`US008833834B2
`
`c12) United States Patent
`MacN eil et al.
`
`(IO) Patent No.:
`(45) Date of Patent:
`
`US 8,833,834 B2
`Sep.16,2014
`
`(54) MOLDED VEHICLE FLOOR TRAY AND
`SYSTEM
`
`(71) Applicant: MacNeil IP LLC, Bolingbrook, IL (US)
`
`(72)
`
`Inventors: David F. MacNeil, Hinsdale, IL (US);
`Scott Vargo, Lombard, IL (US)
`
`USPC ....................................................... 296/97.23
`(58) Field of Classification Search
`USPC ................ 296/75, 97.23, 39.1; 428/167, 169;
`15/215, 216
`See application file for complete search history.
`
`(56)
`
`References Cited
`
`(73) Assignee: MacNeil IP LLC, Bolingbrook, IL (US)
`
`U.S. PATENT DOCUMENTS
`
`( *) Notice:
`
`Subject to any disclaimer, the term ofthis
`patent is extended or adjusted under 35
`U.S.C. 154(b) by O days.
`
`2,188,342 A
`2,709,105 A
`
`1/1940 England
`5/1955 Kramer
`(Continued)
`
`(21) Appl. No.: 14/139,432
`
`(22) Filed:
`
`Dec. 23, 2013
`
`(65)
`
`Prior Publication Data
`
`US 2014/0167443 Al
`
`Jun. 19, 2014
`
`FOREIGN PATENT DOCUMENTS
`
`CA
`CA
`
`5/1981
`1101016 A
`12/1985
`1198466 A
`(Continued)
`
`OTHER PUBLICATIONS
`
`(60)
`
`Related U.S. Application Data
`
`Continuation of application No. 13/773,706, filed on
`Feb. 22, 2013, which is a continuation of application
`No. 13/595,703, filed on Aug. 27, 2012, now Pat. No.
`8,382,186, which is a continuation of application No.
`12/879,899, filed on Sep. 10, 2010, now Pat. No.
`8,267,459, which is a continuation of application No.
`11/463,203, filed on Aug. 8, 2006, now abandoned,
`which is a divisionofapplicationNo. 10/976,441, filed
`on Oct. 29, 2004, now Pat. No. 7,316,847.
`
`(51)
`
`(52)
`
`(2006.01)
`(2006.01)
`(2010.01)
`(2006.01)
`(2006.01)
`
`Int. Cl.
`B62D25/20
`B60N 3/04
`B29D 99/00
`G06F 17150
`B60R 21102
`U.S. Cl.
`CPC ............ B29D 99/0057 (2013.01); B60N 3/048
`(2013.01); G06F 1715086 (2013.01); B60N
`3/044 (2013.01); B60R 21102 (2013.01)
`
`Japanese Patent Office, Rejection issued in connection with Japanese
`Patent Application No. 2005-317635 dispatched on Jan. 5, 2011.
`
`(Continued)
`
`Primary Examiner - Pine! Romain
`(74) Attorney, Agent, or Firm -
`Jefferson Perkins; Perkins
`IP Law Group LLC
`
`ABSTRACT
`(57)
`A vehicle floor tray is molded from a sheet of polymeric
`material of substantially uniform thickness. A reservoir is
`formed in a portion of the central panel of the tray. Hollow
`upstanding baffles disposed in the reservoir impede move(cid:173)
`ment of collected fluid. In a system embodiment including the
`floor tray and a vehicle foot well, upstanding first, second and
`third tray walls exhibit a close conformance to respective
`vehicle foot well walls, such that a large part of the external
`surface area of the first, second and third tray walls is within
`one-eighth of an inch of a respective vehicle foot well wall.
`
`15 Claims, 12 Drawing Sheets
`
`EX1028
`Yita v. MacNeil
`IPR2020-01139
`
`
`
`US 8,833,834 B2
`Page 2
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`3,087,752 A
`3,149,875 A
`3,288,187 A
`3,387,315 A
`3,390,912 A
`3,391,959 A
`3,401,975 A
`3,424,265 A
`3,450,429 A
`3,488,081 A
`3,557,654 A
`3,605,166 A
`0242,136 S
`4,211,447 A
`4,280,729 A
`4,382,986 A
`4,406,492 A
`4,420,180 A
`0278,525 S
`4,579,764 A
`4,591,532 A
`0288,799 S
`4,693,507 A
`4,721,641 A
`4,828,898 A
`4,921,742 A
`D313,789 S
`5,019,993 A
`5,208,995 A
`5,254,384 A
`D342,932 S
`D358,571 S
`5,474,829 A
`5,482,759 A
`D372,011 S
`D377,780 S
`5,725,926 A
`D393,238 S
`D394,037 S
`5,776,583 A
`5,830,560 A
`5,856,828 A
`D408,342 S
`5,891,546 A
`5,919,540 A
`6,007,319 A
`D420,965 S
`6,022,503 A
`6,027,782 A
`D422,256 S
`D425,005 S
`6,058,618 A
`D429,204 S
`D432,478 S
`6,155,629 A
`D442,530 S
`6,261,667 Bl
`D454,323 S
`D454,324 S
`D457,845 S
`6,431,629 Bl
`D471,850 S
`6,534,146 Bl
`6,578,896 Bl
`6,605,333 B2
`6,677,027 Bl
`D489,306 S
`6,732,030 B2
`6,736,442 B2
`D491,122 S
`6,793,872 Bl
`6,794,013 Bl
`D499,057 S
`6,817,649 Bl
`6,953,545 Bl
`
`4/ 1963 Winchester
`9/ 1964 Stata
`1111966 Wheaton
`6/ 1968 Stata
`7/1968 Stata
`7/1968 Stata
`9/1968 Oger
`l/ 1969 Stata
`6/ 1969 Stata
`1/1970 Nolen
`l/ 1971 Weidner, Jr.
`9/1971 Chen
`11/1976 Matlock
`7/1980 DiVincenzo
`7/1981 Morawski
`5/ 1983 Reuben
`9/1983 Cackowski
`12/1983 Dupont et al.
`4/1985 Morawski
`4/ 1986 Peoples, Jr. et al.
`5/ 1986 Tanaka
`3/ 1987 Peress
`9/ 1987 Dresen et al.
`l/ 1988 Bailey
`5/ 1989 Bailey
`5/ 1990 Altus
`l/ 1991 Thundercloud
`5/1991 Montalcini et al.
`5/1993 McKendrick
`10/ 1993 Gordon
`1/1994 Primeau
`5/1995 Thundercloud
`12/1995 Woosley
`1/1996 Primeau
`7 / 1996 Tyler
`2/1997 MacNeil
`3/1998 Wang
`4/1998 Kraines
`5/ 1998 Mauffette
`7/1998 Peyton
`11/1998 Koa
`l/ 1999 Letcher, Jr.
`4/1999 Yang
`4/1999 Sherman
`7/1999 Bailey
`12/1999 Jacobson
`2/2000 Iacovelli et al.
`2/2000 Hudkins et al.
`2/2000 Sherman
`4/2000 Lu
`5/2000 Rizvi
`5/2000 Hemmelgarn et al.
`8/2000 Lu
`10/2000 Lu
`12/2000 Sherman
`5/2001 Lu
`7/2001 Yang
`3/2002 Lu
`3/2002 Lu
`5/2002 Kraines
`8/2002 Emery
`3/2003 Kraines
`3/2003 Mentz, Jr.
`6/2003 Peterson
`8/2003 Ferreira et al.
`1/2004 Lu
`5/2004 Kraines
`5/2004 Jones
`5/2004 Gebreselassie et al.
`6/2004 Kraines
`9/2004 Buss
`9/2004 Iacovelli et al.
`11/2004 Lafleur
`11/2004 Stanesic
`10/2005 Tyler
`
`D525,576 S
`7,215,430 B2
`7,316,847 B2
`7,401,837 B2
`7,444,748 B2
`7,607,713 B2
`2001/0020316 Al
`2002/0045029 Al
`2003/0143358 Al
`2004/0048036 Al
`2004/0224130 Al
`2005/0191459 Al
`2006/0091694 Al
`2006/0288578 Al
`2008/0061580 Al
`2009/0092795 Al
`2009/0230717 Al
`
`7/2006 Lu
`5/2007 Kacyra et al.
`1/2008 MacNeil
`7/2008 MacNeil
`11/2008 MacNeil
`10/2009 MacNeil
`9/2001 Ferreira et al.
`4/2002 Yung
`7/2003 Needles
`3/2004 Nakasuji et al.
`11/2004 Melucci et al.
`9/2005 Ferreira et al.
`5/2006 MacNeil
`12/2006 MacNeil
`3/2008 MacNeil
`4/2009 MacNeil
`9/2009 MacNeil
`
`FOREIGN PATENT DOCUMENTS
`
`CA
`CA
`CA
`DE
`DE
`DE
`EP
`EP
`EP
`JP
`JP
`JP
`JP
`JP
`JP
`JP
`JP
`JP
`WO
`
`1292028 A
`1302459
`2431099 A
`1863477 U
`8434890 Ul
`19928720 Al
`0258162 A2
`0379630 Al
`0968875 Bl
`1172040 A
`H3-47245
`406227305 A
`H8-85377
`8332976 A
`Hll-268570
`200052835
`2002-362209 A
`2002356124
`95/34443 Al
`
`11/1991
`6/1992
`1/2004
`12/1962
`2/1985
`1/2001
`3/1988
`8/1990
`1/2000
`7 /1989
`5/1991
`8/1994
`4/1996
`12/1996
`10/1999
`2/2000
`12/2002
`12/2002
`12/1995
`
`OTHER PUBLICATIONS
`
`Canadian Intellectual Property Office, Requisition by the Examiner
`issued in connection with Canadian Patent Application No.
`2,672,095, Jan. 14, 2011.
`Photographs of Ford Windstar floor mat with unknown manufacture
`date, obtained by Applicant in 2010, and believed to be on sale and in
`public use prior to Oct. 29, 2003.
`Canadian Intellectual Property Office, Requisition by the Examiner
`issued in connection with Canadian Patent Application No.
`2,672,423, Dec. 14, 2010.
`Husky Liner for 1999 Ford Super Duty, downloaded from http://
`www.huskyliners.com/superduty.html on Jan. 3, 2005.
`Autoform Trunk Liner, English web page, downloaded from http://
`www.autoform.se/eng/products_trunk_liners.htmon Oct. 20, 2004.
`"Installation Instructions for Your F-150/F-250 Ford Truck Front
`Floor Liners", Winfield Consumer Products, Feb. 1, 2001, down(cid:173)
`loaded from http://www.huskyliners.com on Jan. 3, 2005.
`Husky Deep Tray Floor Liner, downloaded from http://www.
`truckstuffusa.corn/cusfitdeeptr.html on Jan. 3, 2005.
`Web pages featuring products from 3D Carpet Liners, Weatherboots,
`Nifty Products, Inc. and Husky, downloaded from http:/ /www.
`premiermotoring.net on Aug. 11, 2004.
`WeatherTech Floor Mat and Cargo Liner Product Sheets, MacNeil
`Automotive Products Limited, Downers Grove, IL, Nov. 1994, 4 pp.
`Faro Laser ScanArm, downloaded from http://www.faro.com/Prod(cid:173)
`ucts/ScanArm.asp on Sep. 23, 2004.
`Faro ScanArm Product Techsheet, downloaded from http://www.
`faro.corn/Products/Product_ Techsheet.asp?techsheet_id~ 106
`on
`Oct. 11, 2004.
`"CMM Produces Bikes With Custom-Look", downloaded from
`http://manufacturingcenter.com/man/articles/0604/0604CMM.asp
`on Oct. 11, 2004.
`"Stereolithography (SLA) for Rapid Precision Prototypes", p. 1,
`downloaded from http://www.boedeker.com/sla.htm on Oct. 12,
`2004.
`
`
`
`US 8,833,834 B2
`Page 3
`
`(56)
`
`References Cited
`
`OTHER PUBLICATIONS
`
`"About Coordinate Measuring Machines (CMM)", downloaded from
`http://cmm.globalspec.com on Oct. 11, 2004.
`"Bagagerumsmattor", downloaded from http://www.autoform.se/sv /
`produkter_bagagerumsmattor.htm on Oct. 20, 2004.
`Strictly Catalog for Explorer/Mountaineer/Expedition/Navigator.
`MacNeil Automotive Products Limited, Downers Grove, IL, 1999,
`pp. 1-2 and 4-7.
`British Patent Office, Search Report on GB Patent Appln. No. GB
`0522091.8, Claims 47-66, 77 and 78, Jun. 23, 2006.
`British Patent Office, Search Report on Patent Appln. No. GB
`0522091.8, Claims 67-70, Jun. 26, 2006.
`British Patent Office, Search Report on Patent Appln. No. GB
`0522091.8, Claims 71-73, Jun. 27, 2006.
`British Patent Office, Search Report on Patent Appln. No. GB
`0522091.8, Claims 79-84 and 101-105, Jun. 23, 2006.
`British Patent Office, Search Report on Patent Appln. No. GB
`522091.8, claims 85-100, Jun. 27, 2006.
`British Patent Office, Search Report on Patent Appln. No. GB
`0522091.8, claims 1-46 and 74-76, Feb. 14, 2006.
`Canadian Intellectual Property Office, Requisition by Examiner
`issued on Canadian Application No. 2,524,795 on Apr. 23, 2008.
`U.S. Patent and Trademark Office, Office Action issued on U.S.Appl.
`No. 11/463,215 on Nov. 27, 2007.
`U.S. Patent and Trademark Office, Office Action issued on U.S.Appl.
`No. 11/463,215 on Jun. 6, 2007.
`British Patent Office, Search Report issued on GB Application No.
`0625354.6 dated Nov. 6, 2007.
`British Patent Office, Search Report on GB Appln. No. 0625354.6
`dated Mar. 3, 2008.
`U.S. Patent and Trademark Office, Office Action issued on U.S.Appl.
`No. 11/463,203 on Aug. 13, 2009.
`U.S. Patent and Trademark Office, Office Action issued on U.S.Appl.
`No. 11/934,320 on Jun. 10, 2009.
`U.S. Patent and Trademark Office, Office Action issued on U.S.Appl.
`No. 12/332,757 on Jun. 11, 2009.
`Canadian Intellectual Property Office, Requisition by the Examiner
`dated Dec. 17, 2009 on Canadian Patent Application No. 2,672,116.
`Canadian Intellectual Property Office, Requisition on CA 2,672,095,
`dated Jan. 14, 2011.
`German Patent and Trademark Office, Official Action on DE 10 2005
`063 533.4-21, dated Sep. 1, 2011.
`Canadian Intellectual Property Office, Requisition on CA 2,672,097,
`dated on Dec. 19, 2011.
`Photographs of a Highland Floor Guard with unknown date of manu(cid:173)
`facture, obtained by Applicant in 2010, and believed to be on sale and
`in public use prior to Oct. 29, 2003.
`American Specialty Equipment Corp., "Big Book" catalog for "Per(cid:173)
`formance Parts, Truck Accessories, and Sport Compact Equipment,"
`2000, p. 366.
`Add-On 2002-2003 Automotive Accessory Catalog, 2002, pp. 192
`and 447.
`Floor Mat Comparison Chart, Stylinconcepts.com, Jun. 2, 2002.
`Advertisement for Highland's Black Armor Floor Guard, Stylin Con(cid:173)
`cepts "Custom Truck Accessories" catalog, 2003, pp. 1, 2 and 109.
`Image from advertisement for Black Armor Floor Guard,
`Stylinconcepts.com; Apr. 3, 2002, recovered from http://webarchive.
`org/2 00 2 0403 230 231 / stylinconcepts. com/Images/
`BlackArmorWLogo.jpg.
`List of "front custom auto floor mats", etrailer.com (as downloaded
`by web.archive.org), Jun. 4, 2004.
`Description and illustration of "Front Custom Auto floor Mats";
`etrailer.com (as downloaded by web.archive.org), Jun. 4, 2004.
`
`Advertisement for Highland floor guards, Counterman Info Pages,
`prior to Nov. 2002, p. 27.
`Highland Catalog and Jobber sheet; prior to 2004.
`Highland Application Guide, 2004.
`Volvo Accessories brochure, 1990, pp. 1 and 23.
`Volvo 760 GLE Accessories Brochure, 1983, pp. 1-3.
`Volvo Accessories brochure, 1981, pp. 1, 27.
`Volvo Accessories brochure, 1983, p. 1, 11, 16.
`Photographs of Volvo floor mat with unknown manufacture date,
`obtained by Applicant in 2010, and believed to be on sale and in
`public use prior to Oct. 29, 2003.
`Photographs of a Husky Liner floor tray with unknown manufacture
`date, obtained by Applicant in 2010, and believed to be on sale and in
`public use prior to Oct. 29, 2003.
`Husky Liners Product Catalog, 2001, pp. 1-2.
`Husky Liners Product Catalog, 2002, selected pages.
`Husky Liners Product Catalog, 2003 ½, SEMA Show Edition,
`selected pages.
`Photographs of Winfield's Husky Liner Model 3780 for 2000-2001
`BMW X-5 possessed by Applicant, believed to be on sale and in
`public use prior to Oct. 29, 2003.
`1998 Lund Product Catalog, p. 24, Lund SportMat Molded Floor
`Trays.
`Web advertisement for Fox Weatherboots, foxweatherboots.com (as
`downloaded by web.archive.org), Mar. 3, 2000.
`Nifty Products Catalog, 2003-2004, selected pages.
`Advertisement of unknown publication date for Husky Liner 3D
`Molded Carpeted Front Floor Liners, obtained by Applicant in 2010,
`and believed to be on sale and in public use prior to Oct. 29, 2003.
`Photographs of Husky Liner 3D Floor Liners manufactured Aug.
`2010, in possession of Applicant, and believed to be on sale and in
`public use prior to Oct. 29, 2003.
`Geomagic Press Release, "Geomagic, Inc. Wins Second Computer
`Graphics World Innovation Award," Dec. 10, 1998.
`Geomagic Press Release, "Geomagic to Introduce Unique Solution
`for 3D Content Creation at SIGGRAPH '99," Aug. 3, 1999.
`Geomagic Press Release, "Geomagic Announces Geomagic Studio
`2.0," Jan. 14, 2000.
`Geomagic Press Release, "Geomagic, QTE Offer RevQuick, Auto(cid:173)
`matic Surface Generation for Mastercarn," Sep. 25, 2000.
`Advertisement, "Third Party Options (Romer, A CimCore Com(cid:173)
`pany)," 2000.
`Son, Seokbae; Park, Hyunpung; and Lee, Kwan; "Automated laser
`scanning system for reverse engineering and inspection," Int. J.
`Machine Tools & Manufacture, 42, 889-897 (2002).
`"Competition Rising in Portable CMMs," Quality Magazine, May 5,
`2003.
`Press Release by Brown and Sharpe, "Portable K Series Optical
`CMMs," Sep. 1, 2002.
`"CAM2 software," as downloaded from http://web.archive.org/web/
`20040215065613/www.faro.com/Products on Nov. 4, 2010.
`"Laser Scanner edges out CMM in the race to market," Machine
`Design.com, Feb. 5, 2004.
`"Highres Delivers Complete Reverse Engineering Software Suite for
`SolidWorks 2001Plus," Reverse Engineering.com, Apr. 25, 2002.
`"HighRes Provides 3D Reverse Engineering Software to Higher
`Education Learning Institutions", ReverseEngineering.com, May 21,
`2002.
`"HighRes Reverse Engineering Software now Ships with Every
`Romer 3000i and Stinger II Portable CMM in North America,"
`ReverseEnginering.com, Oct. 14, 2002.
`Press Release, "FARO Debuts Affordable "Advantage" Line of Mea(cid:173)
`surement Products," Sep. 4, 2003.
`Canadian Intellectual Property Office, Requisition by the Examiner
`in connection with Canadian Patent Application No. 2,672,423 dated
`Dec. 14, 2010.
`
`
`
`~
`00
`•
`~
`~
`~
`
`~ = ~
`
`/ 100
`
`rJJ
`('D
`
`gm.5:2:m8.53:253HaScm9%.».quwN
`
`FIG. I
`
`'? ....
`0 ....
`
`~Cl's
`N
`
`.i;...
`
`('D
`('D
`
`rJJ =(cid:173)
`.....
`....
`0 ....
`....
`
`N
`
`00
`
`d r.,;_
`00 w
`w
`00 w
`~ = N
`
`
`
`142 134
`
`150
`
`9 4132 3 4
`
`122
`
`204
`
`~100
`
`~
`00
`•
`~
`~
`~
`
`~ = ~
`
`134
`
`l I / 202
`tli
`
`120~
`1;,. 11('
`
`l
`
`( 111
`
`,,,:•" ii\\
`~
`
`200
`
`'
`',,,,
`---------
`
`/
`~~/
`
`'
`
`I
`
`I
`
`I
`
`/
`
`1 2 4
`
`:::::::::::·v, \; 11111iillllil!!III'
`iill
`104-? ,nil
`
`.:·.:::·,:~:
`
`li111...
`
`208
`
`I
`
`10
`
`l
`
`130
`
`I l 4 l
`
`rJJ
`('D
`
`'? ....
`0 ....
`
`~Cl's
`N
`
`.i;...
`
`('D
`('D
`
`rJJ =(cid:173)
`.....
`N
`0 ....
`....
`
`N
`
`FIG. 2
`
`9-4 3-4
`
`140
`
`00
`
`d r.,;_
`00 w
`w
`00 w
`~ = N
`
`
`
`U.S. Patent
`US. Patent
`
`Sep.16,2014
`Sep. 16, 2014
`
`Sheet 3 of 12
`Sheet 3 of 12
`
`US 8,833,834 B2
`US 8,833,834 B2
`
`0
`0
`T"""
`
`N
`
`0
`T"""
`
`
`
`co
`
`T"""
`
`T"""
`
`
`
`U.S. Patent
`US. Patent
`
`Sep.16,2014
`Sep. 16, 2014
`
`Sheet 4 of 12
`Sheet 4 of 12
`
`US 8,833,834 B2
`US 8,833,834 B2
`
`
`
`
`
`U.S. Patent
`US. Patent
`
`Sep. 16, 2014
`Sep.16,2014
`
`Sheet 5 of 12
`Sheet 5 of 12
`
`US 8,833,834 B2
`US 8,833,834 B2
`
`0
`(Y)
`
`
`
`
`
`tr')
`
`FIG.5
`~
`~
`
`V
`
`J
`
`-
`
`
`
`N
`(Y)
`T"""
`
`0
`I.()
`T"""
`
`CX)
`(Y)
`T"""
`
`
`
`U.S. Patent
`
`Sep.16,2014
`
`Sheet 6 of 12
`
`US 8,833,834 B2
`
`/100
`
`606
`
`600
`
`604
`
`_l
`
`a l b J
`
`300
`
`FIG. 6
`
`f
`
`C
`
`700
`
`701
`
`702
`
`703
`
`704
`
`705
`
`706
`
`707
`
`709
`
`CMM VEHICLE FOOT WELL
`POINT AQUISITION
`
`SPLINES
`
`VEHICLE FOOT WELL
`SURFACE MODEL
`
`TOP, BOTTOM SKETCH PLANES
`
`SIDEWALLS
`
`FIT CURVES
`
`RADIUSING
`
`ADJUST FOR SURFACE
`IRREGULARITIES
`
`IMPORT RESERVOIR, CHANNELS
`
`711
`
`708
`
`714
`
`TRIEXTRUSION
`SHEETS
`
`SHELL
`
`TRAY DATA
`FILE
`
`SLA
`
`MOLD
`
`VEHICLE
`FLOOR TRAYS
`FIG. 7
`
`710
`
`712
`
`716
`
`
`
`U.S. Patent
`US. Patent
`
`Sep.16,2014
`Sep. 16, 2014
`
`Sheet 7 of 12
`Sheet 7 of 12
`
`US 8,833,834 B2
`US 8,833,834 B2
`
`818
`13
`820
`822 }.
`824
`808 810
`~
`
`
`
`FIG.8
`
`
`
`U.S. Patent
`U.S. Patent
`
`Sep.16,2014
`Sep.16,2014
`
`Sheet 8 of 12
`Sheet80f12
`
`US 8,833,834 B2
`US 8,833,834 B2
`
`0
`0 -.-
`
`
`
`N
`0 c:o
`
`
`
`U.S. Patent
`US. Patent
`
`Sep.16,2014
`Sep. 16, 2014
`
`Sheet 9 of 12
`Sheet 9 of 12
`
`US 8,833,834 B2
`US 8,833,834 B2
`
`
`
`
`
`U.S. Patent
`US. Patent
`
`Sep.16,2014
`Sep. 16, 2014
`
`Sheet 10 of 12
`Sheet 10 of 12
`
`US 8,833,834 B2
`US 8,833,834 B2
`
`150
`150
`
`0.022
`0.039
`
`826
`0.039
`0.042
`0.061
`
`
`
`0.125
`
`FIG. 11
`
`0.078
`
`110
`
`
`----------0.067
`
`
`‘ ...
`— — ——’/
`r..A’:h..‘P
`
`FIG. 12
`802
`
`
`
`U.s. Patent
`
`Sep. 16, 2014
`
`Sheet 11 of 12
`
`Vs 8,833,834 B2
`
`g ,_
`
`
`
`0
`
`
`
`U.S. Patent
`US. Patent
`
`Sep. 16, 2014
`Sep.16,2014
`
`Sheet 12 of 12
`Sheet 12 of 12
`
`US 8,833,834 B2
`US 8,833,834 B2
`
`833
`
`802
`
`100'-..
`
`802
`
`830
`
`FIG. 14
`
`
`
`US 8,833,834 B2
`
`1
`MOLDED VEHICLE FLOOR TRAY AND
`SYSTEM
`
`RELATED APPLICATIONS
`
`5
`
`This application is a continuation of copending U.S. Non(cid:173)
`provisional application Ser. No. 13/773,706 filed Feb. 22,
`2013, which in tum is a continuation of U.S. Nonprovisional
`application Ser. No. 13/595,703 filed on Aug. 27, 2012, now
`U.S. Pat. No. 8,382,186, which is in turn a continuation of 10
`U.S. Nonprovisional application Ser. No. 12/879,899 filed on
`Sep. 10, 2010, now U.S. Pat. No. 8,267,459, which is in tum
`a continuation of U.S. Nonprovisional application Ser. No.
`11/463,203 filed onAug. 8, 2006, now abandoned, which is in
`turn a division of U.S. Nonprovisional application Ser. No. 15
`10/976,441 filed on Oct. 29, 2004, now U.S. Pat. No. 7,316,
`847. All of the foregoing pending applications and issued
`patents are owned by a common assignee and the disclosure
`and drawings of all of them are fully incorporated by refer(cid:173)
`ence herein.
`
`BACKGROUND OF THE INVENTION
`
`2
`ply rubber or plastic material, exhibits enough stiffness to
`retain a three-dimensional shape, but is also at least somewhat
`flexible. Fitting such a tray to the complex three-dimensional
`surface of a vehicle foot well has proven to be difficult, and
`the products currently in the marketplace have limited con(cid:173)
`sumer acceptance because of their loose fit inside the foot
`well. There is often, and in many places, a considerable space
`between the exterior wall of these conventional trays and the
`interior surface of the foot well. This causes the wall to
`noticeably deform when the occupant's foot contacts it.
`Vehicle owners have a tendency to dislike floor trays which
`rattle, deform, shift and flop about. A need therefore persists
`for a floor tray that will have a more exact fit to the vehicle foot
`well for which it is provided, that stays in place once it is
`installed, and that provides a more solid and certain feel to the
`occupants' feet.
`Some vehicle floor mats that are now on the market have
`fluid reservoirs built into them. Particularly in cold or wet
`climates, dirty water has a tendency to be shed onto the floor
`20 mat, where it persists until it evaporates. If there is enough of
`it, it will leak off of the floor mat and stain the carpeting of the
`foot well that the mat was meant to protect. These reservoirs
`typically are recessed areas in the mats that provide the mats
`with an enhanced ability to retain snow-melt and the like,
`25 until the water evaporates or can be disposed ofby the vehicle
`owner or user. One advanced design places treads in the
`middle of the reservoir, such that the feet of the occupant are
`held above any fluid that the reservoir collects. But including
`such a reservoir within a floor tray that otherwise has an
`30 acceptable fit to the surface of a vehicle foot well has not yet
`been done, since there are problems in incorporating a three(cid:173)
`dimensional liquid-holding vessel into a product that ideally
`conforms, on its lower surface, to the surface of the foot well.
`Further, a reservoir which collects drip water from a large
`35 surface, such as a vehicle floor tray, will exhibit more prob(cid:173)
`lems in keeping the collected fluid from sloshing about in a
`moving vehicle.
`Conventional vehicle floor mats and trays are molded from
`a single rubber or plastic material. The selection of this mate-
`40 rial is controlled by its cost, its resistance to shear forces, its
`tensile strength, its abrasion resistance, its ability to conform
`to the surface of the vehicle foot well, its sound-deadening
`properties and how slippery or nonslippery it is relative to the
`occupants' feet, with nonslipperiness (having a relatively
`45 high coefficient of friction) being advantageous. Often the
`designer must make tradeoffs among these different design
`constraints in specifying the material from which the tray or
`mat is to be made.
`
`Motor vehicles are almost always operated in the out of
`doors and are frequently parked there. It is therefore very
`common for their occupants to have wet or muddy feet-if
`the occupants have not just finished an outdoor activity, at
`least they have had to walk across a possibly wet, snowy or
`muddy surface to access their vehicles. For decades, there(cid:173)
`fore, vehicle owners have been attempting to protect the
`enclosed interiors of their vehicles ( cars, trucks, SUV s) from
`what they themselves track into them. The conventional solu(cid:173)
`tion to this has been to provide a vehicle floor mat which may
`be periodically removed by the owner and cleaned.
`Human beings have a tendency to move their feet around,
`and foot motion is an absolute requirement in operating most
`vehicles. This has caused a problem, in that the occupants of
`a vehicle have a tendency to push around the floor mats with
`their feet. The floor mats end up not being centered on the area
`protected, or pushed up so as to occlude the gas, brake or
`clutch pedals, or bunched up or folded over-all undesirable
`conditions. One objective of floor mat manufacturers has
`therefore been to provide a floor mat that will stay put and
`which will not adversely affect vehicle operation.
`The foot wells of cars, trucks and SUVs vary in size in
`shape from one model of vehicle to the next. Floor mat manu(cid:173)
`facturers have noticed that floor mats which at least approxi(cid:173)
`mately conform to the shape of the bottom surface of the foot
`well stay in place better and offer more protection. It is also
`common for such floor mats, where provided for front seat 50
`foot wells, to have portions which are meant to lie against the
`firewalls or front surfaces of the foot wells. Even as so
`extended it is not too hard to provide a floor mat of flexible
`material that will approximately conform to these two sur(cid:173)
`faces, as the designer only has to mark a two-dimensional
`periphery of the mat in providing one which will fit reason(cid:173)
`ably well.
`More recently, vehicle floor trays have come onto the mar(cid:173)
`ket. Most front-seat vehicle foot wells are actually three(cid:173)
`dimensional concave shapes, typically with complex curved
`surfaces. Floor trays have sidewalls that offer enhanced pro(cid:173)
`tection to the surfaces surrounding the vehicle floor, as might
`be needed against wearers with very muddy or snowy shoes.
`Conventional vehicle floor trays try to fit into these three(cid:173)
`dimensional cavities, but so far their fit to the surfaces that
`they are supposed to protect has been less than optimum. A
`conventional vehicle floor tray is typically molded of a single-
`
`SUMMARY OF THE INVENTION
`
`According to one aspect of the invention, there is provided
`a vehicle floor cover, mat or tray which is removably install(cid:173)
`able by a consumer and which is formed of at least three
`55 layers that are bonded together, preferably by coextrusion.
`The three layers include a central layer whose composition is
`distinct from a bottom layer and a top layer. Preferably, all
`three layers are formed of thermoplastic polymer materials.
`In another aspect of the invention, the top layer exhibits a
`60 kinetic coefficient of friction with respect to a sample meant
`to emulate a typical shoe outsole (neoprene rubber, Shore A
`Durometer 60) of at least about 0.82.
`Preferably, a major portion of the central layer is a poly(cid:173)
`olefin. More preferably, the polyolefin is either a polypropy-
`65 lene or a polyethylene. Most preferably, the polyolefin is high
`molecular weight polyethylene (HMPE) as herein defined. In
`an alternative embodiment, the central layer can be a styrene-
`
`
`
`US 8,833,834 B2
`
`3
`acrylonitrile copolymer (SAN) or an acrylonitrile-butadiene(cid:173)
`styrene (ABS) polymer blend.
`Preferably, a major portion of the top layer is a thermoplas-
`tic elastomer, such as one of the proprietary compositions
`sold under the trademarks SANTOPRENE®, GEOLAST®
`and VYRAM®. VYRAM® is particularly preferred. In
`another embodiment, a major portion of the top layer can be
`anABS polymer blend. Where ABS is used in both the top and
`central layers, it is preferred that the amount of the polybuta(cid:173)
`diene phase in the top layer be greater than the amount ofthis
`phase in the central layer.
`It is further preferred that a major portion of the bottom
`layer likewise be a thermoplastic elastomer, and conveniently
`it can be, but does not have to be, of the same composition as
`the major portion of the top layer.
`Preferably one or more of the layers is actually a polymer
`blend, in which a minor portion is preselected for its coextru(cid:173)
`sion compatibility with the adjacent layer(s). Thus, a minor
`portion of the top and bottom layers can consist of a polyole(cid:173)
`fin, while a minor portion of the central layer can consist of a 20
`thermoplastic elastomer. In each case, it is preferred that the
`minor portion be no more than about one part in four by
`weight of each layer, or a weight ratio of 1 :3. Where all three
`layers are preselected to be ABS blends, the amount of polyb(cid:173)
`utadiene preferably is decreased in the central layer relative to 25
`the top and bottom layers.
`While the preferred embodiment of the vehicle floor cover
`consists of three integral layers, any one of the recited layers
`can in fact be made up of two or more sub layers, such that the
`total number of sublayers in the resultant mat or tray can 30
`exceed three.
`In another embodiment, the thermoplastic elastomer con(cid:173)
`stituent of the top, central and/or bottom layers described
`above can be replaced with a natural or synthetic rubber,
`including styrene butadiene rubber, butadiene rubber, acry(cid:173)
`lonitrile butadiene rubber (NBR) or ethylene propylene rub(cid:173)
`ber (EPDM).
`According to a related aspect of the invention, a vehicle
`floor cover is provided that has three layers bonded together,
`preferably by coextrusion. Major portions of the top and
`bottom layer consist of thermoplastic elastomer(s ). The top
`and bottom layers have compositions distinct from the central
`layer, which can be chosen for its relatively low expense. It is
`preferred that a major portion of the central layer be a poly(cid:173)
`olefin and that major portions of the top and bottom layers be
`one or more thermoplastic elastomers. The polyolefin may be
`selected from the group consisting of polypropylene and
`polyethylene, and preferably is a high molecular weight poly(cid:173)
`ethylene (HMPE). The thermoplastic elastomer can, for
`example, be SANTOPRENE®, GEO LAST® or VYRAM®,
`with VYRAM® being particularly preferred. It is also pre(cid:173)
`ferred that each of the layers be a polymer blend, with a minor
`portion of each layer being chosen for its coextrusion com(cid:173)
`patibility with adjacent layers. For example, the top and bot(cid:173)
`tom layers can consist of a 3:1 weight ratio ofVYRAM®/
`HMPE, and the central layer of a 3: 1 weight ratio of HMPE/
`VYRAM®.
`In an embodiment alternative to the one above, the top and
`bottom layers can consist of ABS polymer blends and the
`central layer can consist of SAN or an ABS in which the
`polybutadiene phase is present in a smaller concentration
`than in the top and bottom layers.
`In yet another embodiment, the thermoplastic elastomer
`recited in this aspect of the invention may be replaced with a
`natural or synthetic rubber, such as styrene butadiene rubber
`(SBR), butadiene rubber, acrylonitrile butadiene rubber
`(NBR) or ethylene propylene rubber (EPDM).
`
`4
`In a further aspect of the invention, a vehicle floor tray or
`mat according to the invention is made of three layers,
`wherein a top layer and a bottom layer have composition(s)
`distinct from the central layer, and wherein at least one of the
`5 shear strength per cross-sectional area, tensile strength per
`cross-sectional area and stiffness per cross-sectional area is
`greater than any one of the layers from which the tray or mat
`is composed. It has been found that a triextruded vehicle mat
`or floor tray according to the invention exhibits a tensile
`10 strength at yield, a tensile stress at break, a tensile modulus, a
`shear strength and a flexural modulus (stiffness) which are
`superior to either a polyolefin-dominated single extrusion or
`a thermoplastic elastomer-dominated single extrusion. The
`triextrusion tray demonstrates these enhanced physical prop-
`15 erties while at the same time affording an enhanced coeffi(cid:173)
`cient of friction to the feet of the occupant and improved
`tactile properties. By presenting such a surface to the shoe of
`the driver or passenger, the footing of the driver or passenger
`will be more sure and comfortable.
`In a further aspect of the invention, a vehicle foot well tray
`is provided as a part of a system that has the vehicle foot well
`as its other main component. The tray is molded from a sheet
`of polymeric material of substantially uniform thickness and
`has a greatly enhanced conformance to the surface of the
`vehicle foot well for which it is provided. At least first, second
`and third upstanding walls of the tray, each extending from
`the tray central panel to an upper margin, conform to respec(cid:173)
`tive upstanding walls of the vehicle foot well. In one embodi(cid:173)
`ment, this conformance is close enough that at least 90% of
`that one-third of the upstanding walls' outer surfaces that are
`adjacent the walls' upper margins is within one-eighth of an
`inch of the respective foot well walls. Alternatively, 90% of
`that one-half of the upstanding walls' outer surfaces which
`are adjacent the tray walls' upper margins is within one-
`35 eighth of the respective foot well wall. Additionally or alter(cid:173)
`natively, 50% of the entire external surface of each of the first,
`second and third upstanding tray walls is within one-eighth of
`an inch of a respective upstanding foot well wall. The
`upstanding tray walls are each joined to the central panel and
`40 at least one other of the upstanding tray walls. These upstand(cid:173)
`ing tray wall surfaces may be opposed surfaces or adjacent
`surfaces, and preferably are both. In an embodiment, the
`vehicle foot well further includes a door sill plate and the tray
`has a sill plate panel which substantially conforms to the sill
`45 plate.
`In a still further aspect of the invention, a top margin of a
`vehicle floor tray is substantially coplanar on at least two
`upstanding sidewalls thereof. Preferably, the top margin of
`the tray is substantially coplanar through three or even four
`50 continuous upstanding sidewalls. This eases the design of the
`floor tray, increases hoop strength and assures that all
`upstanding surfaces of the vehicle foot well will receive
`adequate protection from muddy footwear. In a particularly
`preferred embodiment, the plane of the top margin is for-
`55 wardly and upwardly tilted relative to a horizontal floor. This
`provides enhanced protection to the vehicle foot