CA1292028C - Floor mat with integral retainer means - Google Patents
Floor mat with integral retainer meansInfo
- Publication number
- CA1292028C CA1292028C CA000533674A CA533674A CA1292028C CA 1292028 C CA1292028 C CA 1292028C CA 000533674 A CA000533674 A CA 000533674A CA 533674 A CA533674 A CA 533674A CA 1292028 C CA1292028 C CA 1292028C
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- CA
- Canada
- Prior art keywords
- retainer
- carpeting
- construction defined
- fastening means
- floor mat
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Landscapes
- Passenger Equipment (AREA)
- Carpets (AREA)
Abstract
ABSTRACT OF DISCLOSURE
There is disclosed an automotive floor mat having an integral-retainer with retaining means provided substantially over the entire underside thereof mounted to a piece of automotive carpet which, in the preferred embodiment has only the scrim and tuftlock layers, with the bottom layer of laytex (or other material) being eliminated, and thus being much lighter than previous constructions.
There is disclosed an automotive floor mat having an integral-retainer with retaining means provided substantially over the entire underside thereof mounted to a piece of automotive carpet which, in the preferred embodiment has only the scrim and tuftlock layers, with the bottom layer of laytex (or other material) being eliminated, and thus being much lighter than previous constructions.
Description
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04988-4 GWH:jy FLOOR MAT WITH INTEGRAL RETAINER MEANS
BACKGROUND OF THE INVENTION
Field of The Invention The present invention relates to floor mats for use in passenger carrying vehicles, and more particularly to floor mats intended for use in automotive type vehicles. The improvements disclosed in the present application relate to a floor mat with ~integral retainer means which is much lighter than previous floor mats by virtue of its construction, but still is able to prevent movement of the floor mat when installed in a motor ~vehicle.
Description of The Prior Art A review of the prior art involving automotive floor mats will show that there are three main areas of concern to the de~signers of such products. These are the need to cut costs due ` to ever increasing price pressures on automotive suppliers due to foreign competition; the need to continually cut the weight :: ~
of automotive floor mats due to the pressures on auto makers to improve fuel economy; and, the need while cutting price and weight to effectively retain the floor mat on the automotive oarpet. ~The~efforts of myself and other employed by Applicant's as~s~ignee show the tremendous~amoun;t~of~work that has been put for~th~in this field. These efforts started as early as March of 1980~ and~resulted in the ~issuance of~ United States Letters Patent~No. 4,361,610 in November 1982 to ROTH and culminated with-~the issuance of United States Letters Patent No. 4,588,628 in May 1986 to ROTH before I myself became involved with this ;work. The floor mat disclosed and claimed in ,....
~2~8 04988-4 G~JH:jy United States Patent No. 4,S88,628, which is the clo.sest prior art of which I am aware, is a double sided floor mat with detachable, rotatable, retainer means of a particular construction, which is very effective in retaining such a floor mat on an au-tomotive carpet.
However, such floor mats have proven to be ratner heavy, and rather expensive to manufacture. It was thought that one of the varieties of floor ma-ts claimed in said United States Letters Patents would suffice if further reductions in weight would have to be made. This is the floor mat which is claimed with carpeting on only one side and a retainer with bristles on only one side. However, even though there was a saving in weight, the solution was unsatisfactory, because without bristles on the top side of the retainer acting on the carpeting on the bottom of the retainer, the retainer was free to slip relative to the floor mat for a short distance, which gave an annoying and dangerous slipping feeling when the passenger was first entering the vehicle, and because of this slippage, the tabs on the retainer started to show damage because of the strain put on them from the slipping action.
~ ecause of this problem, such solution was not accepted by the automakers, and much additional work and invention had to take place before a satisfactory solution was ;arrived at. the inventions which have been made are claimed and disclosed in the present application, and in a previous Canadian application No. 527,747 filed January 20, 1987, in which I am ~ 04983-4 G~7H:jy the inventor entitled "Light Weight Floor Mat Wi-th Retainer Means".
A further example of an attempt made by others to provide a floor mat is described in U.S. Patent No. 4,174,991 dated November 20, 1979 which issued to Reuben. In this floor mat nubs are used to provide an antiskid surface. In the example that is disclosed the nubs measure approximately 2.3 mm in height and have a base diameter of 2.5 mm and a trunkated peak diameter of l.9 mm. These nubs are not effective as an antiskid surface because they crush the top sur~ace of the carpet on which the floor mat is mounted to form an impression in the top surface into which the bottom of the floor mat fits.
In contrast, I achieve a very effective antiskid attachment by providing bristles rather than nubs. The bristles penetrate the surface of the carpet and mash with the carpe-t fibers to achieve the required antiskid results.
Summary of The Invention In order to save weight, and at the same time avoid the sllppage problems of the aforementioned single sided retainer, I have developed an integral retainer having retaining means substantially over the entire under side thereof, and into which a piece of automotive carpet is mounted which, in the ::
preferred embodiment has only the scrim and tuftlock layers, with the bottom layer of laytex (or other material) being eliminated, thus saving a great deal of weight.
~; 3 ~ 04988-4 GWH:jy I have found that it is possible to provide an improved ligh-t weight floor mat which will remain in place during operation of a motor vehicle, as well as during entry and exit of occupants oE said motor vehicle.
My improved floor mat is easily removable and replaceable on the floor of a motor vehicle~
I also provide an improved, light weight, nonskid floor mat having integral retaining means forming the bottom thereof.
I have also found that it is possible to provide for the use of a lighter weight carpet in my floor mat construction by virtue of the opportunity to eliminate the bottom layer of laytex (or similar material) found on normal carpets.
According to one aspect of the present invention there is provided a floor mat construction including: carpeting having nap on at least one side thereof; a separate retainer of ~substantially the same size as said carpet, said retainer having at least a single planar surface and a lower bristled surface depending downwardly therefrom; and fastening means to secure said carpet to said separate retainer.
According to a further aspect of the present invention there is provided a floor mat construction including: carpeting having nap on at least one side thereo~; and a separate lipped retainer of substantially the same size as said carpet, said retainer including at least a single planar surface and a lower bristled surface depending downwardly from said single planar ` -~3`
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surface; and fastening means to secure said carpeting to said separate lipped retainer.
According to another aspect of the present invention there is provided a floor mat construction including: a retainer having a top side, and having a plurality of bristles depending downwardly from the underside thereof; and carpeting having a nap on at least one side thereof and secured upon said top side.
According to a still further aspect of the present invention a floor mat construction including: carpeting having a nap on at least one side thereof; a retainer of substantially the same size as said carpeting, said retainer having at least a~top surface and a lower bristle surface depending downwardly therefrom, sald carpeting being secured upon said top surface.
Brief Description of The Drawinas Figure 1 is an exploded perspective view of a floor mat construction embodying the present invention.
Figure 2 is a partial perspective view of the construction shown in Figure 1 when assembled.
Figure 3 is a sectional view, taken in the direction of the arrows, along the section line 3-3 of Figure 2.
Figure 4 is an exploded perspective view showing a modified construction embodying the present invention.
Figure 5 is a~partial perspective view showing the floor ma~t construction of Figure 4 in its assembled condition.
Flgure 6 is a sectional view, taken in the direction of the arrows, along the section line 6-6 of Figure 5.
1 ~9~0::~3 Figure 7 is an enlarged view of a portion of Figure 6.
Figure 8 is a view similar in large part to Figure 3, but representative of several other means of attaching the edge binding to the carpet and retainer such as heat sealing, sonic welding or ad'nesive bonding.
Figure 9 is a sectional view, ta~en in the direction of the arrows, o along the section line 9-9 vf Figure 4.
Figure 10 is a mcdification of the construction shown in Figure 9.
-O Figure 11 is a view in large part similar to Figure 6, showing the u carpet riveted in place.
Figure 12 is a view similar in large part to Figure 3, showing the -Z~ edge binding riveted in place.
O Figure 13 is a perspective view, partially cut away, of the construction shown in Figure 1 applied to a rear floor mat. j ~z Figure 14 is an exploded perspective view, partially cut away, -, o showing`the construction of Figure 4 applied to a rear floor mat. :
0~ Figure 15 is a perspective view of a front-floor mat made according z ~o the constructlon shown in Figure 1 or Figure 4 with the bristles remLved i N where the floor mat is to cover a heel pad found in autcmotive carpeting.
3 It is to be understocd that the present invention is not limited to `-a the details of construction and arrangement of parts illustrated in the accompanying dr3wings, since the invention is capable of other embodiments, and of being practioe d or carried out in various within the scope of the d aims~ Plso, it is to be understood that the phraseology and tenninology .!
employed herein is for the purpose~of descript~on, and not of limitation.
Referring now to Figures 1-3, there is shGwn one embodiment of the >~ present invention. m ere is shown in Figure 1 an automotive floor mat generally designated by the numeral 20, which includes a retainer, generally ~:
~o desiganted by the numeral 21, a piecs of carpet generally designated by the numeral 22, and an edge binding 23.
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~ 0~8 m e retainer 21 consists of two portions, the heel portion 24, so named because this is the portion on which the occupants heel rests during operation of a motor vehicle, and the toe portion 25, so named because it is the portion which rests up against the toe board of the automobile. Of course, in the mcdern day automobile, the toe board or toe pan is covered O with automotive carpet 26, as is the floor pan, on which the heel portion of the retainer rests. In order to facilitate confonming to the shape of the ,"
-O floor pan and toe pan of the automobile, the retainer 21 may be formed with a 5 ~
I crease along the toe line 27. Ib facilitate this, a living hinge 28 may be prcvided, or other means well kn~wn in the art may be used.
Z~ Whether or not a living hinge 28, or other type of hinge means are m O provided along the toe line 27, the retainer 21 will oonsist of a t oe portionw 25 having a first planar surface 30 with bristles 35 downwardly depending z therefrom to fo~m a lower bristled surface. ~he heel portion 24 will consist of a second planar surface 31 having bristles 35 depending downwardly ~o therefrom. Of course, if the a ~loor mat construction is intended to be used z on a flat surface, such as will be discussed later concerning Figures 13 and 14, only a single planar surface will be present.
o ~ In the construction shcwn in Figures 1 - 3, a piece of automotive o ~ carpet 22, substantially identical in size to the retainer 21, is placed ;!
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thereon, with an edge binding 23 placed about the entire perimeter and t ~ stitched in place to bind the carpet 22, the retainer 21, and the edge binding 23 td each other. Ihe stitching, using thread well known in the t:: -.
automotive art, is shown at 33. It can be seen that the lower bristled I surfaee oE the heel portion~24 of the retainer 20 is fo~med by bristles 35 oz 3 > depending downwardly from the second planar surface 31.
Tt ~ should be understocd that it is possible to attach the edge binding 23 to the carpet 22 and the retainer 21, in a wide variety of ways. Figure 8, for example, is ~ ..
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j ~ ,0:~8 I -representative of the use of heat sealing, sonic welding or adhesive bonding - to bind the construction together. Figure 12 shows riveting the edge binding 23 to the carpet 22 and retainer 21. As can be seen, any practicable method can be used 1:~
Ihe length and sharpness of the bristles are a matter to be selected ,-.
$ by experimentation depending on the particular application to which the floor mat is to be put. For example, if the floor mat 20 is to be used in an ..s O automotive vehicle with a loop pile carpeting, the loop pile gives a better I grab, and shorter and/or duller bristles are permissable. If cut pile carpet ~ is to be used, the bristles should be sharper, with the sharpness of the Z~ bristles in this case being more important than the length. Plso, the shape ;--O of the particular automotive fLoor pan and toe pan will have a bearing on the selection of bristles, and the lower bristled surface of either the heel z portion 24, or the toe portion 25, or both, may have a portion of the lower -c bristled s~rfa oe tapered if necessary.
O If a mat is to be of rather large size, the bristles should be z longer and sharper for more gripping, while a small mat d oe s not need as long ~
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~ a bristle. Regardless of the particular application to which the floor mat --; Y is to be put, the bristles 35 fo~ming the lower-bristled surface should be no longer than 1~2 to 3/4 of the length of the al~tomotive carpet 26 found in the vehicle.
In certain applications, it has been found desirable to place a saw !-tooth portion 39 proximate the front edge of the heel portion of the retainer to prevent the retainer 21 from riding up on the toe pan of the motor vehicle. In this case the bristles are removed ~rom an area 40 around the saw .->~ tooth portion 39 to make the saw tooth portion ef~ective, and a floor mat 20 O~`having a saw tooth portion on the retainer will have the bristles remcved o proximate the saw tooth portion 39 as well as proximate the fastening means t, such as the edge binding 23. It is to be noted that a plurality of mass '~ ...... ~ . . '`
` , ",,, ,,~) , .' ~9~0~s8 ~s reduction openings 38 are prcvided in both the heel portion 24 and the toe portion 25 of the retainer 21. Ihe amount of area which can be removed by .' these mass reduction openings again depends on the particular application to ,;
which the floor mat 20 is to be put.lt has been found that the lcwer bristled surfaoe should comprise frcm 1/3 to 100~ of the area covered by the retain~r, ,-~ depending on application, to give satisfactory retention. ~
n A modification of my invention is shown in Figure 4. Ihe ,-, O construction shcwn in Figure 4 is similar in many respects to that shcwn in I Fi~ur~ 1. A retainer, generally designated by the numeral 21, is provided, 2 , -.; ^, 2 to which is attached a piece of carpet 22 of substantially the s~ne size as s, Z2 the retainer. 'rhe retainer again has a toe portion 25, and a heel portion J
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0 24, separated by a (real or imaginary) toe line 27, which again may have a t!l : ; i' w~ living hinge or other hinge means provided there along to facilitate the ' 3 fIoor mat 20 conf~nming to the shape o~ tl~e floor pan of the autanobile, > . -~
@ thus, again separating the retainer into a first planar surface 30, and a seoond planar surfa oe 3~. If the retainer is to be used on a flat surface, z ~he first planar surface 30 and the second planar surface 31 would merge into ~ a single planar surface 32. As before, mass reduction openings 38 may be o ~ provided, as can the saw tooth portion 39. Again, the bristles 35 forming n the lower bristled surface will depend downwardly from the- second planar surfa oe 31 of the heel portion Z4 of the retainer 21, and from the first ¢ planar surfa oe 30 of the toe portion 25 of the retainer. m e bristles will not be found proximate the saw tooth portion 39, or the integral fastening ~; means 42, which will now be described.
Ihe integral fastening means 42 found in this modification of my invention comprises a lip 45 fon~ed suhstantially continuously around the perimeter of the retainer 21 and depending upwardly from the first planar o surface 30 and the second planar surface 31. Ihe lip 45 is continuous except for a plurality of fonming breaks 46 which allow the lip to be folded over : ' ' ' ' . .~' ., . .
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~ qzo~.s onto the top of the planar surfaces 31 and 32 to securely hold the carpet 22 in place as shown in Figure 6. Ihe lip 45 may be folded down approximately 90 to hold tne carpet 22-in pla oe , and may be aided hy means of stitching ' 33. A heat seal (not shcwn~ may also be used or, as shown in Figure ll, a rivet type construction may be used whereby rivets 49 are pa~sed through the o lip 45 and the heel portion 24 of the ~ oor mat 21 to securely hold the ~ carpet 22 in place. As before, any practicable ~ethod of attachment may be O used- , , I Having now explained the basic construction of my floor mat 20, it -3, can now be understood why a large weight savings is possible. While I have z ~ thus far illustrated my invention using a conventional piece of automotive 0 carpet 22, and by conventional I mean one having a scrim layer 53 into which N
w are tufted a plurality of loops which are then severed to form the upwardly w ;
~' extending severed loop~ 54, with these loops then bound to the scrim layer 53a by a bonding layer 55, and then having a laytex (or s~milar) layer (not O shown) plaoe d on the back thereof to give the pet anti slip properties and z durability. Ey reference to Figure 7, it can be seen that the carpet 22 is now made in a manner which has the scrim layer 53 with the upwardly extending -severed loops 54 locked in place with a bondin~ layer 55, but there is a Q notable absence of the laytex layer. This is because the laytex layer is no w longer needed for durability, since the bonding layer 55 will directly 1 0 ~contact the retainer 21, nor is the laytex 1~y~r needed to give the carpet Is non-skid properties, because it nG longer contacts the automotive carpet 26 s d1rect1y.
e significant weight saving in my construction ccmes frcn the fact z , .
that the laytex layer which is eliminated is a heavy rubber construction which weighs substantially more than the entire retainer 21 which is made of o a polyethelyne, or similar plastic material, which is very light weight. It v -.i is es inated thut for an average fro~t set of floor ma~s the savlng in weight¦ -!JD
gz,0~,8 -! -, can be as much as 1 1/2 pounds, and for a full set of four floor mats the weight saving ~sing the construction of the present invention can be as high as two pounds, thus making a significant weight savings over present retainers, and keeping the weight of the entire set of retainers under 3 pounds, ~hich means it does not have to be counted in the weight of the car for EPA fuel economy purposes. This is a significant advance in the automotive floor mat art. While conventional carpet can be used in my O construction, in the preferred embodiment, the carpet 22 will not have the laytex layer to give the benefit of the weight saving.
Referring ncw to Figures g and 10, the importance of the saw tooth 2 portion 39 of the retainer 21 can he seen. Proximate the front edge of the m .
o heel portion 24 of the retainer 21 is a saw tooth portion 39 which, in Figure 9, is planar with the heel portion 24 of the retainer. If the floor mat 20 z tries to ride up the carpet 26 which is on top of the floor pan 58, the saw > .
¢ ~tooth portion 39 will dig into the carpet 26, blocking the lifting of the 0 retainer. This saw tooth portion 39 may be planar with the heel portion 24, z or as shcwn in Figure 10, may extend downwardly therefrom.
O
N R~ferring now to Figures 13 and 14, there are shcwn the Q constructions shown in Figures 1 and 4 respectively adapted for use in rear 8 floor mats. In ~his situation, for purposes of illustration. there will be a single planar surface 32 having ~ristl~s depending downwardly there~rom except proximate the fastening means, which in this illustration takes the z form of ed~e binding 23, which secures the carpet 22 to the retainer 21. In - ~ Fiyure 14, there is shown a retainer 21 having a single planar surface 32 O having a lip 45 depen~ing upwardly therefrom, and the bristles 35 forming the ~ ~ ~ lower bristled surface depending dcwnwardly therefrom. ~he carpet 22 is ; ~ ~ inserted into the retainer 21, the lip 45 is folded over approximately 90 as previously de~cribed in connection with the construction shown in Figure 4, o ~ and th lip, if desired, is fastened to the floor m~t construction by 1~ ' I
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~ 8 stitching, heat sealing, riveting, or the like to form the improved ~ oor mat of the present construction.
Referring now to Figure 15, it has been found in some automobiles having large vinyl heel pads sewn into the automotive carpet proximate the ac oelerator that ~f bristles are prcvided over the vinyl heel pad, slippage could occur. Figure 15 shows a ~ oor mat made according to the present invention, and having the lower bristled surface removed from the area L
enclosed by the phanton line 60, which has been found to solve the slippage problem. Thus, by providing a novel carpet construction not having a bonding layer~ and usin~-the same in connection with-the retainer oovering the entire bottom area of a floor mat construc~ion, I have prcvided a novel floor mat construction of substantially lighter weigh~ and less manufacturing expense . .~
than previously available.
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04988-4 GWH:jy FLOOR MAT WITH INTEGRAL RETAINER MEANS
BACKGROUND OF THE INVENTION
Field of The Invention The present invention relates to floor mats for use in passenger carrying vehicles, and more particularly to floor mats intended for use in automotive type vehicles. The improvements disclosed in the present application relate to a floor mat with ~integral retainer means which is much lighter than previous floor mats by virtue of its construction, but still is able to prevent movement of the floor mat when installed in a motor ~vehicle.
Description of The Prior Art A review of the prior art involving automotive floor mats will show that there are three main areas of concern to the de~signers of such products. These are the need to cut costs due ` to ever increasing price pressures on automotive suppliers due to foreign competition; the need to continually cut the weight :: ~
of automotive floor mats due to the pressures on auto makers to improve fuel economy; and, the need while cutting price and weight to effectively retain the floor mat on the automotive oarpet. ~The~efforts of myself and other employed by Applicant's as~s~ignee show the tremendous~amoun;t~of~work that has been put for~th~in this field. These efforts started as early as March of 1980~ and~resulted in the ~issuance of~ United States Letters Patent~No. 4,361,610 in November 1982 to ROTH and culminated with-~the issuance of United States Letters Patent No. 4,588,628 in May 1986 to ROTH before I myself became involved with this ;work. The floor mat disclosed and claimed in ,....
~2~8 04988-4 G~JH:jy United States Patent No. 4,S88,628, which is the clo.sest prior art of which I am aware, is a double sided floor mat with detachable, rotatable, retainer means of a particular construction, which is very effective in retaining such a floor mat on an au-tomotive carpet.
However, such floor mats have proven to be ratner heavy, and rather expensive to manufacture. It was thought that one of the varieties of floor ma-ts claimed in said United States Letters Patents would suffice if further reductions in weight would have to be made. This is the floor mat which is claimed with carpeting on only one side and a retainer with bristles on only one side. However, even though there was a saving in weight, the solution was unsatisfactory, because without bristles on the top side of the retainer acting on the carpeting on the bottom of the retainer, the retainer was free to slip relative to the floor mat for a short distance, which gave an annoying and dangerous slipping feeling when the passenger was first entering the vehicle, and because of this slippage, the tabs on the retainer started to show damage because of the strain put on them from the slipping action.
~ ecause of this problem, such solution was not accepted by the automakers, and much additional work and invention had to take place before a satisfactory solution was ;arrived at. the inventions which have been made are claimed and disclosed in the present application, and in a previous Canadian application No. 527,747 filed January 20, 1987, in which I am ~ 04983-4 G~7H:jy the inventor entitled "Light Weight Floor Mat Wi-th Retainer Means".
A further example of an attempt made by others to provide a floor mat is described in U.S. Patent No. 4,174,991 dated November 20, 1979 which issued to Reuben. In this floor mat nubs are used to provide an antiskid surface. In the example that is disclosed the nubs measure approximately 2.3 mm in height and have a base diameter of 2.5 mm and a trunkated peak diameter of l.9 mm. These nubs are not effective as an antiskid surface because they crush the top sur~ace of the carpet on which the floor mat is mounted to form an impression in the top surface into which the bottom of the floor mat fits.
In contrast, I achieve a very effective antiskid attachment by providing bristles rather than nubs. The bristles penetrate the surface of the carpet and mash with the carpe-t fibers to achieve the required antiskid results.
Summary of The Invention In order to save weight, and at the same time avoid the sllppage problems of the aforementioned single sided retainer, I have developed an integral retainer having retaining means substantially over the entire under side thereof, and into which a piece of automotive carpet is mounted which, in the ::
preferred embodiment has only the scrim and tuftlock layers, with the bottom layer of laytex (or other material) being eliminated, thus saving a great deal of weight.
~; 3 ~ 04988-4 GWH:jy I have found that it is possible to provide an improved ligh-t weight floor mat which will remain in place during operation of a motor vehicle, as well as during entry and exit of occupants oE said motor vehicle.
My improved floor mat is easily removable and replaceable on the floor of a motor vehicle~
I also provide an improved, light weight, nonskid floor mat having integral retaining means forming the bottom thereof.
I have also found that it is possible to provide for the use of a lighter weight carpet in my floor mat construction by virtue of the opportunity to eliminate the bottom layer of laytex (or similar material) found on normal carpets.
According to one aspect of the present invention there is provided a floor mat construction including: carpeting having nap on at least one side thereof; a separate retainer of ~substantially the same size as said carpet, said retainer having at least a single planar surface and a lower bristled surface depending downwardly therefrom; and fastening means to secure said carpet to said separate retainer.
According to a further aspect of the present invention there is provided a floor mat construction including: carpeting having nap on at least one side thereo~; and a separate lipped retainer of substantially the same size as said carpet, said retainer including at least a single planar surface and a lower bristled surface depending downwardly from said single planar ` -~3`
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surface; and fastening means to secure said carpeting to said separate lipped retainer.
According to another aspect of the present invention there is provided a floor mat construction including: a retainer having a top side, and having a plurality of bristles depending downwardly from the underside thereof; and carpeting having a nap on at least one side thereof and secured upon said top side.
According to a still further aspect of the present invention a floor mat construction including: carpeting having a nap on at least one side thereof; a retainer of substantially the same size as said carpeting, said retainer having at least a~top surface and a lower bristle surface depending downwardly therefrom, sald carpeting being secured upon said top surface.
Brief Description of The Drawinas Figure 1 is an exploded perspective view of a floor mat construction embodying the present invention.
Figure 2 is a partial perspective view of the construction shown in Figure 1 when assembled.
Figure 3 is a sectional view, taken in the direction of the arrows, along the section line 3-3 of Figure 2.
Figure 4 is an exploded perspective view showing a modified construction embodying the present invention.
Figure 5 is a~partial perspective view showing the floor ma~t construction of Figure 4 in its assembled condition.
Flgure 6 is a sectional view, taken in the direction of the arrows, along the section line 6-6 of Figure 5.
1 ~9~0::~3 Figure 7 is an enlarged view of a portion of Figure 6.
Figure 8 is a view similar in large part to Figure 3, but representative of several other means of attaching the edge binding to the carpet and retainer such as heat sealing, sonic welding or ad'nesive bonding.
Figure 9 is a sectional view, ta~en in the direction of the arrows, o along the section line 9-9 vf Figure 4.
Figure 10 is a mcdification of the construction shown in Figure 9.
-O Figure 11 is a view in large part similar to Figure 6, showing the u carpet riveted in place.
Figure 12 is a view similar in large part to Figure 3, showing the -Z~ edge binding riveted in place.
O Figure 13 is a perspective view, partially cut away, of the construction shown in Figure 1 applied to a rear floor mat. j ~z Figure 14 is an exploded perspective view, partially cut away, -, o showing`the construction of Figure 4 applied to a rear floor mat. :
0~ Figure 15 is a perspective view of a front-floor mat made according z ~o the constructlon shown in Figure 1 or Figure 4 with the bristles remLved i N where the floor mat is to cover a heel pad found in autcmotive carpeting.
3 It is to be understocd that the present invention is not limited to `-a the details of construction and arrangement of parts illustrated in the accompanying dr3wings, since the invention is capable of other embodiments, and of being practioe d or carried out in various within the scope of the d aims~ Plso, it is to be understood that the phraseology and tenninology .!
employed herein is for the purpose~of descript~on, and not of limitation.
Referring now to Figures 1-3, there is shGwn one embodiment of the >~ present invention. m ere is shown in Figure 1 an automotive floor mat generally designated by the numeral 20, which includes a retainer, generally ~:
~o desiganted by the numeral 21, a piecs of carpet generally designated by the numeral 22, and an edge binding 23.
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~ 0~8 m e retainer 21 consists of two portions, the heel portion 24, so named because this is the portion on which the occupants heel rests during operation of a motor vehicle, and the toe portion 25, so named because it is the portion which rests up against the toe board of the automobile. Of course, in the mcdern day automobile, the toe board or toe pan is covered O with automotive carpet 26, as is the floor pan, on which the heel portion of the retainer rests. In order to facilitate confonming to the shape of the ,"
-O floor pan and toe pan of the automobile, the retainer 21 may be formed with a 5 ~
I crease along the toe line 27. Ib facilitate this, a living hinge 28 may be prcvided, or other means well kn~wn in the art may be used.
Z~ Whether or not a living hinge 28, or other type of hinge means are m O provided along the toe line 27, the retainer 21 will oonsist of a t oe portionw 25 having a first planar surface 30 with bristles 35 downwardly depending z therefrom to fo~m a lower bristled surface. ~he heel portion 24 will consist of a second planar surface 31 having bristles 35 depending downwardly ~o therefrom. Of course, if the a ~loor mat construction is intended to be used z on a flat surface, such as will be discussed later concerning Figures 13 and 14, only a single planar surface will be present.
o ~ In the construction shcwn in Figures 1 - 3, a piece of automotive o ~ carpet 22, substantially identical in size to the retainer 21, is placed ;!
~ :
thereon, with an edge binding 23 placed about the entire perimeter and t ~ stitched in place to bind the carpet 22, the retainer 21, and the edge binding 23 td each other. Ihe stitching, using thread well known in the t:: -.
automotive art, is shown at 33. It can be seen that the lower bristled I surfaee oE the heel portion~24 of the retainer 20 is fo~med by bristles 35 oz 3 > depending downwardly from the second planar surface 31.
Tt ~ should be understocd that it is possible to attach the edge binding 23 to the carpet 22 and the retainer 21, in a wide variety of ways. Figure 8, for example, is ~ ..
: . `~
,~.. ''~ `.
. .
j ~ ,0:~8 I -representative of the use of heat sealing, sonic welding or adhesive bonding - to bind the construction together. Figure 12 shows riveting the edge binding 23 to the carpet 22 and retainer 21. As can be seen, any practicable method can be used 1:~
Ihe length and sharpness of the bristles are a matter to be selected ,-.
$ by experimentation depending on the particular application to which the floor mat is to be put. For example, if the floor mat 20 is to be used in an ..s O automotive vehicle with a loop pile carpeting, the loop pile gives a better I grab, and shorter and/or duller bristles are permissable. If cut pile carpet ~ is to be used, the bristles should be sharper, with the sharpness of the Z~ bristles in this case being more important than the length. Plso, the shape ;--O of the particular automotive fLoor pan and toe pan will have a bearing on the selection of bristles, and the lower bristled surface of either the heel z portion 24, or the toe portion 25, or both, may have a portion of the lower -c bristled s~rfa oe tapered if necessary.
O If a mat is to be of rather large size, the bristles should be z longer and sharper for more gripping, while a small mat d oe s not need as long ~
o :,.
~ a bristle. Regardless of the particular application to which the floor mat --; Y is to be put, the bristles 35 fo~ming the lower-bristled surface should be no longer than 1~2 to 3/4 of the length of the al~tomotive carpet 26 found in the vehicle.
In certain applications, it has been found desirable to place a saw !-tooth portion 39 proximate the front edge of the heel portion of the retainer to prevent the retainer 21 from riding up on the toe pan of the motor vehicle. In this case the bristles are removed ~rom an area 40 around the saw .->~ tooth portion 39 to make the saw tooth portion ef~ective, and a floor mat 20 O~`having a saw tooth portion on the retainer will have the bristles remcved o proximate the saw tooth portion 39 as well as proximate the fastening means t, such as the edge binding 23. It is to be noted that a plurality of mass '~ ...... ~ . . '`
` , ",,, ,,~) , .' ~9~0~s8 ~s reduction openings 38 are prcvided in both the heel portion 24 and the toe portion 25 of the retainer 21. Ihe amount of area which can be removed by .' these mass reduction openings again depends on the particular application to ,;
which the floor mat 20 is to be put.lt has been found that the lcwer bristled surfaoe should comprise frcm 1/3 to 100~ of the area covered by the retain~r, ,-~ depending on application, to give satisfactory retention. ~
n A modification of my invention is shown in Figure 4. Ihe ,-, O construction shcwn in Figure 4 is similar in many respects to that shcwn in I Fi~ur~ 1. A retainer, generally designated by the numeral 21, is provided, 2 , -.; ^, 2 to which is attached a piece of carpet 22 of substantially the s~ne size as s, Z2 the retainer. 'rhe retainer again has a toe portion 25, and a heel portion J
¢ ..
0 24, separated by a (real or imaginary) toe line 27, which again may have a t!l : ; i' w~ living hinge or other hinge means provided there along to facilitate the ' 3 fIoor mat 20 conf~nming to the shape o~ tl~e floor pan of the autanobile, > . -~
@ thus, again separating the retainer into a first planar surface 30, and a seoond planar surfa oe 3~. If the retainer is to be used on a flat surface, z ~he first planar surface 30 and the second planar surface 31 would merge into ~ a single planar surface 32. As before, mass reduction openings 38 may be o ~ provided, as can the saw tooth portion 39. Again, the bristles 35 forming n the lower bristled surface will depend downwardly from the- second planar surfa oe 31 of the heel portion Z4 of the retainer 21, and from the first ¢ planar surfa oe 30 of the toe portion 25 of the retainer. m e bristles will not be found proximate the saw tooth portion 39, or the integral fastening ~; means 42, which will now be described.
Ihe integral fastening means 42 found in this modification of my invention comprises a lip 45 fon~ed suhstantially continuously around the perimeter of the retainer 21 and depending upwardly from the first planar o surface 30 and the second planar surface 31. Ihe lip 45 is continuous except for a plurality of fonming breaks 46 which allow the lip to be folded over : ' ' ' ' . .~' ., . .
, ' ' ~
I ,',`
~ qzo~.s onto the top of the planar surfaces 31 and 32 to securely hold the carpet 22 in place as shown in Figure 6. Ihe lip 45 may be folded down approximately 90 to hold tne carpet 22-in pla oe , and may be aided hy means of stitching ' 33. A heat seal (not shcwn~ may also be used or, as shown in Figure ll, a rivet type construction may be used whereby rivets 49 are pa~sed through the o lip 45 and the heel portion 24 of the ~ oor mat 21 to securely hold the ~ carpet 22 in place. As before, any practicable ~ethod of attachment may be O used- , , I Having now explained the basic construction of my floor mat 20, it -3, can now be understood why a large weight savings is possible. While I have z ~ thus far illustrated my invention using a conventional piece of automotive 0 carpet 22, and by conventional I mean one having a scrim layer 53 into which N
w are tufted a plurality of loops which are then severed to form the upwardly w ;
~' extending severed loop~ 54, with these loops then bound to the scrim layer 53a by a bonding layer 55, and then having a laytex (or s~milar) layer (not O shown) plaoe d on the back thereof to give the pet anti slip properties and z durability. Ey reference to Figure 7, it can be seen that the carpet 22 is now made in a manner which has the scrim layer 53 with the upwardly extending -severed loops 54 locked in place with a bondin~ layer 55, but there is a Q notable absence of the laytex layer. This is because the laytex layer is no w longer needed for durability, since the bonding layer 55 will directly 1 0 ~contact the retainer 21, nor is the laytex 1~y~r needed to give the carpet Is non-skid properties, because it nG longer contacts the automotive carpet 26 s d1rect1y.
e significant weight saving in my construction ccmes frcn the fact z , .
that the laytex layer which is eliminated is a heavy rubber construction which weighs substantially more than the entire retainer 21 which is made of o a polyethelyne, or similar plastic material, which is very light weight. It v -.i is es inated thut for an average fro~t set of floor ma~s the savlng in weight¦ -!JD
gz,0~,8 -! -, can be as much as 1 1/2 pounds, and for a full set of four floor mats the weight saving ~sing the construction of the present invention can be as high as two pounds, thus making a significant weight savings over present retainers, and keeping the weight of the entire set of retainers under 3 pounds, ~hich means it does not have to be counted in the weight of the car for EPA fuel economy purposes. This is a significant advance in the automotive floor mat art. While conventional carpet can be used in my O construction, in the preferred embodiment, the carpet 22 will not have the laytex layer to give the benefit of the weight saving.
Referring ncw to Figures g and 10, the importance of the saw tooth 2 portion 39 of the retainer 21 can he seen. Proximate the front edge of the m .
o heel portion 24 of the retainer 21 is a saw tooth portion 39 which, in Figure 9, is planar with the heel portion 24 of the retainer. If the floor mat 20 z tries to ride up the carpet 26 which is on top of the floor pan 58, the saw > .
¢ ~tooth portion 39 will dig into the carpet 26, blocking the lifting of the 0 retainer. This saw tooth portion 39 may be planar with the heel portion 24, z or as shcwn in Figure 10, may extend downwardly therefrom.
O
N R~ferring now to Figures 13 and 14, there are shcwn the Q constructions shown in Figures 1 and 4 respectively adapted for use in rear 8 floor mats. In ~his situation, for purposes of illustration. there will be a single planar surface 32 having ~ristl~s depending downwardly there~rom except proximate the fastening means, which in this illustration takes the z form of ed~e binding 23, which secures the carpet 22 to the retainer 21. In - ~ Fiyure 14, there is shown a retainer 21 having a single planar surface 32 O having a lip 45 depen~ing upwardly therefrom, and the bristles 35 forming the ~ ~ ~ lower bristled surface depending dcwnwardly therefrom. ~he carpet 22 is ; ~ ~ inserted into the retainer 21, the lip 45 is folded over approximately 90 as previously de~cribed in connection with the construction shown in Figure 4, o ~ and th lip, if desired, is fastened to the floor m~t construction by 1~ ' I
.- 11,,.
~ 8 stitching, heat sealing, riveting, or the like to form the improved ~ oor mat of the present construction.
Referring now to Figure 15, it has been found in some automobiles having large vinyl heel pads sewn into the automotive carpet proximate the ac oelerator that ~f bristles are prcvided over the vinyl heel pad, slippage could occur. Figure 15 shows a ~ oor mat made according to the present invention, and having the lower bristled surface removed from the area L
enclosed by the phanton line 60, which has been found to solve the slippage problem. Thus, by providing a novel carpet construction not having a bonding layer~ and usin~-the same in connection with-the retainer oovering the entire bottom area of a floor mat construc~ion, I have prcvided a novel floor mat construction of substantially lighter weigh~ and less manufacturing expense . .~
than previously available.
,.~
z i:
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o 'i 3 .
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Claims (45)
1. A floor mat construction including:
(a) carpeting having nap on at least one side thereof;
(b) a separate retainer of substantially the same size as said carpet, said retainer having at least a single planar surface and a lower bristled surface depending downwardly therefrom; and (c) fastening means to secure said carpet to said separate retainer.
(a) carpeting having nap on at least one side thereof;
(b) a separate retainer of substantially the same size as said carpet, said retainer having at least a single planar surface and a lower bristled surface depending downwardly therefrom; and (c) fastening means to secure said carpet to said separate retainer.
2. The construction defined in claim 1, wherein:
(a) said lower bristled surface depends downwardly from said planar surface except proximate said fastening means.
(a) said lower bristled surface depends downwardly from said planar surface except proximate said fastening means.
3. The construction defined in claim 2, wherein:
(a) said retainer has at least one mass reduction opening therein.
(a) said retainer has at least one mass reduction opening therein.
4. The construction defined in claim 3, wherein:
(a) the bristles forming said lower bristled surface cover from ? to one hundred percent of the area of said retainer.
(a) the bristles forming said lower bristled surface cover from ? to one hundred percent of the area of said retainer.
5. The construction defined in claim 4, wherein the length of said bristles is no more than 4 of the average length of the automotive carpet on which said floor mat is used.
6. The construction defined in claim 5, wherein said fastening means includes:
04988-4 GWH:jy (a) an edge binding securing said retainer to said carpeting.
04988-4 GWH:jy (a) an edge binding securing said retainer to said carpeting.
7. The construction defined in claim 6, wherein said carpeting comprises:
(a) a scrim layer, (b) a plurality of loops tufted into said scrim layer; and (c) a bonding layer securing said loops to said scrim layer.
(a) a scrim layer, (b) a plurality of loops tufted into said scrim layer; and (c) a bonding layer securing said loops to said scrim layer.
8. The construction defined in claim 7, wherein said retainer includes:
(a) a toe portion; and (b) a heel portion.
(a) a toe portion; and (b) a heel portion.
9. The construction defined in claim 8, wherein:
(a) said toe portion includes a -first planar surface; and (b) said heel portion includes a second planar surface joined to said first planar surface about a toe line.
(a) said toe portion includes a -first planar surface; and (b) said heel portion includes a second planar surface joined to said first planar surface about a toe line.
10. The construction defined in claim 9, wherein and said heel portion of said retainer has a saw tooth portion formed proximate the front thereof proximate said toe line.
11. The construction defined in claim 10, wherein:
(a) said lower bristled surface depends downwardly from said planar surface and said second planar surface except proximate said first fastening means and said saw tooth portion.
(a) said lower bristled surface depends downwardly from said planar surface and said second planar surface except proximate said first fastening means and said saw tooth portion.
12. The construction defined in claim 11, wherein said fastening means include stitching securing said edge binding to said carpeting and said retainer.
04988-4 GWH:jy
04988-4 GWH:jy
13. The construction defined in claim 11, wherein said fastening means include a heat seal securing said edge binding to said carpeting and said retainer.
14. The construction defined in claim 13, wherein said fastening means include rivets securing said edge binding to said carpeting and said retainer.
15. The construction defined in claim 12, 13 or 14, wherein said bristles are absent from said lower bristled surface where said lower bristled surface is to contact a heel pad of an automotive carpet.
16. The construction defined in claim 12, 13 or 14, wherein the bristles forming said lower bristled surface are formed in a manner to provide a taper to at least part of said lower bristled surface.
17. The construction defined in claim 5, wherein said fastening means include:
(a) an upstanding lip formed integrally with said the retainer around at least a portion of the perimeter thereof to be bent over upon said carpeting.
(a) an upstanding lip formed integrally with said the retainer around at least a portion of the perimeter thereof to be bent over upon said carpeting.
18. The construction defined in claim 17, wherein said upstanding lip includes a plurality of forming braks to aid in bending said upstanding lip over said carpet.
19. The construction defined in claim 18, wherein said carpeting comprises:
(a) a scrim layer, (b) a plurality of loops tufted into said scrim layer; and 04988-4 GWH:jy (c) a bonding layer securing said loops to said scrim layer.
(a) a scrim layer, (b) a plurality of loops tufted into said scrim layer; and 04988-4 GWH:jy (c) a bonding layer securing said loops to said scrim layer.
20. The construction defined in claim 19, wherein said retainer includes:
(a) a toe portion; and (b) a heel portion.
(a) a toe portion; and (b) a heel portion.
21. The construction defined in claim 20, wherein:
(a) said toe portion includes a first planar surface; and (b) said heel portion includes a second planar surface joined to said first planar surface about a toe line.
(a) said toe portion includes a first planar surface; and (b) said heel portion includes a second planar surface joined to said first planar surface about a toe line.
22. The construction defined in claim 21, wherein said heel portion of said retainer has a saw tooth portion formed proximate the front thereof proximate said toe line.
23. The construction defined in claim 22, wherein:
(a) said lower bristled surface depends downwardly from said first planar surface and said second planar surface except proximate said fastening means and said saw tooth portion.
(a) said lower bristled surface depends downwardly from said first planar surface and said second planar surface except proximate said fastening means and said saw tooth portion.
24. The construction defined in claim 23, wherein said fastening means include stitching securing said lip to said carpeting and said retainer.
25. The construction defined in claim 24, wherein said fastening means include a heat seal securing said lip to said carpeting and said retainer.
26. The construction defined in claim 23, wherein said fastening means include rivets securing said lip to said carpeting and said retainer.
04988-4 GWH:jy
04988-4 GWH:jy
27. The construction defined in claim 26, wherein said bristles are absent from said lower bristled surface where said lower bristled surface is to contact a heel pad of an automotive carpet.
28. The construction defined in claim 24, 25, 26 or 27, wherein the bristles forming said lower bristled surface are formed in a manner to provide a taper to at least part of said lower bristled surface.
29. A floor mat construction including:
(a) carpeting having nap on at least one side thereof; and (b) a separate lipped retainer of substantially the same size as said carpet, said retainer including at least a single planar surface and a lower bristled surface depending downwardly from said single planar surface;
and (c) fastening means to secure said carpeting to said separate lipped retainer.
(a) carpeting having nap on at least one side thereof; and (b) a separate lipped retainer of substantially the same size as said carpet, said retainer including at least a single planar surface and a lower bristled surface depending downwardly from said single planar surface;
and (c) fastening means to secure said carpeting to said separate lipped retainer.
30. The construction defined in claim 29, wherein said fastening means include bending the lip of said lipped retainer over the edge of said carpeting.
31. A retainer adapted to accept and retain a piece of carpeting and thereby became floor mat with retainer including:
(a) a single planar surface capable of receiving a piece of carpet on the topside thereof, and having a plurality of bristles depending downwardly from the underside thereof; and (b) carpeting having nap on at least on side thereof; and 04988-4 GWH:jy (c) fastening means securing said carpeting to said retainer.
(a) a single planar surface capable of receiving a piece of carpet on the topside thereof, and having a plurality of bristles depending downwardly from the underside thereof; and (b) carpeting having nap on at least on side thereof; and 04988-4 GWH:jy (c) fastening means securing said carpeting to said retainer.
32. The retainer defined in claim 31, said fastening means further including:
(a) a lip depending upwardly from the topside of said planar surface and extending around at least a portion of the periphery of said retainer to accept and retain said carpet.
(a) a lip depending upwardly from the topside of said planar surface and extending around at least a portion of the periphery of said retainer to accept and retain said carpet.
33. The construction defined in claim 31, wherein said fastening means includes an edge binding.
34. The construction defined in claim 32 or 33, wherein the length of said bristles is no more than 4 of the average length of the automotive carpet on which said retainer is to be used.
35. The construction defined in claim 34, wherein the carpeting attached to said retainer comprises:
(a) a scrim layer, (b) a plurality of loops tufted in said scrim layer; and (c) a bonding layer securing said loops to said scrim.
(a) a scrim layer, (b) a plurality of loops tufted in said scrim layer; and (c) a bonding layer securing said loops to said scrim.
36. A floor mat construction including:
(a) a retainer having a top side, and having a plurality of bristles depending downwardly from the underside thereof; and (b) carpeting having a nap on at least one side thereof and secured upon said top side.
(a) a retainer having a top side, and having a plurality of bristles depending downwardly from the underside thereof; and (b) carpeting having a nap on at least one side thereof and secured upon said top side.
37. A floor mat as recited in claim 36, wherein said retainer and said carpeting being formed of separate materials.
04988-4 GWH:jy
04988-4 GWH:jy
38. A floor mat as recited in claim 36, wherein fastening means secured said carpeting to said retainer.
39. A floor mat as recited in claim 38, wherein said fastening means including an edge binding for securing said retainer to said carpeting.
40. A floor mat as recited in claim 36, wherein said retainer has a planar surface on said top side.
41. A floor mat construction including:
(a) carpeting having a nap on at least one side thereof;
(b) a retainer of substantially the same size as said carpeting, said retainer having at least a top surface and a lower bristle surface depending downwardly therefrom, said carpeting being secured upon said top surface.
(a) carpeting having a nap on at least one side thereof;
(b) a retainer of substantially the same size as said carpeting, said retainer having at least a top surface and a lower bristle surface depending downwardly therefrom, said carpeting being secured upon said top surface.
42. A floor mat as recited in claim 41, wherein said retainer having a planar surface on said top surface.
43. A floor mat as recited in claim 41, wherein said retainer and said carpeting are formed of separate materials.
44. A floor mat as recited in claim 41, wherein fastening means secures said carpet to said retainer.
45. A floor mat as recited in claim 44, wherein said fastening means includes an edge binding securing said retainer to said carpeting.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US07/017,708 | 1987-02-23 | ||
| US07/017,708 US4758457A (en) | 1987-02-24 | 1987-02-24 | Floor mat with integral retainer means |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1292028C true CA1292028C (en) | 1991-11-12 |
Family
ID=21784110
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000533674A Expired - Fee Related CA1292028C (en) | 1987-02-23 | 1987-04-02 | Floor mat with integral retainer means |
Country Status (2)
| Country | Link |
|---|---|
| JP (1) | JPS63215439A (en) |
| CA (1) | CA1292028C (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7686371B2 (en) | 2004-10-29 | 2010-03-30 | Macneil David F | Thermoformed vehicle floor tray with tread-containing reservoir |
| US8267459B2 (en) | 2004-10-29 | 2012-09-18 | Macneil Ip Llc | Designing and manufacturing vehicle floor trays |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS57187236A (en) * | 1981-05-14 | 1982-11-17 | Toray Ind Inc | Manufacture of rubber connector |
-
1987
- 1987-04-02 CA CA000533674A patent/CA1292028C/en not_active Expired - Fee Related
- 1987-05-29 JP JP13191287A patent/JPS63215439A/en active Pending
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7686371B2 (en) | 2004-10-29 | 2010-03-30 | Macneil David F | Thermoformed vehicle floor tray with tread-containing reservoir |
| US8267459B2 (en) | 2004-10-29 | 2012-09-18 | Macneil Ip Llc | Designing and manufacturing vehicle floor trays |
| US8336945B2 (en) | 2004-10-29 | 2012-12-25 | Macneil Ip Llc | Designing and manufacturing vehicle floor trays |
| US8336944B2 (en) | 2004-10-29 | 2012-12-25 | Macneil Ip Llc | Designing and manufacturing vehicle floor trays |
Also Published As
| Publication number | Publication date |
|---|---|
| JPS63215439A (en) | 1988-09-07 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKLA | Lapsed |