JP2002283904A - Car floor mats - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an automobile floor mat with no uncomfortable odor in which a toxic gas is hardly generated at the time of burning, a fog is not generated even if it is used for a long period of time, an abrasion-resistance and a cushion property are excellent, a stain deposited on a surface can be easily removed and a cleaning is easy. SOLUTION: A surface resin layer 2 having a thickness of 100-500 μm in which 50% by weight or more of resin component is constituted by an olefin resin is integrally laminated on an upper surface side of an intermediate resin layer 3 containing a specific amount of filter and having a thickness of 0.5-2.0 mm in which 50% by weight or more of resin component is constituted by an olefin resin. A backing layer 4 comprising an unwoven cloth and having a thickness of 1-8 mm and a METSUKE of 50-1,000 g/m<2> is integrally laminated on the tower surface side of the intermediate resin layer 3.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a floor mat for an automobile which is used by being laid on a fiber rug such as a carpet laid on the floor of an automobile.

[0002]

2. Description of the Related Art A fiber rug such as a carpet is previously laid on the floor in an automobile interior, and a floor mat which can be further removed on the fiber rug for the purpose of preventing the fiber rug from being stained. It is often carried out. As such a floor mat, a resin sheet mat made of a polyvinyl chloride resin, a floor mat made by stacking and integrating a surface material made of a pile fabric on the resin sheet, and the like are known. The former polyvinyl chloride resin floor mat is excellent in abrasion resistance and can contain a large amount of filler, so that the cost can be reduced and it is economical. Also, in the latter pile fabric floor mat, a sufficient cushioning property can be imparted by the surface pile.

[0003]

However, the above-mentioned conventional floor mats have the following problems. That is, in the former floor mat made of polyvinyl chloride resin, a large amount of smoke is generated at the time of combustion, and a toxic gas such as hydrogen chloride is generated, so that evacuees may inhale the toxic gas during a fire. There was a problem of disaster prevention, and a problem of causing environmental pollution by incineration at the time of disposal.
In addition, the floor mat made of polyvinyl chloride resin contains a large amount of plasticizer, so it has a peculiar odor, and the plasticizer is volatilized after many years of use, and the flexibility of the floor mat is reduced. In addition, there has been a problem that the plasticizer bleeds to the surface due to long-term use and fogging is likely to occur, resulting in poor appearance.

On the other hand, in the latter pile mat made of pile fabric,
There is a problem that it is difficult to secure a clean feeling because dust and dust are easily adsorbed to the surface pile. Also, it is not easy to remove dust and dirt etc. between piles.For example, when spilling beverages etc., traces are likely to remain and the appearance is often deteriorated. There was also a problem that it was difficult.

[0005] The present invention has been made in view of the above technical background, and hardly generates toxic gas during combustion, has no unpleasant odor, does not cause fogging even when used for many years, and An object of the present invention is to provide an automobile floor mat which has excellent wear resistance and cushioning property, and which can easily remove dirt and the like adhered to the surface by sand, mud, dust, dust, food and drink, etc., and can be easily cleaned. .

[0006]

SUMMARY OF THE INVENTION The object of the present invention is to provide an intermediate resin layer having a thickness of 0.5 to 2.0 mm containing a filler and comprising at least 50% by weight of a resin component of an olefin resin. A 100 to 500 μm thick surface resin layer composed of an olefin resin in which 50% by weight or more of the resin component is laminated and integrated, and a 1 to 8 mm thick nonwoven fabric is formed on the lower surface side of the intermediate resin layer. , Basis weight 50 to 1000 g / m ²
The backing layer is laminated and integrated, and the compounding amount of the filler in the intermediate resin layer is the same as that of the resin 1 constituting the intermediate resin layer.
This is achieved by an automotive floor mat characterized by being in the range of 20-500 parts by weight per 00 parts by weight.

[0007] Since 50% by weight or more of the constituent resin of each resin layer is an olefin resin, toxic gas is not generated at the time of combustion, the combustion safety is excellent, the disaster prevention is convenient, and the environment is protected. Can also contribute enough. Further, since the surface layer is composed of a resin layer having no pile, and 50% by weight or more of the resin component constituting the surface resin layer is an olefin-based resin, the floor mat has excellent wear resistance on the surface of the floor mat and also has a stain and the like. Can be easily removed, cleaning is easy, and the stain resistance is excellent. In addition, since the thickness of the surface resin layer is specified to be 100 to 500 μm, it is possible to ensure excellent dimensional stability and prevention of warpage while ensuring sufficiently excellent wear resistance. In addition, since the intermediate resin layer contains the filler in a specific amount, the floor mat has excellent dimensional stability and sufficient tensile strength. In addition, since the thickness of the intermediate resin layer is specified to be 0.5 to 2.0 mm, it is possible to ensure good dimensional stability and good followability to the floor shape of the vehicle. Further, since the backing layer of a specific thickness and specific weight made of a nonwoven fabric is laminated and integrated on the lower surface side of the intermediate resin layer, excellent cushioning properties can be obtained. In addition, since it is not necessary to contain a plasticizer, there is no generation of odor peculiar to the plasticizer, no fogging occurs on the surface even after long-term use, and the durability is excellent.

The durometer D hardness of the surface resin layer is 40 to
70, and the durometer D hardness of the intermediate resin layer is preferably in the range of 35 to 65, so that it can be laid sufficiently in conformity with the floor shape of an automobile and has sufficient tensile strength. It can be made to have excellent properties. When the softness (of the floor mat) specified in JIS L1096 is in the range of 3 to 30 N, the tensile strength can be further improved while further improving the followability to the floor shape of the automobile. .

Preferably, 50% by weight or more of the resin component constituting the backing layer is an olefin resin. With such a configuration, the backing layer has a heat shrinkage equivalent to that of the surface resin layer, so that the upward warpage tendency of the surface resin layer can be offset and the upward warpage of the floor mat can be effectively reduced. Can be prevented.

The backing layer has a thickness of 2 to 5 mm and a basis weight of 1
It is preferable to use a needle-punched nonwoven fabric of 00 to 500 g / m ² . As a result, more excellent cushioning properties can be ensured, and the frictional resistance can be increased to provide excellent anti-slip properties for the underlying fiber rug.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, an embodiment of an automobile floor mat according to the present invention will be described with reference to the drawings. As shown in FIG. 1, this automotive floor mat (1) has a thickness of 100 to 500 μm on an upper surface side of an intermediate resin layer (3) having a thickness of 0.5 to 2.0 mm containing a filler. Surface resin layer (2) is laminated and integrated, and the intermediate resin layer (3)
1 to 8 mm of nonwoven fabric on the underside of
The intermediate resin layer (3) and the surface resin layer (2) each have a laminated structure in which a backing layer (4) of 1000 g / m ² is laminated and integrated. % Or more of the olefin resin, and the amount of the filler in the intermediate resin layer (3) is 20 to 500 parts by weight based on 100 parts by weight of the resin constituting the intermediate resin layer (3). It is specified in the range of parts.

In the surface resin layer (2), 50% by weight or more of the resin component constituting the surface resin layer (2) is made of an olefin resin. The surface layer is made of such a specific resin,
Moreover, since the surface layer is made of a resin layer without a pile, the floor mat (1) has excellent abrasion resistance and contamination resistance on the surface. Further, since 50% by weight or more of the resin component is an olefin-based resin, toxic gas is not easily generated during combustion.

The olefin resin is not particularly limited, but may be, for example, a polyethylene resin, a polypropylene resin, an amorphous poly-α-olefin resin, an ethylene propylene-diene copolymer, or an ethylene-vinyl acetate copolymer. And an ethylene ionomer resin. When a resin other than the olefin resin is used in combination as a resin component constituting the surface resin layer (2),
Any resin having no chlorine atom in the chemical structure can be used.

The surface resin layer (2) may be composed of a single layer or a multilayer as long as it is composed of the resin according to the above constitution.

The surface resin layer (2) is usually provided with a cosmetic in order to improve the design. Means for applying such makeup includes means for providing a printed pattern on the upper surface, lower surface, or inside the surface resin layer of the surface resin layer (2). In any case, the surface side of the floor mat (1) may be used. The configuration is not particularly limited to the above configuration as long as the printed pattern can be viewed from the viewpoint. Among them, as shown in FIG. 1, a printing layer (8) such as pattern printing is formed on the lower surface of the surface resin layer (2).
It is more preferable to laminate the printed layer (8)
Is disposed under the surface resin layer (2), so that the printed layer (8) is rubbed and damaged by contact or the like during use,
Peeling can be prevented, and excellent design can be ensured over a long period of time. The printing method for providing the print pattern is not particularly limited, and examples thereof include an inkjet method, a gravure printing method, a screen printing method, and a transfer printing method.

As another means for applying makeup, there is a means for mixing a pattern material into the surface resin layer (2). By mixing such a pattern material in the surface resin layer (2), the pattern material is randomly mixed in the transparent or translucent surface resin layer (2), and a deep pattern pattern can be displayed. it can.

As the pattern material, known materials can be used and are not particularly limited. For example, granules made of thermosetting urea resin or thermoplastic polyester resin, cellulose or aluminum as a main raw material A square or flake-shaped handle chip, or a needle-like material containing cellulose as a main raw material is preferably used. These pattern materials may be used alone or in combination of two or more. A color pigment may be mixed into the surface resin layer (2) instead of or in combination with the pattern material.

In order to further improve the design, irregularities may be formed on the surface of the surface resin layer (2) by embossing or the like. Rather, from the viewpoint of preventing slippage, irregularities may be formed on the surface of the surface resin layer (2). Is preferably formed.

Further, for the purpose of improving abrasion resistance, antifouling property, antistatic property, etc., a treating agent is applied to the surface of the flooring material (1), that is, the upper surface of the surface resin layer (2), if necessary. Alternatively, a film may be formed. For example, from the viewpoint of improving abrasion resistance, a coating mainly composed of a urethane resin, an acrylic resin, or a silicone resin may be formed on the upper surface of the surface resin layer (2). In addition, such a film is generally formed to a thickness of 50 μm or less.

The thickness of the surface resin layer (2) is from 100 to
It needs to be 500 μm. If it is less than 100 μm, the abrasion resistance is reduced. On the other hand, if it is more than 500 μm, the floor mat (1) tends to be warped and the dimensional stability is reduced. Among them, the thickness of the surface resin layer (2) is 150 to 3
It is preferably set to 00 μm.

On the other hand, the intermediate resin layer (3) has a sufficient strength for imparting durability as a floor mat and has a role of bonding the surface resin layer (2) and the backing layer (4). The intermediate resin layer (3) comprises a resin composition containing a filler and comprising at least 50% by weight of a resin component of an olefin resin. As described above, since 50% by weight or more of the resin component is an olefin-based resin, it is difficult to generate a toxic gas during combustion.

The olefin resin is not particularly limited. For example, polyethylene resin, polypropylene resin, amorphous poly-α-olefin resin, ethylene propylene-diene copolymer, ethylene-vinyl acetate copolymer And an ethylene ionomer resin. Among them, as the olefin resin constituting the intermediate resin layer (3), at least one resin selected from the group consisting of amorphous poly-α-olefin resin and ethylene-vinyl acetate copolymer, and polypropylene resin It is preferable to use a resin having a heat distortion temperature of 100 ° C. or higher in combination, since it enables high filling of the filler and sufficiently secures heat resistance. When a resin other than the olefin resin is used in combination as the resin component constituting the intermediate resin layer (3), any resin having no chlorine atom in the chemical structure may be used. it can.

The intermediate resin layer (3) may be formed as a single layer or as a multilayer as long as the intermediate resin layer (3) is formed of the resin having the above structure.

The amount of the filler is determined by the amount of the intermediate resin layer (3).
Is in the range of 20 to 500 parts by weight based on 100 parts by weight of the resin constituting the above. If the amount is less than 20 parts by weight, the dimensional stability decreases, and if it exceeds 500 parts by weight, the tensile strength decreases and the durability becomes poor. Among them, the amount of the filler is 1 to 100 parts by weight of the resin constituting the intermediate resin layer (3).
It is preferably in the range of 00 to 350 parts by weight.

The filler is not particularly limited, but may be any of those conventionally known as fillers for flooring materials, such as calcium carbonate, barium sulfate, aluminum hydroxide, magnesium hydroxide, clay, and talc. , Alumina, silica and the like. Aluminum hydroxide,
When magnesium hydroxide is used, flame retardancy can be imparted.

The thickness of the intermediate resin layer (3) is 0.5 to
2.0 mm. If it is less than 0.5 mm, sufficient dimensional stability cannot be obtained and the tensile strength decreases. On the other hand, if it exceeds 2.0 mm, the weight increases, handling becomes poor, and the ability to follow the shape of the floor of the vehicle is also reduced, so that the layability is reduced.

The surface resin layer (2) and the intermediate resin layer (3) each have an antioxidant, an ultraviolet absorber, a lubricant, a stabilizer, a light stabilizer, a flame retardant, a colorant, and an antistatic agent. ,
Various additives such as a patterning agent may be appropriately contained.

The backing layer (4) is a layer composed of a nonwoven fabric, and its thickness needs to be set to 1 to 8 mm. If it is less than 1 mm, the cushioning properties will be insufficient, and if it exceeds 8 mm, the overall thickness will be large and it will not be practical as a floor mat (1). In particular, the thickness of the backing layer (4) is preferably set in the range of 2 to 5 mm.

The basis weight of the backing layer (4) is 50 to 100.
It must be set in the range of 0 g / m ² . 50 g / m ²
If it is less than 100, the cushioning property becomes insufficient, and 100
If it exceeds 0 g / m ² , it is difficult to secure lightness. In particular, the basis weight of the backing layer (4) is preferably set in the range of 100 to 500 g / m ² .

The nonwoven fabric used for the backing layer (4) is not particularly limited, but examples thereof include a needle punched nonwoven fabric, a spunbonded nonwoven fabric, a thermal bonded nonwoven fabric, and a chemical bonded nonwoven fabric. The material is not particularly limited, and for example, a polypropylene nonwoven fabric, a polyester nonwoven fabric, a nylon nonwoven fabric, or the like is used. Among them, 50% by weight or more of the resin component constituting the backing layer (4) is preferably made of an olefin resin. Since 50% by weight or more of the resin component constituting the surface resin layer (2) is an olefin-based resin, the surface resin layer (2) is liable to undergo heat shrinkage and the floor mat (1) tends to be slightly warped. However, when the olefin resin is used in 50% by weight or more of the resin component constituting the backing layer (4), the backing layer (4) has a heat shrinkage equivalent to that of the surface resin layer. In addition, the warpage of the surface resin layer (2) can be offset, and the warp of the floor mat (1) can be effectively prevented.

The backing layer (4) has a thickness of 2
To 5 mm, preferably used basis weight 100 to 500 g / m ² needle punched nonwoven. By adopting such a configuration, a more excellent cushioning property can be ensured, and an increase in frictional resistance further improves the anti-slipping property against the underlying fiber rug, thereby further improving safety.

In the present invention, the durometer D hardness of the surface resin layer (2) is in the range of 40 to 70, and the durometer D hardness of the intermediate resin layer (3) is in the range of 35 to 65. Preferably, by being set in such a range, it is possible to lay the vehicle sufficiently following the floor shape of the vehicle, and it is possible to provide a structure having sufficient tensile strength and excellent durability. There are advantages. The “durometer D hardness” is a value measured in accordance with JIS K7215, and a D-type durometer (protruding amount of a needle of 2.5 m) is applied to a test piece adjusted to a temperature of 23 ± 2 ° C.
m, a pressing force of 49.03 N). The maximum value of the D-type durometer is read within 1 second after the indenter enters the test piece, and this value is read as the durometer D.
Hardness.

The rigidity of the floor mat (1) (JI
(SL1096) is preferably in the range of 3 to 30N. If it is less than 3N, it is not preferable because the tensile strength is reduced and the durability is reduced. On the other hand, if it is more than 30N, the ability to follow the floor shape of the automobile is reduced and the laying workability is unpreferably reduced. Above all, it is particularly preferable that the rigidity of the floor mat (1) is set in the range of 10 to 25N.

The thickness of the floor mat (1) for an automobile of the present invention is not particularly limited, but is generally 2 to 10 mm.

The method for producing the floor mat (1) for an automobile according to the present invention is not particularly limited. For example, a known apparatus such as a calender, an extruder, a doctor coater, or a roll coater may be used. Can be manufactured. Further, a three-dimensional structure obtained by subjecting this to secondary molding may be used.

[0036]

Next, specific embodiments of the present invention will be described.

Example 1 As shown in Table 1, an amorphous propylene-ethylene copolymer (number average molecular weight: 6,000)
6 parts by weight, 8 parts by weight of ethylene-α-olefin copolymer (number average molecular weight 160,000), polypropylene resin 11
A Banbury mixer containing a composition consisting of parts by weight, 75 parts by weight of calcium carbonate (filler), 0.4 parts by weight of an antioxidant (hindered phenolic antioxidant) and 1.2 parts by weight of a lubricant (phosphate ester). And an intermediate sheet (intermediate resin layer) having a thickness of 0.8 mm was prepared using a calender molding machine.

On the other hand, a thickness of 200
A predetermined pattern was printed on the back surface of the μm sheet (surface resin layer) by gravure printing to obtain an upper layer sheet.

The upper sheet and the intermediate sheet are laminated and integrated by hot laminating, and then a powder (adhesive) of an ethylene-vinyl acetate copolymer is sprayed on the back surface of the intermediate sheet, and the infrared ray is applied by a far-infrared ray device. The powder was melted and mixed with a needle-punched non-woven fabric (4 m thick).
m, the basis weight of 350 g / m ² )
The floor mat was obtained. The composition of the needle punched nonwoven fabric was 60% by weight of polypropylene and 40% by weight of polyethylene terephthalate (PET) resin.

After the above-mentioned raw floor mat was formed and processed, it was cut into a predetermined shape to obtain an automobile floor mat.

<Example 2> A needle-punched nonwoven fabric made of polypropylene resin (4 mm in thickness, 350 g / m in basis weight)
² ) and a spunbonded nonwoven fabric made of polyethylene terephthalate resin (having a basis weight of 50 g / m ² ) were needle-entangled to prepare a composite nonwoven fabric. A composition having the composition shown in Table 1 was applied and laminated on the upper surface of this composite nonwoven fabric by an extruder (coating amount: 1400 g / m ² ).
An intermediate resin layer was formed, and at the same time, a 200 μm-thick polypropylene sheet (surface resin layer) having a gravure print applied to the back surface was laminated thereon to obtain an original floor mat. This raw floor mat was formed and cut into a predetermined shape to obtain an automobile floor mat.

<Examples 3 and 4> Floor mats were obtained in the same manner as in Example 1 except that the conditions such as the composition and thickness of each layer were as shown in Table 2.

Example 5 A floor mat was obtained in the same manner as in Example 1, except that the composition of the needle-punched nonwoven fabric was 10% by weight of polypropylene and 90% by weight of a polyethylene terephthalate resin.

[0044]

[Table 1]

[0045]

[Table 2]

[0046]

[Table 3]

<Comparative Example 1> The thickness of the surface resin layer was set to 20 μm.
Except for having been set to, a floor mat was obtained in the same manner as in Example 1.

<Comparative Example 2> The thickness of the surface resin layer was set to 1000
A floor mat was obtained in the same manner as in Example 1 except that the thickness was set to μm.

Comparative Example 3 Example 1 was repeated except that polyethylene terephthalate was used as the constituent resin of the surface resin layer.
A floor mat was obtained in the same manner as described above.

Comparative Example 4 The thickness of the intermediate resin layer was 0.3 m
A floor mat was obtained in the same manner as in Example 1 except that m was set.

Comparative Example 5 The thickness of the intermediate resin layer was 3.0 m
A floor mat was obtained in the same manner as in Example 1 except that m was set.

Comparative Example 6 A floor mat was obtained in the same manner as in Example 1, except that the filler was not contained in the intermediate resin layer.

<Comparative Example 7> The amount of the filler (calcium carbonate) in the intermediate resin layer was changed to 1 in place of 75 parts by weight.
A floor mat was obtained in the same manner as in Example 1 except that the weight was 50 parts by weight.

Comparative Example 8 A floor mat was obtained in the same manner as in Example 1 except that the thickness of the backing layer was set to 0.5 mm.

<Comparative Example 9> The basis weight of the backing layer was 20 g / m ^2.
Except for having been set to, a floor mat was obtained in the same manner as in Example 1.

The following tests were performed on each of the floor mats obtained as described above. Table 4 shows the test results.

<Abrasion resistance test> According to the friction test method for building materials and building components according to JIS A1453,
Using a worn wheel around which a predetermined abrasive paper was wound around the surface of each floor mat, the tape was worn 1000 times with a taper abrasion tester, and the abrasion loss (g) was measured. Those with a loss on wear of 0.25 g or less were marked with “◎”, those with 0.25 to 0.30 g were marked with “○”, and those with more than 0.30 g were marked with “x”.

<Stain resistance test> According to the stain test of the vinyl flooring material according to JIS A5705, 2 mL of the contaminated material was dropped on the surface of each floor mat and allowed to stand for 24 hours. After washing with alcohol and further with alcohol,
After wiping with gauze and leaving for 1 hour, changes in color, gloss, and swelling of the dropped portion were visually observed. Contaminants include soybean oil, lubricating oil, 95% ethyl alcohol, 2%
The measurement was performed using a soda with sodium hydroxide, 5% acetic acid, and 5% hydrochloric acid cement paste. The sample that did not change by any of the observations was marked with “◎”, and the sample with at least one change was marked with “×”.

<Dimensional stability test> In accordance with the length change test of vinyl flooring by heating according to JIS A5705,
After heating each floor mat at 80 ° C. for 6 hours, it was allowed to stand in a room for 1 hour, and the rate of change with respect to the length before heating was measured. If the rate of change in length is less than 1.0%, the result is indicated as "◎".
-1.5% was evaluated as "○", and 1.5% or more was evaluated as "X".

<Evaluation of the ability to follow the laid floor surface> The one that follows the floor shape of the automobile very well and is very familiar is marked with “、”, and the one that follows the floor shape well and is familiar is called “」 ”. ○ ”, and those with poor follow-up to the floor shape and unfamiliarity were rated“ x ”.

<Upward warpage prevention test> JIS L4406
JIS G in accordance with the warp test of tile carpet
A floor material test piece (cut to a size of 50 cm × 50 cm) is placed on a stainless steel plate having a thickness of 3 mm specified in 4305, and is horizontally placed in a standard state (20 ± 2 ° C., 65 ±
(2% RH) for 24 hours, and then placed on a horizontal test table to measure the size of the gap between the four corners of each test piece and the test table. The sum of the gaps with the test table at the four corners of each test piece is
Those with a diameter of 1.0 mm or less were marked with “◎”, those with a diameter of more than 1.0 mm and 1.5 mm or less were marked with “○”, and those with a diameter of more than 1.5 mm were marked with “x”.

<Tensile strength test method> A floor mat test piece (cut to 5 cm x 30 cm) using an autograph in accordance with the tensile strength test of a woven fabric according to JIS L1096.
Was measured for tensile strength. Samples with a measured value of 100 N / cm or more were marked with “◎”, those with a value of 50 N / cm or more and less than 100 N / cm were marked with “○”, and those with a measured value of less than 50 N / cm were marked with “x”.

<Cushioning Property Test Method> A load of 20 g / cm ² was applied to the floor mat test piece, and the thickness after 30 seconds was measured. Next, a load of 1000 g / cm ² was applied to the floor mat test piece, and the thickness after 30 seconds was measured. 20g / c
When the difference between the thickness when a load of m ² is applied and the thickness when a load of 1000 g / cm ² is applied is 0.8 mm or more, “◎” is used, and when it is less than 0.8 mm, “×” is used. And

[0064]

[Table 4]

As is clear from Table 4, the floor mats of Examples 1 to 5 of the present invention have abrasion resistance, stain resistance, dimensional stability, followability to the floor surface, anti-warpage, cushioning, All of the tensile strengths were excellent. Further, since it does not contain a plasticizer, there is no odor, and no fogging occurs on the surface even after long-term use.

On the other hand, the floor mat of Comparative Example 1, in which the thickness of the surface resin layer deviates below the specified range of the present invention, has insufficient abrasion resistance and deviates beyond the specified range. The floor mat No. 2 was inferior in dimensional stability and warpage prevention. Further, the floor mat of Comparative Example 3 in which the constituent resin of the surface resin layer was PET was inferior in abrasion resistance and stain resistance. The floor mat of Comparative Example 4 in which the thickness of the intermediate resin layer deviates below the specified range of the present invention has insufficient dimensional stability and tensile strength, and the floor mat of Comparative Example 5 in which the thickness deviates beyond the specified range. The floor mat had insufficient followability with the floor surface. Further, the floor mat of Comparative Example 6 in which the filler was not contained in the intermediate resin layer had insufficient dimensional stability, and the floor mat of Comparative Example 7 in which the filler content deviated beyond the specified range of the present invention was used. The tensile strength was insufficient. Comparative Example 8 in which the thickness of the backing layer deviates below the specified range of the present invention.
The floor mat of Comparative Example 9 in which the weight of the floor mat and the weight of the backing layer deviated below the specified range of the present invention were all insufficient in cushioning properties.

[0067]

The floor mat for automobiles according to the present invention is low in smoke emission and generates little toxic gas during combustion because 50% by weight or more of the resin constituting each resin layer is an olefin resin. It is excellent in combustion safety and convenient in disaster prevention, and can also contribute sufficiently to environmental conservation. In addition, since the surface layer is composed of a resin layer having no pile and 50% by weight or more of the resin component constituting the surface resin layer is an olefin resin, the abrasion resistance and the stain resistance are excellent. Also,
Since the thickness of the surface resin layer is defined in a specific range, the thickness is excellent in abrasion resistance, dimensional stability and prevention of warpage. Further, since the intermediate resin layer contains a specific amount of the filler, the intermediate resin layer has sufficient tensile strength while having excellent dimensional stability. In addition, since the thickness of the intermediate resin layer is defined in a specific range, the intermediate resin layer can be laid with excellent dimensional stability while following the floor shape of the automobile. Further, since a backing layer made of a nonwoven fabric and having a specific thickness and specific weight is laminated and integrated on the lower surface side of the intermediate resin layer, the cushioning property is excellent. In addition, since it is not necessary to contain a plasticizer, there is no generation of odor peculiar to the plasticizer, no fogging occurs on the surface even after long-term use, and the durability is excellent.

The durometer D hardness of the surface resin layer is 40 to
70, and the durometer D hardness of the intermediate resin layer is 35 to
When it is 65, it is possible to further improve the followability with respect to the floor shape, and to have sufficient durability with sufficient tensile strength.

When the stiffness (of the floor mat) specified in JIS L1096 is in the range of 3 to 30 N, the ability to follow the floor shape is further improved.
The tensile strength can be further improved.

When at least 50% by weight of the resin component constituting the backing layer is an olefin-based resin, the floor mat can be effectively prevented from warping.

The backing layer has a thickness of 2 to 5 mm and a basis weight of 100 to
When it is made of a needle-punched nonwoven fabric of 500 g / m ² , more excellent cushioning properties can be ensured, and the non-slip property against the underlying fiber rug is excellent.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing an automobile floor mat according to an embodiment of the present invention.

[Explanation of symbols]

 1: Floor mat 2: Surface resin layer 3: Intermediate resin layer 4: Backing layer

Continued on the front page F term (reference) 3B088 FB03 FB04 FB05 3B120 AA23 AA24 AB06 BA21 CA08 DB01 EA10 EB04 EB11 EB18 4F100 AA04H AA08H AH02H AK03A AK03B AK03C AK07 AK42 AK64 CA03 BA03A03 CA05 AL05 BA05A03 JK02 JK09 JK11 JK12A JK12B JK13 JL00 JL04 JL06 YY00A YY00B YY00C YY00H

Claims (5)

[Claims] Claims 1. A filler containing 50% by weight of a resin component
The thickness is 0.5 to 2.
On the upper surface side of the 0 mm intermediate resin layer, 50% by weight of the resin component
The above is a thickness of 100 to 50 composed of an olefin resin.
A 0 μm surface resin layer is laminated and integrated, and a backing layer made of non-woven fabric having a thickness of 1 to 8 mm and a basis weight of 50 to 1000 g / m ² is laminated and integrated on the lower surface side of the intermediate resin layer. The amount of the filler in the resin layer is 20 to 5 parts by weight per 100 parts by weight of the resin constituting the intermediate resin layer.
An automobile floor mat characterized by being in the range of 00 parts by weight. 2. The floor mat according to claim 1, wherein the surface resin layer has a durometer D hardness of 40 to 70, and the intermediate resin layer has a durometer D hardness of 35 to 65. 3. The floor mat for vehicles according to claim 2, wherein the rigidity defined by JIS L1096 is in the range of 3 to 30N. 4. The floor mat for an automobile according to claim 1, wherein 50% by weight or more of the resin component constituting the backing layer is an olefin resin. 5. The backing layer has a thickness of 2 to 5 mm and a basis weight of 1
00-500g / m ^TwoNeedle-punched non-woven fabric
An automobile floor mat according to any one of claims 1 to 4.
G.