Method and apparatus for manufacturing base member bearing projections, and base member bearing projections

Abstract

A method is provided including a step of preparing a base member; a step of preparing a metal mold which comprises a reference surface and plural projection-shaping die parts which have ring-like protruding sections projecting from a reference surface and surrounding hollow spaces which are shaped to match with the profiles of the projections; a step of placing a thermoplastic or thermosetting sheet-like molding material on the base member; a step of pressing the metal mold against the molding material placed on the base member, pressurizing the molding material at least with the ring-like protruding sections and accordingly bonding the molding material thus pressurized with the ring-like protruding sections to the base member, and forming and shaping projections from the molding material which is opposed against the insides of the hollow spaces surrounded by the ring-like protruding sections; and a step of leaving on the base member the molding material which is opposed against the plural projection-shaping die parts and stripping off the molding material other than the molding material which is opposed against the plural projection-shaping die parts.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram which shows a floor mat manufacturing apparatus according to a first preferred embodiment;

FIG. 2 is an enlarged cross sectional view of a projection-shaping die part of a cylindrical mold roller;

FIG. 3 is a cross sectional view which shows a section in which a molding material is pressure bonded to a mat base member;

FIG. 4 is a perspective view which shows a state that the molding material, except for where it is opposed against the projection-shaping die parts, is being stripped off from the mat base member;

FIG. 5 is a perspective view of a floor mat;

FIG. 6 is a cross sectional view of a floor mat;

FIG. 7 is a cross sectional view of a press machine which is used for a floor mat manufacturing method according to a second preferred embodiment;

FIGS. 8A and 8B are enlarged cross sectional views, each of which shows a state that the molding material is being pressure bonded to the mat base member using the press machine which is shown in FIG. 7;

FIG. 9 is a diagram which shows a projections-seating base member manufacturing apparatus according to a third preferred embodiment;

FIG. 10 is a graph of acoustic absorption coefficients of absorbing a vertically-incident sound measured on samples alone in an acoustic absorption capability test;

FIG. 11 is a graph which shows acoustic absorption coefficients of absorbing a vertically-incident sound measured on samples which are set on car flooring materials in an acoustic absorption capability test;

FIG. 12 is a graph which shows the values of skid resistance measured on test samples set on car flooring materials in an antiskid capability test;

FIG. 13 is a cross sectional view which shows a conventional floor mat in which the entire back surface of a mat base member is covered with a resin sheet; and

FIG. 14 is a cross sectional view which shows a conventional floor mat in which a sound absorbing material is bonded to the back surface of a mat base member.

Claims

1. A method of manufacturing a projections-seating base member according to which plural projections are formed in a spaced arrangement on a first surface or a second surface of a base member or on both said first surface and said second surface, comprising: a step of preparing said base member;a step of preparing a metal mold which comprises a reference surface and plural projection-shaping die parts which have ring-like protruding sections projecting from said reference surface and surrounding hollow spaces which are shaped to match with the profiles of said projections;a step of placing a thermoplastic or thermosetting sheet-like molding material on said base member;a step of pressing said metal mold against said molding material placed on said base member, pressurizing said molding material at least with said ring-like protruding sections and accordingly bonding said molding material thus pressurized with said ring-like protruding sections to said base member, and forming and shaping projections from said molding material which is opposed against the insides of said hollow spaces surrounded by said ring-like protruding sections; anda step of leaving on said base member said molding material which is opposed against said plural projection-shaping die parts and stripping off said molding material other than said molding material which is opposed against said plural projection-shaping die parts.

2. The method of manufacturing a projections-seating base member of claim 1, further comprising a step of heating and accordingly softening said molding material before placing said molding material on said base member.

3. The method of manufacturing a projections-seating base member of claim 1, further comprising a step of heating and accordingly softening said molding material after placing said molding material on said base member.

4. The method of manufacturing a projections-seating base member of claim 3, wherein said molding material is heated while being molded by said metal mold.

5. The method of manufacturing a projections-seating base member of claim 1, wherein said base member is made of a fiber material.

6. The method of manufacturing a projections-seating base member of claim 1, wherein said molding material is a resin or rubber.

7. An apparatus for manufacturing a projections-seating base member in which plural projections are formed in a spaced arrangement on a surface of said base member, comprising: a means which presses a metal mold, which comprises a reference surface and plural projection-shaping die parts which have ring-like protruding sections projecting from said reference surface and surrounding hollow spaces which are shaped to match with the profiles of said projections, against a thermoplastic or thermosetting sheet-like molding material which is set on the surface of said base member, pressurizes said molding material at least with said ring-like protruding sections and accordingly bonds said molding material thus pressurized with said ring-like protruding sections to said base member, and forms and shapes said projections from said molding material which is opposed against the insides of said hollow spaces surrounded by said ring-like protruding sections; anda means which leaves on said base member said molding material which is opposed against said plural projection-shaping die parts and strips off said molding material other than said molding material which is opposed against said plural projection-shaping die parts.

8. The apparatus for manufacturing a projections-seating base member of claim 7, wherein said means which forms and shapes said projections is disposed opposed against said metal mold and comprises a support member which firmly presses, together with said metal mold, said base member and said molding material.

9. The apparatus for manufacturing a projections-seating base member of claim 7, wherein said metal mold is formed by a cylindrical roller which has a cylindrical surface which serves as said reference surface.

10. The apparatus for manufacturing a projections-seating base member of claim 8, wherein said support member is formed by a cylindrical roller.

11. The apparatus for manufacturing a projections-seating base member of claim 7, wherein said means which strips off comprises a first means which pulls said base member, to which said molding material opposed against said plural projection-shaping die parts is bonded, toward a first direction and a second means which pulls said molding material exclusive of said molding material opposed against said plural projection-shaping die parts toward a second direction which is different from said first direction.

12. An apparatus for manufacturing a projections-seating base member in which plural first projections and plural second projections are formed in a spaced arrangement respectively on a first surface and a second surface of said base member, comprising: a first molding means which presses a first metal mold, which comprises a first reference surface and plural first projection-shaping die parts which have first ring-like protruding sections projecting from said first reference surface and surrounding first hollow spaces which are shaped to match with the profiles of said first projections, against a thermoplastic or thermosetting sheet-like molding material set on said first surface of said base member, pressurizes said molding material at least with said first ring-like protruding sections and accordingly bonds said molding material thus pressurized with said first ring-like protruding sections to said base member, and forms and shapes said first projections from said molding material which is opposed against the insides of said first hollow spaces surrounded by said first ring-like protruding sections;a second molding means which presses a second metal mold, which comprises a second reference surface and plural second projection-shaping die parts which have second ring-like protruding sections projecting from said second reference surface and surrounding second hollow spaces which are shaped to match with the profiles of said second projections, against a thermoplastic or thermosetting sheet-like molding material set on said second surface of said base member, pressurizes said molding material at least with said second ring-like protruding sections and accordingly bonds said molding material thus pressurized with said second ring-like protruding sections to said base member, and forms and shapes said second projections from said molding material which is opposed against the insides of said second hollow spaces surrounded by said second ring-like protruding sections;a first strip-off means which leaves on said first surface of said base member said molding material which is opposed against said plural first projection-shaping die parts and strips off said molding material other than said molding material which is opposed against said plural first projection-shaping die parts; anda second strip-off means which leaves on said second surface of said base member said molding material which is opposed against said plural second projection-shaping die parts and strips off said molding material other than said molding material which is opposed against said plural second projection-shaping die parts.

13. The apparatus for manufacturing a projections-seating base member of claim 12, wherein said first metal mold is formed by a first cylindrical roller which has a first cylindrical surface which serves as said first reference surface, while said second metal mold is formed by a second cylindrical roller which has a second cylindrical surface which serves as said second reference surface.

14. The apparatus for manufacturing a projections-seating base member of claim 13, comprising a reversing means which reverses said base member upside down and is disposed between said first molding means and said second molding means.

15. A projections-seating base member manufactured by the method of claim 1.

16. The apparatus for manufacturing a projections-seating base member of claim 8, wherein said means which strips off comprises a first means which pulls said base member, to which said molding material opposed against said plural projection-shaping die parts is bonded, toward a first direction and a second means which pulls said molding material exclusive of said molding material opposed against said plural projection-shaping die parts toward a second direction which is different from said first direction.

17. The apparatus for manufacturing a projections-seating base member of claim 9, wherein said means which strips off comprises a first means which pulls said base member, to which said molding material opposed against said plural projection-shaping die parts is bonded, toward a first direction and a second means which pulls said molding material exclusive of said molding material opposed against said plural projection-shaping die parts toward a second direction which is different from said first direction.

18. The apparatus for manufacturing a projections-seating base member of claim 10, wherein said means which strips off comprises a first means which pulls said base member, to which said molding material opposed against said plural projection-shaping die parts is bonded, toward a first direction and a second means which pulls said molding material exclusive of said molding material opposed against said plural projection-shaping die parts toward a second direction which is different from said first direction.

19. A projections-seating base member manufactured by the method of claim 2.

20. A projections-seating base member manufactured by the method of claim 3.

21. A projections-seating base member manufactured by the method of claim 4.

22. A projections-seating base member manufactured by the method of claim 5.

23. A projections-seating base member manufactured by the method of claim 6.