absorbing functions, or as a bulkhead material. For example, if the upper surface of the floor panel 90 has an uneven shape, the floor member 10 is formed so that the lower surface has an uneven shape corresponding to the uneven shape. In the example of this embodiment, since the slide rail 80 protrudes from the upper surface of the floor panel 90, the floor member 10 is formed with a receiving portion 21 (for example, a hole or a recess) that opens to the lower surface of the floor member 10 and receives the slide rail 80.

[0009] In this embodiment, the slide rails 80 extend in the front-rear direction, and for example, a pair of slide rails 80 are provided for one seat, side by side in the width direction of the seat. A slide member 92 provided on the underside of the seat is slidably connected to the slide rails 80, thereby enabling the seat to slide relative to the floor panel 90. The slide rail 80 has, for example, a square cylindrical outer wall portion with a part of the upper surface (in this embodiment, the central portion in the width direction of the slide rail 80) open, and the slide member 92 of the seat is received in the slide rail 80 from the open portion 81.

[0010] As shown in FIG. 2, the floor member 10 includes a floor member body 20, a molding member 40, and a carpet member 30.

[0011] 2 and 3, the floor member main body 20 is plate-shaped and has a storage section 21 that stores the slide rail 80. The storage section 21 opens on the underside of the floor member main body 20 and extends in the longitudinal direction of the slide rail 80. In this embodiment, the storage section 21 is formed by an elongated hole that passes through the floor member main body 20 in the vertical direction.

[0012] The floor member main body 20 may have a single-layer structure or a laminated structure. The floor member main body 20 preferably includes, for example, a foamed resin layer. In the present embodiment, the floor member main body 20 has a single-layer structure of a foamed resin layer. The foamed resin layer may be made of a foamed thermosetting resin (for example, polyurethane resin) or a foamed thermoplastic resin (for example, a polyolefin resin such as polyethylene resin or polypropylene resin). The foamed resin layer may be breathable (for example, one with an open cell structure) or non-breathable (for example, one with a closed cell structure). When the foamed resin layer is breathable, it can exhibit sound absorption properties. The floor member main body 20 may be made of a resin other than a foam (for example, an elastic resin other than a foam).

[0013] As shown in FIG. 4, the molding member 40 extends along the storage section 21 in the longitudinal direction of the storage section 21 (i.e., extends along the slide rail 80), and is overlaid on the upper surface of the slide rail 80 as shown in FIG. 1. In this embodiment, the molding member 40 includes an embedded portion 41 that is embedded and fixed in the floor member main body 20 (i.e., the foamed resin layer), and a protruding portion 42 that protrudes from the floor member main body 20 toward the storage section 21. For example, the molding member 40 is arranged so that the embedded portion 41 is fixed to the upper opening edge of the storage section 21 (long hole) of the floor member main body 20, and the protruding portion 42 covers the storage section 21 from above. Note that a claw portion 42T that engages with the opening edge of the open portion 81 of the slide rail 80 is formed at the protruding tip of the protruding portion 42.

[0014] In this embodiment, the cross-sectional shape of the molding member 40 when viewed in its longitudinal direction (i.e., the longitudinal direction of the accommodating portion 21) is T-shaped. For example, the molding member 40 may be an extrusion-molded product made of resin with a uniform cross-sectional shape.

[0015] In this embodiment, the molding member 40 having a T-shaped cross section is provided with a horizontal plate portion 44 that is arranged substantially horizontally and has a long plate shape including the protruding portion 42, and a long vertical plate portion 45 that hangs down from the horizontal plate portion 44 (from the middle of the horizontal plate portion 44 in the width direction). The horizontal plate portion 44 is embedded in the upper opening edge of the storage section 21 (long hole) of the floor member main body 20, overlapping it from above. The vertical plate portion 45 is embedded in the floor member, overlapping it with the inner surface of the storage section 21 (long hole). In this embodiment, the portion of the horizontal plate portion 44 that overlaps the floor member main body 20 and the vertical plate portion 45 form the embedded portion 41. The configuration of the molding member 40 is not limited to that of this embodiment.

[0016] In this embodiment, a pair of molding members 40 are provided and fixed to the opening edge portions on both sides of the width direction of the storage section 21 of the floor member main body 20. The pair of molding members 40 are arranged so that the protruding portions 42 butt against each other with a gap between them. This gap S is arranged to overlap the open portion 81 of the slide rail 80, and the slide member 92 of the sheet passes through this gap S (see FIG. 1). Note that, for example, the protruding portion 42 may be flexibly deformable, and the slide member 92 may pass through the gap S by flexibly deforming the protruding portion 42.

[0017] As shown in FIG. 2 , the carpet member 30 is in a sheet form and is joined to the upper surface of the floor member main body 20. A portion of the carpet member 30 is positioned above the molding member 40 and overlaps the molding member 40 (i.e., the molding member 40 is sandwiched between the floor member main body 20 and the carpet member 30). In this embodiment, the overlapping portion 35 of the carpet member 30 that overlaps the molding member 40 from above is positioned above the storage section 21 and overlaps the overhanging portion 42 of the molding member 40 from above. The overlapping portion 35 of the carpet member 30 may cover the molding member 40 up to the protruding tip of the overhanging portion 42. This can improve the appearance of the floor member 10. In this embodiment, a slit 30S that overlaps the gap S between a pair of molding members 40 is formed in the carpet member 30, and the opening edge of the slit 30S in the carpet member 30 overlaps the overhanging portion 42 of the molding member 40.

[0018] The overlapping portion 35 of the carpet member 30 may or may not be joined to the molding member 40. For example, the overlapping portion 35 may be bonded to the molding member 40 with an adhesive or with a hook-and-loop fastener. Alternatively, for example, a foamed resin portion extending from the foamed resin layer of the floor member main body 20 may be provided between the overlapping portion 35 and the molding member 40, and the overlapping portion 35 and the molding member 40 may be bonded by this foamed resin portion.

[0019] The carpet member 30 may have a single layer structure or a laminated structure. The carpet member 30 includes, for example, a fiber layer. In this embodiment, the carpet member 30 has a single layer structure of a fiber layer.

[0020] This fiber layer may be composed of a fiber sheet such as a nonwoven fabric. The fibers constituting the fiber layer may be synthetic fibers or natural fibers. Examples of such fibers include polyethylene terephthalate (PET) fibers, polyester fibers, polypropylene fibers, polyamide fibers, acrylic fibers, vinylon fibers, and polyurethane fibers (spandex). Examples of natural fibers include wool, cotton, and cellulose nanofibers. The form of the fiber layer is not limited to nonwoven fabric, and may be woven fabric, knitted fabric, or the like. Examples of nonwoven fabrics include spunlace nonwoven fabric, spunbond nonwoven fabric, and needle-punched nonwoven fabric.

[0021] In this embodiment, the floor member 10 is an integrally molded product in which the floor member main body 20 is molded integrally with the carpet member 30 and the molding member 40. For example, the fiber layer of the carpet member 30 has an impregnated portion where the raw material of the foamed resin layer of the floor member main body 20 has been impregnated and hardened. Note that at least one of the carpet member 30 and the molding member 40 may be joined to the floor member main body 20 after molding.

[0022] In this embodiment, the floor member main body 20 also functions as a spacer that fills in the step of the slide rail 80 on the upper surface of the floor panel 90, and the carpet member 30 is layered substantially evenly across the floor member main body 20 and the molding member 40. This makes it possible to hide the step of the slide rail 80 and improve the appearance. Note that, for example, a floor mat 95 (see FIG. 1) may be laid on the floor member 10 (on the carpet member 30). For example, the floor mat 95 has a slit formed in a position that overlaps with the slit 30S of the carpet member 30, through which the slide member 92 of the seat passes.

[0023] The floor member 10 of this embodiment is manufactured, for example, as follows. Figure 5 shows a mold 50 used to foam-mold the floor member main body 20. The mold 50 comprises an upper mold 51 and a lower mold 52. With the upper mold 51 and the lower mold 52 separated from each other in the mold open state, the carpet member 30 is set on the molding surface of the upper mold 51. A slit 30S is formed in advance in the carpet member 30 by punching or the like.

[0024] The molding surface of the lower mold 52 is provided with a molding recess 52U that forms a cavity for foam molding the floor member main body 20. The lower mold 52 is provided with a protrusion 52T that is used to mold the storage section 21. The protrusion 52T protrudes from the bottom surface of the molding recess 52U. At least a portion of the molding member 40 (in this embodiment, the protrusion 42) is placed on the upper surface of the protrusion 52T, and a pair of molding members 40 is set.

[0025] Then, raw material 11G is injected into molding recess 52U, and upper mold 51 and lower mold 52 are brought together to close mold 50 (see FIG. 6). By closing mold 50, molding member 40 and carpet member 30 are sandwiched between upper mold 51 and lower mold 52 (more specifically, protruding portions 52T). At this time, slit 30S of carpet member 30 overlaps with gap S between protruding portions 42 of a pair of molding members 40. In this state, when raw material 11G foams and hardens, floor member main body 20 is foam-molded (see FIG. 7), and carpet member 30 and molding member 40 are integrated. These are removed from mold 50, and floor member 10 is obtained.

[0026] As described above, this embodiment provides a novel structure and manufacturing method for the floor member 10. In the floor member 10 of this embodiment, a portion of the carpet member 30 is positioned above the molding member 40, making it possible to improve the appearance of the floor member 10 by covering the molding member 40 with the carpet member 30. In the floor member 10 of this embodiment, the carpet member 30 and the molding member 40 are integrated into the floor member main body 20 when the floor member main body 20 is molded, making it possible to improve the workability of assembling the floor member 10 into a vehicle.

[0027] [Other embodiments] As shown in FIG. 8 , through-holes 48 may be formed in the molding member 40, penetrating it vertically (for example, the through-holes may be formed at multiple positions along the length of the molding member 40). In this case, the resin of the floor member main body 20 enters the through-holes 48 when the floor member main body 20 is molded. Furthermore, for example, an impregnated portion impregnated with the raw resin of the floor member main body 20 (for example, the raw resin of the foamed resin layer) is provided in the portion of the carpet member 30 corresponding to the through-hole 48 (the overlapping portion). This secures the overlapping portion 35 of the carpet member 30 to the floor member main body 20. Furthermore, providing the through-holes 48 in the molding member 40 in this manner facilitates the formation of a resin portion 28 (for example, a foamed resin portion) extending from the floor member main body 20 between the molding member 40 and the overlapping portion 35 of the carpet member 30, allowing the molding member 40 and the carpet member 30 to be bonded together by the resin portion 28. Furthermore, when providing through holes 48 in this manner, by providing grooves 47 on the upper surface of the molding member 40 that extend from the through holes 48 toward the protruding tip of the overhanging portion 42 (for example, extending to the protruding tip) (see FIGS. 9 and 10), it becomes easy to provide the resin portion 28 up to the protruding tip of the overhanging portion 42 when molding the floor member main body 20 (see FIG. 11). For example, the grooves 47 may be configured to extend in multiple branches (for example, bifurcated) from the through holes 48 to the protruding tip of the overhanging portion 42. Furthermore, the tips of such multiple branched grooves 47 may be connected by a groove that extends in the longitudinal direction of the molding member 40.

[0028] In the above embodiment, the molding member 40 does not have to be provided with the embedded portion 41, and in this case, for example, the molding member 40 may be adhered to the floor member main body 20 with an adhesive. Also, in the above embodiment, the molding member 40 does not have to be fixed to the floor member main body 20, and the molding member 40 may be configured to be fixed when the floor member 10 is placed on the floor panel 90.

[0029] In the above embodiment, the floor member 10 may be divided into a plurality of parts in the horizontal direction (for example, it may be divided at the position of the storage section 21).

[0030] In the above embodiment, the slits 30S were formed in advance in the carpet member 30 by punching or the like, and then the floor member main body 20 was foam-molded, but the slits 30S may also be formed by punching or the like after the floor member main body 20 has been foam-molded together with the carpet member 30.

[0031] <Additional Notes> The following describes the features extracted from the above-described embodiments and examples, highlighting their effects as necessary.

[0032] For example, the following group of features relate to floor members and their manufacturing methods and can be considered to have been conceived with the objective of "providing a novel structure for this type of floor member" in light of the background art that states, "Floor members that are placed on floor panels equipped with seat slide rails have been known (see, for example, JP 2015-123669 (Figs. 1, 2, etc.))." There has long been a demand for novel structures and novel manufacturing methods for floor members.

[0033] [Feature 1] A floor member placed on a floor panel equipped with a seat slide rail, a floor member body having a housing portion in which the seat slide rail is housed when the floor member body is placed on the floor panel; a molding member that extends along the accommodation portion and is superimposed on an upper surface of the seat slide rail; a carpet member joined to the upper surface of the floor member body, A floor member in which a portion of the carpet member is disposed above the molding member.

[0034] [Feature 2] The floor member body includes a foamed resin layer, 2. The flooring member of claim 1, wherein the carpet member includes a fibrous layer.

[0035] [Feature 3] 3. The floor member according to claim 2, wherein the molding member has an embedded portion that is embedded in the foamed resin layer.

[0036] [Feature 4] 3. The floor member according to claim 2, further comprising a foamed resin portion extending from the foamed resin layer of the floor member body between the molding member and the carpet member.

[0037] [Feature 5] The molding member has a through hole extending vertically therethrough, 3. The floor member according to claim 2, wherein the carpet member has an impregnated portion in which the raw material resin of the foamed resin layer is impregnated in a portion corresponding to the through hole.

[0038] [Feature 6] A method for manufacturing a floor member including: a floor member body that is placed on a floor panel that is provided with a seat slide rail and has a storage portion that stores the seat slide rail; and a molding member that extends along the storage portion and is superimposed on an upper surface of the seat slide rail, a protruding portion for molding the storage portion is provided on a lower mold of a mold for foam molding the floor member body, and at least a portion of the molding member is placed on an upper surface of the protruding portion; A carpet member for covering the upper surface of the floor member body is placed on the upper mold of the mold; A method for manufacturing a floor member, in which the molding member and the carpet member are sandwiched between the upper and lower molds by closing the mold, and the floor member main body is foam-molded.

[0039] According to the above features, a novel structure of the floor member is provided. According to the above features, a part of the carpet member is located above the molding member, so that the appearance of the floor member can be improved.

[0040] Although the present specification and drawings disclose specific examples of the technology included in the scope of the claims, the technology described in the claims is not limited to these specific examples, but also includes various modifications and variations of the specific examples, and also includes parts of the specific examples taken out alone. [Explanation of symbols]

[0041] 10 Flooring 11G raw material 20 Floor member body 21 Storage unit 28 Resin part 30 Carpet materials 30S slit 35 Overlap 40 Molding material 40D step 40K folded part 41 Buried part 42 Overhang 44 Horizontal plate part 45 Vertical plate section 47 Groove 48 through holes 50 molds 51 Upper mold 52 Lower mold 52T protrusion 80 Seat slide rail (slide rail) 90 Floor Panel

Claims

1. A floor member placed on a floor panel equipped with a seat slide rail, a floor member body having a housing portion in which the seat slide rail is housed when the floor member body is placed on the floor panel; a molding member that extends along the accommodation portion and is superimposed on an upper surface of the seat slide rail; a carpet member joined to the upper surface of the floor member body, A floor member in which a portion of the carpet member is disposed above the molding member.

2. The floor member body includes a foamed resin layer, 10. The flooring member of claim 1, wherein the carpet member comprises a fibrous layer.

3. The floor member according to claim 2 , wherein the molding member has an embedded portion that is embedded in the foamed resin layer.

4. 3. The floor member according to claim 2, further comprising a foamed resin portion extending from the foamed resin layer of the floor member body between the molding member and the carpet member.

5. The molding member has a through hole extending vertically therethrough, 3. The floor member according to claim 2, wherein the carpet member has an impregnated portion in which the raw material resin of the foamed resin layer is impregnated in a portion corresponding to the through hole.

6. A method for manufacturing a floor member including: a floor member body that is placed on a floor panel that is provided with a seat slide rail and has a storage portion that stores the seat slide rail; and a molding member that extends along the storage portion and is superimposed on an upper surface of the seat slide rail, a protruding portion for molding the storage portion is provided on a lower mold of a mold for foam molding the floor member body, and at least a portion of the molding member is placed on an upper surface of the protruding portion; A carpet member for covering the upper surface of the floor member body is placed on the upper mold of the mold; A method for manufacturing a floor member, in which the molding member and the carpet member are sandwiched between the upper and lower molds by closing the mold, and the floor member main body is foam-molded.

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