Floor mats

Abstract

To provide a floor mat capable of suppressing difficulty of bending.SOLUTION: A floor mat 1 installed on a floor surface (50a) includes a backing layer 10 formed by elastomer. The backing layer 10 has a reverse surface 12 including: a plane part 15 along the floor surface (50a); a plurality of projections 20 projecting from the plane part 15 for slip resistance; and a groove 30 recessed from the plane part 15 at a position away from the plurality of projections 20 so as to divide the plurality of projections 20 into more than one. The groove 30 may be recessed from the plane part 15 so as to divide the plane part 15 into a plurality of divided areas A0. The plurality of divided areas A0 may include a plurality of first areas A1 of the same shape and a plurality of second areas A2 which are adjacent to any of the plurality of first areas A1 and have different shapes from the first areas A1.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a floor mat installed on a floor surface.

Background Art

[0002] In order to prevent the floor carpet installed in an automobile from getting dirty, a floor mat having an underlay layer formed of an elastomer is laid on the floor carpet. Since there are pedals such as an accelerator pedal and a brake pedal under the driver's seat, the underlay layer of the floor mat installed under the driver's seat has a plurality of protrusions for anti-slip. Patent Document 1 discloses a carpet mat provided with an underlay material made of rubber or thermoplastic elastomer or the like. Anti-slip protrusions are aligned on the back surface of the underlay material. Each anti-slip protrusion is in a ring shape having a cavity at the center of the anti-slip protrusion.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In order to enhance the anti-slip effect, it is necessary to increase the rigidity of the underlay material around the protrusions. On the other hand, considering that the rigidity of the floor mat installed under the driver's seat may affect the operation of the pedals, it is necessary to suppress the floor mat from becoming difficult to bend. Therefore, a floor mat having an underlay layer that achieves both a good anti-slip function and the ease of bending of the floor mat is desired. Furthermore, with floor mats installed in the passenger and rear passenger footwells, it is possible to insert a portion of the floor mat into the gap. In this case, the backing layer that maintains the shape of the floor mat does not need to have anti-slip protrusions, but it is necessary to prevent the floor mat from becoming difficult to bend when a portion of it is inserted into the gap.

[0005] This invention discloses a floor mat capable of suppressing the tendency for the mat to become difficult to bend. [Means for solving the problem]

[0006] The floor mat of the present invention includes a backing layer made of elastomer and is a floor mat installed on a floor surface, The backing layer has a back surface that includes a flat portion that is aligned with the floor surface, a plurality of protrusions that extend from the flat portion to prevent slipping, and grooves that are recessed from the flat portion at positions separated from the plurality of protrusions so as to divide the plurality of protrusions into a plurality of sections. death, The groove divides the planar portion into multiple divided regions, including one or more of the protrusions. The plurality of divided regions include a plurality of first regions having the same shape and a plurality of second regions adjacent to any of the plurality of first regions and having a different shape from the plurality of first regions. , has the characteristics of. Furthermore, the floor mat of the present invention includes a backing layer made of elastomer and is a floor mat installed on a floor surface, The backing layer has a back surface that includes a flat portion that is aligned with the floor surface, a plurality of protrusions that extend from the flat portion for anti-slip purposes, and grooves that are recessed from the flat portion at positions separated from the plurality of protrusions so as to divide the plurality of protrusions into a plurality of sections. The groove has a semicircular cross-section. The depth of the groove is less than the thickness of the backing layer in the portion of the groove.

[0007] Furthermore, the floor mat of the present invention includes a backing layer made of elastomer and is a floor mat installed on a floor surface. The backing layer has a back surface that includes a flat portion along the floor surface and grooves recessed from the flat portion so as to divide the flat portion into a plurality of divided regions. The plurality of divided regions have an embodiment that includes a plurality of first regions having the same shape and a plurality of second regions adjacent to any of the plurality of first regions and having a different shape from the first region. [Effects of the Invention]

[0008] According to the present invention, it is possible to provide a floor mat that can suppress being difficult to bend.

Brief Description of the Drawings

[0009] [Figure 1] A cross-sectional view schematically showing an example of a cross-section of a vehicle in which a floor mat is overlaid on a floor carpet. [Figure 2] A perspective view schematically showing an example of the back surface of the lining layer. [Figure 3] A bottom view schematically showing an example of the back surface of the lining layer. [Figure 4] A view schematically showing an example of the size of each part in the lining layer. [Figure 5] A cross-sectional view schematically showing an example of a floor mat bent starting from a groove in the lining layer. [Figure 6] A bottom view schematically showing an example of the back surface of another lining layer. [Figure 7] A bottom view schematically showing an example of the back surface of another lining layer. [Figure 8] A bottom view schematically showing an example of the back surface of another lining layer. [Figure 9] A bottom view schematically showing an example of the back surface of another lining layer. [Figure 10] A bottom view schematically showing an example of the back surface of another lining layer. [Figure 11] A cross-sectional view schematically showing an example of a cross-section of a floor mat according to a comparative example.

Modes for Carrying Out the Invention

[0010] Hereinafter, embodiments of the present invention will be described. Of course, the following embodiments are merely illustrative of the present invention, and not all of the features shown in the embodiments are necessarily essential to the solution means of the invention.

[0011] (1) Outline of the technology included in the present invention: First, an overview of the technology included in the present invention will be described with reference to the examples shown in Figures 1 to 11. Note that the figures in this application are schematic examples, and the magnification in each direction shown in these figures may differ, and the figures may not be consistent. Of course, the elements of this technology are not limited to the specific examples indicated by the reference numerals. Furthermore, in this application, the numerical range "Min~Max" means a value greater than or equal to the minimum value Min and less than or equal to the maximum value Max.

[0012] [Aspect 1] A floor mat 1 according to one aspect of this technology includes a backing layer 10 made of elastomer and is installed on a floor surface (for example, the surface 50a of a floor carpet 50). The backing layer 10 has a back surface 12 which includes a flat portion 15 along the floor surface (50a), a plurality of protrusions 20 protruding from the flat portion 15 for anti-slip purposes, and grooves 30 recessed from the flat portion 15 at positions spaced apart from the plurality of protrusions 20 so as to divide the plurality of protrusions 20 into a plurality.

[0013] In the above embodiment, on the back surface 12 of the backing layer 10, there is a flat surface 15 that is aligned with the floor surface (50a) around the multiple anti-slip protrusions 20. The surrounding flat surface 15 facing the floor surface (50a) supports the multiple protrusions 20, so that the floor mat 1 installed on the floor surface (50a) exhibits good anti-slip function. However, if the rigidity of the backing layer 10 between the protrusions 20 is high, the floor mat becomes difficult to bend, as illustrated in Figure 11. In the above embodiment, on the back surface 12 of the backing layer 10, there is a groove 30 recessed from the flat surface 15 at positions separated from the multiple protrusions 20 so as to divide the multiple protrusions 20 into multiple sections, so the floor mat 1 in the above embodiment is easy to bend, as illustrated in Figure 5. Therefore, the above embodiment can provide a floor mat that can suppress the decrease in anti-slip function while suppressing the difficulty in bending.

[0014] Here, the floor mat may include at least one of the following: a surface layer such as carpet, a base fabric layer, an adhesive layer, etc. Elastomers include thermoplastic elastomers, rubber, and the like. Furthermore, the above-mentioned supplementary statement also applies in the following embodiments.

[0015] [Aspect 2] As illustrated in Figures 3, 6 to 8, the groove 30 may divide the flat portion 15 into a plurality of divided regions A0, including one or more of the protrusions 20. The plurality of divided regions A0 may include a plurality of first regions A1 of the same shape, or may include a plurality of second regions A2 adjacent to any of the plurality of first regions A1 and having a different shape from the first region A1. In the above case, the multiple divided regions A0, which are separated on the back surface 12 of the backing layer 10 by grooves 30 recessed from the flat portion 15, include multiple first regions A1 and multiple second regions A2, and the second region A2 adjacent to the first region A1 has a different shape from the first region A1, so the floor mat 1 is easily bent in various orientations. Therefore, the above embodiment can provide a floor mat that can suppress the difficulty of bending in various orientations.

[0016] Here, the shape of the first region can be various shapes, such as polygons like quadrilaterals, shapes in which at least some of the sides of a polygon are curved, circles, ellipses, and so on. The shape of the second region can be various, as long as it differs from the shape of the first region, including polygons such as pentagons, shapes in which at least part of the sides of a polygon are curved, circles, ellipses, and so on. Multiple divided regions may include multiple regions with shapes different from both the first and second regions. In this application, "first," "second," "third," etc., are terms used to identify each component included in a group of similar components, and do not imply any order. Which component among the group corresponds to "first," "second," "third," etc., is determined relatively. Furthermore, the above-mentioned supplementary statement also applies in the following embodiments.

[0017] [Aspect 3] As illustrated in Figures 3,6 to 3, the second region A2 may have a shape with five or more angles C2. In the above case, because the grooves 30 forming the second region A2 are oriented in various directions, the floor mat 1 is easily bent in various directions. Therefore, the above embodiment can provide a suitable example that suppresses the difficulty of bending in various directions.

[0018] [Aspect 4] As illustrated in Figure 4, the plurality of protrusions 20 may include a first protrusion 21 and a second protrusion 22 that are adjacent to each other with the groove 30 in between. The ratio P1 / P0 of the distance P1 between the center of the first protrusion 21 and an intermediate position in the groove 30 along the planar portion 15 to the distance P0 between the center of the first protrusion 21 and the center of the second protrusion 22 along the planar portion 15 may be 0.3 or more and 0.7 or less. Since 0.3 ≤ P1 / P0 ≤ 0.7, the surrounding flat portion 15 facing the floor surface (50a) firmly supports the first projection 21 and the second projection 22, and the floor mat 1 installed on the floor surface (50a) exhibits good anti-slip function. Therefore, the above embodiment can provide a suitable example for suppressing a decrease in anti-slip function.

[0019] [Aspect 5] As illustrated in Figure 1, the groove 30 may have a shape without corners in its cross-section. If the groove 30 has corners in its cross-section, the floor mat 1 may deteriorate starting from the corners due to bending. By eliminating corners in the cross-section of the groove 30, deterioration of the floor mat 1 due to bending is suppressed. Therefore, the above embodiment can improve the durability of the floor mat.

[0020] [Aspect 6] Incidentally, the backing layer 10 of the floor mat 1 according to another embodiment of this technology has a back surface 12 that includes a flat portion 15 along the floor surface (50a) and grooves 30 recessed from the flat portion 15 so as to divide the flat portion 15 into a plurality of divided regions A0. The plurality of divided regions A0 include a plurality of first regions A1 of the same shape and a plurality of second regions A2 adjacent to any of the plurality of first regions A1 and having a different shape from the first regions A1. In the above case, the multiple divided regions A0, which are separated on the back surface 12 of the backing layer 10 by grooves 30 recessed from the flat portion 15, include multiple first regions A1 and multiple second regions A2, and the second region A2 adjacent to the first region A1 has a different shape from the first region A1, so the floor mat 1 is easily bent in various orientations. Therefore, the above embodiment can provide a floor mat that can suppress the difficulty of bending in various orientations.

[0021] Here, the back surface of the backing layer may include multiple protrusions extending from the grooves for anti-slip purposes. Furthermore, the back surface of the backing layer may also include multiple protrusions extending from the flat surface for anti-slip purposes.

[0022] (2) Specific examples of floor mats: Figure 1 schematically shows a cross-section of an automobile 90 in which a vehicle floor mat 1 is placed on top of a vehicle floor carpet 50, as an example of a vehicle. The cross-section of the floor mat 1 is shown at the top of Figure 1. The automobile 90 in which the floor mat 1 can be installed is not particularly limited and can be a wagon-type passenger car with a connected passenger compartment and cargo area, a sedan-type passenger car, etc. Furthermore, in automobile 90, the floor mat 1 can be installed in the driver's footwell, the passenger's footwell, the rear passenger's footwell, the floor of the cargo area, etc.

[0023] The floor carpet 50 is installed directly or indirectly on a metal body panel 80 having a three-dimensional shape. The body panel 80 on which the floor carpet 50 is placed includes a floor panel that is arranged substantially horizontally as a whole, although having irregularities not shown, and a toe board that rises diagonally forward from the front edge of the floor panel. The body panel 80 may also include a dash panel that rises more vertically from the front edge of the toe board. Figure 1 shows that a cushioning material 60 is placed on the upper surface 81 of the floor panel as a body panel 80, thereby creating a cushioning material 60 between the floor panel and the floor carpet 50. The cushioning material 60 is used for at least one of shock absorption, sound absorption, and sound insulation, and may be partially placed on the body panel 80. The cushioning material 60 can be a fibrous material such as felt, a foamed resin such as foamed thermoplastic resin or polyurethane foam, a molded product of crushed foamed resin, a combination of two or more of these, etc.

[0024] The floor carpet 50 has a three-dimensional shape that matches the three-dimensional shape of at least one of the vehicle body panel 80 and the cushioning material 60. The floor carpet 50 shown in Figure 1 includes a carpet layer 51 that is visible on the surface 50a, and a backing resin layer 52 that is integrated with the back surface of the carpet layer 51. The carpet layer 51 is a breathable fibrous material that imparts properties such as aesthetic appeal, good tactile feel, abrasion resistance, and sound absorption to the floor carpet 50. The carpet layer 51 can be a needle-punched carpet with many fluffs on the surface 50a, a tufted carpet with many piles on the surface 50a, etc. Needle-punched carpet is formed, for example, by piercing a nonwoven fabric with many hooked needles and entangling the fibers to form fluff on the surface. Tufted carpet is formed, for example, by inserting pile threads into a base fabric such as a nonwoven fabric such as spunbond nonwoven fabric or a knitted fabric of various fibers using a tufting machine to make the pile stand up. Synthetic fibers can be used for the fibers constituting the carpet layer 51. These synthetic fibers can include polyolefin fibers such as PP (polypropylene) fibers, polyamide fibers, polyester fibers such as PET (polyethylene terephthalate) fibers, acrylic fibers, etc. For the backing resin layer 52, polyolefin resins such as PE (polyethylene) resin and PP (polypropylene) resin, olefin-based thermoplastic elastomers, vinyl resins, acrylic resins, AS (acrylonitrile styrene) resin, ABS (acrylonitrile butadiene styrene) resin, materials to which additives such as fillers and colorants have been added to any of these resins, or combinations of two or more of these.

[0025] The floor mat 1 is installed on the floor carpet 50 so as to face the interior SP1 of the automobile 90. The surface 50a of the floor carpet 50 is an example of the floor surface of the vehicle. The floor mat 1 shown in Figure 1 includes, in the order of thickness direction D1, a surface layer 41, a base layer 42, and a backing layer 10 having a plurality of protrusions 20. Here, the thickness direction D1 is the direction perpendicular to the flat portion 15 of the back surface 12 of the backing layer 10. The base layer 42 includes a base fabric layer 43 integrated with the back surface of the surface layer 41, and a latex layer 44 integrated with the back surface of the base fabric layer 43. Here, the latex layer 44 means a layer of solidified or hardened latex. The latex layer 44 is integrated with the adhesive surface 11 on the backing layer 10 opposite to the back surface 12.

[0026] The surface layer 41 can be made of breathable fibrous material such as carpet. Examples of carpets that can be used as the surface layer 41 include needle-punched carpets and tufted carpets. Therefore, synthetic fibers can be used for the fibers constituting the carpet surface layer 41. These synthetic fibers can include polyolefin fibers such as PP fibers, polyamide fibers, polyester fibers such as PET fibers, acrylic fibers, and combinations of two or more of these. The base fabric layer 43 can be made of nonwoven fabrics such as spunbond nonwoven fabric, or knitted fabrics of various fibers. For the material forming the latex layer 44, synthetic rubber latex such as styrene-butadiene rubber (SBR), acrylonitrile-butadiene rubber (NBR), and methyl methacrylate-butadiene rubber (MBR), natural rubber latex, and combinations thereof can be used. Furthermore, since the base layer 42 only needs to be able to support the surface layer 41, it may be a base fabric layer without a latex layer 44, a latex layer without a base fabric layer 43, a layer containing a resin layer, etc.

[0027] An elastomer can be used for the backing layer 10. The elastomer used to form the backing layer 10 may be a thermoplastic elastomer or a thermosetting elastomer. For the thermoplastic elastomer used to form the backing layer 10, styrene-based elastomers such as styrene-ethylene-butylene-styrene block copolymer (SEBS) elastomer and styrene-butadiene-styrene block copolymer (SBS) elastomer, olefin-based elastomers, PVC-based elastomers, urethane-based elastomers, ester-based elastomers, amide-based elastomers, materials to which additives such as fillers and colorants have been added to any of these elastomers, or combinations of two or more of these. For the thermosetting elastomer used to form the backing layer 10, various synthetic rubbers, natural rubbers, materials to which additives such as vulcanizing agents, fillers and colorants have been added to any of these elastomers, or combinations of two or more of these.

[0028] Figure 2 is a schematic perspective view illustrating the back surface 12 of the backing layer 10. Figure 3 is a schematic bottom view illustrating the back surface 12 of the backing layer 10. Figure 4 schematically illustrates the dimensions of each part of the backing layer 10. As shown in Figures 1-4, the back surface 12 of the backing layer 10 that faces the floor carpet 50 includes a flat surface 15 and multiple anti-slip protrusions 20 and grooves 30. The adhesive surface 11 of the backing layer 10 opposite to the back surface 12 is integrated with the latex layer 44.

[0029] As shown in Figure 1, the flat portion 15 is the part on the back surface 12 that follows the surface 50a of the floor carpet 50. The multiple protrusions 20 are parts that protrude from the flat portion 15 on the back surface 12 to prevent the floor mat 1 from slipping against the floor carpet 50. The grooves 30 are recessed from the flat portion 15 at positions separated from the multiple protrusions 20 so as to divide the multiple protrusions 20 into multiple sections. It can also be said that the grooves 30 are recessed from the flat portion 15 so as to divide the flat portion 15 into multiple divided regions A0.

[0030] The thickness T of the backing layer 10 in the flat portion 15 (see Figure 4) can be, for example, 1.0 to 3.0 mm. The thickness t of the backing layer 10 in the groove portion 30 can be, for example, 0.5 to 2.5 mm. The depth Tt of the groove 30 can be, for example, 0.2 to 0.5 mm. The width W of the groove 30 can be, for example, 0.3 to 1.0 mm.

[0031] The shape of each projection 20 is not limited, but the projections 20 shown in Figures 2 and 4 are frustoconical in shape and protrude from the flat surface 15 in the thickness direction D1. The diameter R1 of the lower base of the projection 20 can be, for example, 0.8 mm or more, more preferably 1.0 mm or more, in order to suppress the tilting of the projection 20 due to force along the flat surface 15 and improve the anti-slip effect. Also, the diameter R1 can be, for example, 3.0 mm or less, more preferably 2.5 mm or less, in order to increase the density of the projection 20 and improve the anti-slip effect. The projection 20 may be conical in shape, but the frustoconical shape of the projection 20 suppresses deformation of the tip of the projection 20. The diameter R2 of the upper base of the projection 20 is smaller than the diameter R1 of the lower base. The diameter R2 can be, for example, 0.1 to 2.0 mm, more preferably 0.2 to 1.0 mm, in order to suppress deformation of the tip of the projection 20 and to allow the projection 20 to easily enter the floor carpet 50.

[0032] The height H of the projection 20 can be, for example, 0.8 mm or more, more preferably 1.0 mm or more, from the standpoint of increasing frictional resistance and improving the anti-slip effect. In addition, the height H can be, for example, 3.0 mm or less, more preferably 2.5 mm or less, from the standpoint of suppressing the tilting of the projection 20 due to force along the flat portion 15 and improving the anti-slip effect, and from the standpoint of moldability of the floor mat 1. The shapes of the multiple protrusions 20 are not limited to being all the same. Therefore, the multiple protrusions 20 may include protrusions of a first shape and protrusions of a second shape that differ from the first shape.

[0033] The density of the protrusions 20 on the back surface 12 is such that, in order to increase frictional resistance and improve the anti-slip effect, for example, 10 cm2 The number of protrusions can be 30 or more, more preferably 50 or more. Furthermore, the density of the protrusions 20 can be set, for example, to 10 cm, considering the need to ensure the required diameter R1 of the protrusions 20 and the moldability of the floor mat 1. 2 The number of items per unit can be 150 or less, more preferably 120 or less.

[0034] A flat surface 15 exists around each protrusion 20, along the surface 50a of the floor carpet 50. The surrounding flat surface 15 facing the surface 50a of the floor carpet 50 supports each protrusion 20, thereby allowing the floor mat 1 placed on the surface 50a of the floor carpet 50 to exhibit good anti-slip functionality. Here, as shown in Figures 1 to 4, the groove 30 is recessed from the flat surface 15 at positions separated from the multiple protrusions 20. This maintains the function of the surrounding flat surface 15 in supporting each protrusion 20, and thus maintains the good anti-slip effect of the floor mat 1.

[0035] Figure 11 schematically illustrates a cross-section of a floor mat 91 according to a comparative example. The floor mat 91 includes, in the order of thickness direction, a surface layer 41, a base layer 42, and a backing layer 10 having a plurality of protrusions 20. The back surface 12 of the backing layer 10 of the floor mat 91 has no grooves. Here, we assume that the floor mat 91 is installed on a substantially horizontal upper surface 81 and an inclined surface 82 rising from the upper surface 81 on the vehicle body panel. When the rigidity of the backing layer 10 between the protrusions 20 is high, the floor mat 91 is difficult to bend, as shown in Figure 11. If the backing layer 10 between the protrusions 20 is made thinner, the floor mat 91 becomes easier to bend, but each protrusion 20 is more likely to fall due to the force along the flat surface 15, and the anti-slip function of the floor mat 91 is reduced.

[0036] Figure 5 schematically illustrates how the floor mat 1 is installed on a floor surface such as the upper surface 81 and inclined surface 82 shown in Figure 11. The floor mat 1 shown in Figure 5 is bent starting from the groove 30 of the backing layer 10. On the back surface 12 of the backing layer 10, the groove 30 is recessed from the flat surface 15 at a position separated from the multiple protrusions 20, so the floor mat 1 is easily bent and the good anti-slip effect of the floor mat 1 is maintained. In addition, because the groove 30 on the back surface 12 divides the multiple protrusions 20 into multiple sections, the floor mat 1, which has a good anti-slip function, is easily bent throughout. In particular, even if the floor mat 1 installed at the driver's feet rests on pedals such as the accelerator pedal and brake pedal, the floor mat 1 is easily bent, so it can prevent interference with pedal operation.

[0037] Here, as shown in Figure 4, two projections 20 adjacent to each other with the groove 30 in between are designated as the first projection 21 and the second projection 22. The distance along the flat portion 15 between the center of the first projection 21 and the center of the second projection 22 is P0, the distance along the flat portion 15 between the center of the first projection 21 and the midpoint of the groove 30 is P1, and the distance along the flat portion 15 between the center of the second projection 22 and the midpoint of the groove 30 is P2. Then P0 = P1 + P2. The ratio of distance P1 to distance P0, P1 / P0, is preferably 0.3 or more and 0.7 or less. If 0.3 ≤ P1 / P0 ≤ 0.7, then 0.3 ≤ P2 / P0 ≤ 0.7. Because 0.3 ≤ P1 / P0 ≤ 0.7, the surrounding flat portion 15 facing the surface 50a of the floor carpet 50 firmly supports the first projection 21 and the second projection 22, and the floor mat 1 installed on the surface 50a of the floor carpet 50 exhibits good anti-slip function.

[0038] The ratio L / H of the distance L between the protrusion and the groove to the height H of the protrusion 20 is preferably 0.3 or higher, and more preferably 0.5 or higher, in order to suppress the tilting of the protrusion 20 due to force along the flat portion 15 and improve the anti-slip effect. Furthermore, the ratio L / H is preferably 2.0 or lower, and more preferably 1.0 or lower, in order to increase the density of the protrusion 20 and improve the anti-slip effect.

[0039] The ratio L / T of the distance L between protrusions and grooves to the thickness T of the backing layer 10 in the flat portion 15 is preferably 0.5 or higher, and more preferably 0.7 or higher, in order to suppress the tilting of the protrusions 20 due to force along the flat portion 15 and improve the anti-slip effect. Furthermore, the ratio L / T is preferably 3.0 or lower, and more preferably 1.5 or lower, in order to increase the density of the protrusions 20 and improve the anti-slip effect.

[0040] The ratio t / L of the thickness t of the backing layer 10 in the groove portion to the distance L between the protrusion and the groove is preferably 0.3 or more, and more preferably 0.5 or more, in order to suppress the tilting of the protrusion 20 due to force along the flat portion 15 and improve the anti-slip effect. Furthermore, the ratio t / L is preferably 2.0 or less, and more preferably 1.0 or less, in order to reduce the rigidity of the backing layer 10 and make the backing layer 10 more flexible.

[0041] The Shore A hardness of the backing layer 10 having grooves 30 is preferably 40 or higher, and more preferably 45 or higher, in order to suppress the bending of the protrusions 20 due to force along the flat portion 15 and improve the anti-slip effect. Furthermore, the Shore A hardness is preferably 70 or lower, and more preferably 65 or lower, in order to reduce the rigidity of the backing layer 10 and make it easier to bend. Here, the Shore A hardness is the Shore hardness measured by a Type A durometer.

[0042] The groove 30 has a shape without corners in its cross-section. The groove 30 shown in Figure 4 has a semicircular cross-section, but the shape without corners in the cross-section may also be a U-shape or the like. Because the groove 30 has no corners in its cross-section, deterioration such as fracture of the backing layer 10 starting from the corners of the groove due to bending motion is suppressed. The cross-sectional shapes of the grooves 30 are not limited to being all the same. Therefore, the grooves 30 may include a portion with a first cross-sectional shape and a portion with a second cross-sectional shape different from the first cross-sectional shape.

[0043] As shown in Figures 2 and 3, the groove 30 is connected as one unit and divides the flat portion 15 into multiple divided regions A0, including one or more protrusions 20. Each of the multiple divided regions A0 includes a plurality of first regions A1 of the same shape, and a plurality of second regions A2 adjacent to any of the plurality of first regions A1 and having a different shape from the first regions A1. Each first region A1 contains one projection 20 and is surrounded by four second regions A2, making it roughly square. Therefore, each first region A1 has four corners C1. No two first regions A1 are adjacent to each other; each first region A1 is adjacent only to a second region A2. Each second region A2 contains two projections 20 and is surrounded by four different second regions A2 and two first regions A1, making it roughly hexagonal. Therefore, each second region A2 has five or more corners C2, specifically six corners C2. Each second region A2 is adjacent to four different second regions A2 and two first regions A1.

[0044] As described above, the orientation of the groove 30 includes a direction D11 along two sides of the square in the first region A1, a direction D12 perpendicular to direction D11, a direction D13 shifted by 45° from directions D11 and D12, and a direction D14 perpendicular to direction D13. As a result, the floor mat 1 is easily bent not only starting from the parts of the groove 30 along directions D11 and D12, but also starting from the parts along directions D13 and D14. Because the second region A2 adjacent to the first region A1 has a different shape from the first region A1, the floor mat 1 is easily bent in various directions. In particular, because the second region A2 has a shape with five or more angles C2, the groove 30 forming the second region A2 is oriented in various directions, and the floor mat 1 is easily bent in various directions. Furthermore, because multiple first regions A1 are dispersed on the back surface 12 of the backing layer 10 so that the first regions A1 do not adjoin each other, the floor mat 1 is easily bent in various directions throughout. In particular, even if the floor mat 1 installed at the driver's feet rests on the pedals, the floor mat 1 is flexible and can bend in various directions, thus preventing it from interfering with pedal operation.

[0045] The number of protrusions 20 included in the first region A1 is not limited to one, and may be two or three. Also, setting integers N1 and N2 such that 1 ≤ N1 < N2 ≤ 3, the plurality of first regions A1 may include a region containing N1 protrusions 20 and a region containing N2 protrusions 20. The number of protrusions 20 included in the second region A2 is not limited to two, and may be one or three. Also, setting integers N1 and N2 such that 1 ≤ N1 < N2 ≤ 3, the plurality of second regions A2 may include a region containing N1 protrusions 20 and a region containing N2 protrusions 20.

[0046] The back surface 12 of the lining layer 10 can have various configurations as illustrated in FIGS. 6 to 10, and may also have a configuration that combines at least a part of the configurations shown in FIGS. 3, 6 to 10.

[0047] FIG. 6 schematically illustrates the back surface 12 of the lining layer 10 of the floor mat 1A included in the concept of the floor mat 1. FIG. 7 schematically illustrates the back surface 12 of the lining layer 10 of the floor mat 1B included in the concept of the floor mat 1. FIG. 8 schematically illustrates the back surface 12 of the lining layer 10 of the floor mat 1C included in the concept of the floor mat 1. In FIGS. 6 to 8, detailed descriptions of the same configurations as those shown in FIGS. 1 to 5 are omitted. The grooves 30 shown in FIGS. 6 to 8 are also connected together, and the flat surface portion 15 including one or more protrusions 20 is divided into a plurality of divided regions A0. The plurality of divided regions A0 includes a plurality of first regions A1 having the same shape and a plurality of second regions A2 that are adjacent to any of the plurality of first regions A1 and have a different shape from the first regions A1.

[0048] Each first region A1 shown in FIG. 6 includes one protrusion 20, is surrounded by eight second regions A2, and is substantially square. The first regions A1 are not adjacent to each other, and only the second regions A2 are adjacent to the first regions A1. Each second region A2 includes one protrusion 20, is surrounded by three different second regions A2 and two first regions A1, and is substantially pentagonal. Therefore, the second region A2 has a shape having five or more corners C2, specifically five corners C2. Three different second regions A2 and two first regions A1 are adjacent to each second region A2. As described above, the orientation of the groove 30 includes a direction D11 along two sides of the square in the first region A1, a direction D12 perpendicular to direction D11, a direction D13 shifted by 45° from directions D11 and D12, and a direction D14 perpendicular to direction D13. As a result, the floor mat 1A is not only easy to bend starting from the portion of the groove 30 along directions D11 and D12, but also easy to bend starting from the portion along directions D13 and D14.

[0049] Each first region A1 shown in Figure 7 includes one projection 20, is surrounded by eight second regions A2, and is roughly circular in shape. No two first regions A1 are adjacent to each other; each first region A1 is adjacent only to a second region A2. Each second region A2 includes one projection 20, has a curved shape at its boundary with the first region A1, and is shaped like a polygon with some of its sides curved. Multiple second regions A2 include regions A21 with five angles C2 and regions A22 with six angles C2. Each region A21 is adjacent to two different regions A21, two regions A22, and one first region A1. No two regions A22 are adjacent to each other; each region A22 is adjacent to four regions A21 and two first regions A1. Because the groove 30 at the boundary between the first region A1 and the second region A2 is curved, and the second region A2 has a shape with five or more angles C2, the floor mat 1B is easily bent in various directions.

[0050] The multiple divided regions A0 shown in Figure 8 include multiple first regions A1 and multiple second regions A2, as well as multiple third regions A3 with shapes different from the first and second regions A2. Each first region A1 includes one projection 20, is surrounded by six second regions A2, and is approximately circular in shape. The first regions A1 are not adjacent to each other; each first region A1 is adjacent only to a second region A2. Each second region A2 includes one projection 20, has a curved shape at its boundary with the first region A1, and has a shape in which part of the sides of a polygon are curved. The multiple second regions A2 include regions A23 with five angles C2 and regions A24 with six angles C2. Each region A23 is adjacent to two different regions A23, one region A24, one first region A1, and one third region A3. Each region A24 is adjacent to one other region A24, two regions A23, one first region A1, and two third regions A3. Each third region A3 contains one projection 20 and is surrounded by eight second regions A2, forming a roughly diamond shape. No third regions A3 are adjacent to each other; each third region A3 is adjacent only to a second region A2. Because the groove 30 at the boundary between the first region A1 and the second region A2 is curved, and the second region A2 has a shape with five or more angles C2, the floor mat 1C is easily bent in various directions.

[0051] As illustrated in Figures 3,6-3,8, when the grooves 30 on the back surface 12 are recessed from the flat surface 15 at positions separated from the multiple anti-slip protrusions 20 so as to divide the multiple protrusions 20, the surrounding flat surface 15 facing the surface 50a of the floor carpet 50 supports the multiple protrusions 20. As a result, the floor mat 1 placed on the surface 50a of the floor carpet 50 exhibits good anti-slip functionality. Furthermore, because the grooves 30 are separated from the multiple protrusions 20, the floor mat 1 is easily bent, as illustrated in Figure 5, and the good anti-slip effect of the floor mat 1 is maintained. Moreover, because the grooves 30 on the back surface 12 of the backing layer 10 are present so as to divide the multiple protrusions 20, the floor mat 1, which has good anti-slip functionality, is easily bent throughout. Based on the above, this specific example can provide a floor mat 1 that can suppress the deterioration of its anti-slip function while also suppressing the difficulty in turning it.

[0052] As illustrated in Figure 9, even a floor mat 1D having a back surface 12 without multiple protrusions 20 can be made less prone to bending in various orientations. The floor mat 1D shown in Figure 9 is also included in the concept of floor mat 1. Detailed explanations of the same configurations shown in Figures 1-5 are omitted in Figure 9. The floor mat 1D shown in Figure 9 has the same configuration as the floor mat 1 shown in Figure 3, except for the multiple protrusions 20. That is, the grooves 30 shown in Figure 9 are also connected as one, dividing the flat portion 15 into multiple divided regions A0. Each of the multiple divided regions A0 includes multiple first regions A1 of the same shape, and multiple second regions A2 adjacent to any of the multiple first regions A1 and having a different shape from the first regions A1.

[0053] From the above, the floor mat 1D is not only easily bent starting from the grooves 30 along two sides of the square in the first region A1 along directions D11 and D12, but also easily bent starting from the grooves along directions D13 and D14. Because the second region A2 adjacent to the first region A1 has a different shape from the first region A1, the floor mat 1D is easily bent in various directions. Because multiple first regions A1 are dispersed on the back surface 12 of the backing layer 10 so that they do not adjoin each other, the floor mat 1D is easily bent in various directions throughout. For example, when a portion of the floor mat 1D installed in the passenger or rear passenger footwell needs to be tucked into a gap, the floor mat 1D has no anti-slip protrusions, making it easy to slide a portion of the floor mat 1D into the gap. Furthermore, because the floor mat 1D is easily bendable in various directions, the process of tucking a portion of the floor mat 1D into a gap is also made easier.

[0054] Although not shown in the illustrations, floor mats having a configuration similar to floor mat 1A shown in Figure 6 but with multiple protrusions 20 removed, floor mats similar to floor mat 1B shown in Figure 7 but with multiple protrusions 20 removed, floor mats similar to floor mat 1C shown in Figure 8 but with multiple protrusions 20 removed, etc., are also included in the concept of floor mat 1. These floor mats without anti-slip protrusions are also easily bent in various directions because the second region A2 adjacent to the first region A1 has a different shape from the first region A1. Furthermore, because multiple first regions A1 are dispersed on the back surface 12 of the backing layer 10 so that the first regions A1 do not adjoin each other, the floor mat as a whole is easily bent in various directions.

[0055] As illustrated in Figure 10, even a floor mat 1E having multiple protrusions 20 projecting in the thickness direction D1 from grooves 30 rather than from flat surfaces 15, can be made less prone to bending in various orientations. The floor mat 1E shown in Figure 10 is also included in the concept of floor mat 1. Detailed explanations of the same configurations shown in Figures 1-5 are omitted in Figure 10. The back surface 12 of the backing layer 10 of the floor mat 1E shown in Figure 10 includes a flat surface 15, grooves 30 recessed from the flat surface 15 to divide the flat surface 15 into multiple divided regions A0, and multiple protrusions 20 protruding from the grooves 30 for anti-slip purposes. The grooves 30 that divide the flat surface 15 into multiple sections include annular grooves 38 surrounding each protrusion 20.

[0056] The multiple divided regions A0 include regions of various shapes. For example, if a region with eight corners C1, as shown in Figure 10, is assigned to the first region A1, then the four regions adjacent to the first region A1 will be assigned to the second region A2. The multiple divided regions A0 also include multiple regions with shapes different from the first region A1 and the second region A2. The second region A2 has eight corners C2. The floor mat 1E, which has grooves 30 that divide the flat surface 15 into multiple divided regions A0 of various shapes, is easily bent in various directions. Because multiple first regions A1 are dispersed on the back surface 12 of the backing layer 10 so that the first regions A1 do not adjoin each other, the floor mat 1E is easily bent in various directions throughout.

[0057] The back surface 12 of the backing layer 10 may include a portion having a configuration with multiple protrusions 20, as shown in Figures 3, 6 to 8, and 10, and a portion having a configuration without anti-slip protrusions, as shown in Figure 9. For example, the portion of the floor mat 1 that is inserted into a gap may have a configuration without anti-slip protrusions, while the remaining portion may have a configuration with multiple protrusions 20. Furthermore, the back surface 12 of the backing layer 10 may include a portion having a configuration with multiple protrusions 20 protruding from a flat portion 15, as shown in Figures 3, 6 to 8, and a portion having a configuration without anti-slip protrusions on the flat portion 15, as shown in Figures 9 and 10.

[0058] The floor mat 1 described above can be manufactured, for example, as follows. First, a base layer formation process is carried out to form a latex layer 44 integrated with the base fabric layer 43 by applying latex to the back surface of the base fabric layer 43 into which the surface layer 41 is integrated. Then, a backing layer formation process is carried out to form the backing layer 10 by integrating the elastomer with the back surface of the latex layer 44 using a backing roll that is shaped to match the back surface 12 of the backing layer 10. This forms the floor mat 1 shown in Figure 1.

[0059] (3) Variations: Various modifications of this invention are conceivable. For example, floor mat 1 is not limited to vehicle use, but may also be a building floor mat installed on top of a carpet fixed to the floor of an indoor or entrance hall. Furthermore, floor mat 1 without anti-slip protrusions may be installed directly on a hard floor rather than on top of a carpet. The floor mat 1 may have a structure in which the surface layer 41 and base layer 42 are embedded in the surface of the backing layer 10, or a structure in which the surface layer 41 and base layer 42 can be separated from the backing layer 10.

[0060] Furthermore, even if the floor mat 1 does not have a base layer 42, if the backing layer 10 has grooves 30, it is possible to suppress the difficulty of bending in various directions, and if the backing layer 10 has multiple protrusions 20 and grooves 30, it is possible to suppress the difficulty of bending while suppressing the deterioration of the anti-slip function.

[0061] (4) Conclusion: As explained above, according to the present invention, it is possible to provide technologies such as floor mats that can suppress the deterioration of anti-slip function while suppressing the difficulty of bending, and floor mats that can suppress the difficulty of bending in various directions, depending on the embodiment. Of course, the above-mentioned basic functions and effects can be obtained even with a technology consisting only of the constituent elements of the independent claim. Furthermore, configurations obtained by substituting or changing the combinations of each configuration disclosed in the above-mentioned examples, configurations obtained by substituting or changing the combinations of each configuration disclosed in the prior art and the above-mentioned examples, etc., are also possible. The present invention also includes these configurations, etc. [Explanation of symbols]

[0062] 1, 1A, 1B, 1C, 1D, 1E... Floor mats, 10...Backing layer, 11...Adhesive surface, 12...Back side, 15...Plane part, 20...Protrusion, 21...First protrusion, 22...Second protrusion, 30...groove, 38...ring groove, 41...Surface layer, 42...Base layer, 43...Base fabric layer, 44...Latex layer 50... Floor carpet, 50a... Surface (example of vehicle floor surface), 90... Automobile (example of a vehicle), A0...divided area, A1...first area, A2...second area, A3...third area, C1,C2...corner, D1... thickness direction, P0...the distance along the plane between the center of the first projection and the center of the second projection. P1... The distance along the flat surface between the center of the first projection and the midpoint of the groove. P2... The distance along the flat surface between the center of the second projection and the midpoint of the groove. R1...Diameter of the lower base of the projection, R2...Diameter of the upper base of the projection. H...height of the projection, L...distance between the projection and the groove. T...Thickness of the backing layer in the flat section, t...Thickness of the backing layer in the grooved section, W... Groove width.

Claims

1. A floor mat that includes a backing layer made of elastomer and is installed on a floor surface, The backing layer has a back surface that includes a flat portion that is aligned with the floor surface, a plurality of protrusions that extend from the flat portion for anti-slip purposes, and grooves that are recessed from the flat portion at positions separated from the plurality of protrusions so as to divide the plurality of protrusions into a plurality of sections. The groove divides the planar portion into multiple divided regions, including one or more of the protrusions. A floor mat in which the plurality of divided regions include a plurality of first regions having the same shape and a plurality of second regions adjacent to any of the plurality of first regions and having a different shape from the first region.

2. The floor mat according to claim 1, wherein the second region has a shape having five or more corners.

3. A floor mat that includes a backing layer made of elastomer and is installed on a floor surface, The backing layer has a back surface that includes a flat portion that is aligned with the floor surface, a plurality of protrusions that extend from the flat portion for anti-slip purposes, and grooves that are recessed from the flat portion at positions separated from the plurality of protrusions so as to divide the plurality of protrusions into a plurality of sections. The groove has a semicircular cross-section. A floor mat in which the depth of the groove is less than the thickness of the backing layer in the portion of the groove.

4. A floor mat that includes a backing layer made of elastomer and is installed on a floor surface, The backing layer has a back surface that includes a flat portion along the floor surface and grooves recessed from the flat portion so as to divide the flat portion into a plurality of divided regions. A floor mat in which the plurality of divided regions include a plurality of first regions having the same shape and a plurality of second regions adjacent to any of the plurality of first regions and having a different shape from the first region.

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