Floor mat for automobile and manufacturing method therefor

An automobile floor mat which is manufactured with a floor mat manufacturing mold comprising:

• a lower mold which has a pad forming hole, boss forming holes, and sill skirt forming protrusions which are shaped in the upper portion thereof in correspondence to the pad, the bosses and the sill skirts of the mat, respectively;
• and
• an upper mold which is combined with the lower mold, to thus cover the pad forming hole, the sill skirt forming protrusions, and the boss forming holes, and has sill skirt forming grooves corresponding to the sill skirt forming protrusions of the lower mold on the bottom thereof,
• wherein the lower mold is separately formed into a base mold on which coupling grooves each having a certain depth are formed inwards from the sill skirt forming protrusions and a boss forming mold which are supported and combined with the coupling grooves of the base mold in which a number of the boss forming holes are penetrated and formed,
• wherein a number of coupling holes are formed in the boss forming mold and the base mold, respectively, so as to penetrate the bottom of the base mold, and
• wherein a number of coupling bolts are engaged into the coupling holes, respectively to thus integrally combine the boss forming mold and the base mold with each other to then form the lower mold.

An automobile floor mat manufacturing method which is executed with a floor mat manufacturing mold comprising:

• a lower mold which has a pad forming hole, boss forming holes, and sill skirt forming protrusions which are shaped in the upper portion thereof in correspondence to the pad, the bosses and the sill skirts of the mat, respectively;
• and an upper mold which is combined with the lower mold, to thus cover the pad forming hole, the sill skirt forming protrusions, and the boss forming holes, and has sill skirt forming grooves corresponding to the sill skirt forming protrusions of the lower mold on the bottom thereof, wherein the lower mold is separately formed into a base mold on which coupling grooves each having a certain depth are formed inwards from the sill skirt forming protrusions and a boss forming mold which are supported and combined with the coupling grooves of the base mold in which a number of the boss forming holes are penetrated and formed, wherein a number of coupling holes are formed in the boss forming mold and the base mold, respectively, so as to penetrate the bottom of the base mold, and wherein a number of coupling bolts are engaged into the coupling hole to thus integrally combine the boss forming mold and the base mold with each other to then form the lower mold, the automobile floor mat manufacturing method comprising the steps of:
• injecting a molding material into the boss forming mold and the base mold formed in the lower mold;
• heating the molding material injected into the lower mold with a high temperature and pressurizing the same with a high pressure at the same time of combining the lower mold with the upper mold;
• and
• discharging air remaining in not only the pad forming hole and the boss forming holes which are positioned between the upper mold and the lower mold but also air remaining between the sill skirt forming protrusions and the sill skirt forming grooves, and gas generated from the molding material, through a coupling surface formed between the boss forming mold and the base mold and a coupling surface formed between the respective coupling holes and the respective coupling bolts,
• whereby the molding material is filled between the pad forming hole and the boss forming holes formed in the lower mold and between the sill skirt forming protrusions of the lower mold and the sill skirt forming grooves of the upper mold, to thus form the pad, the bosses and the smooth sill skirts of the mat.