O
`
`United States Patent (19)
`Grace
`
`H||||||IIII
`11
`Patent Number:
`5,207,963
`45) Date of Patent:
`May 4, 1993
`
`US005207963A
`
`2,918,696 12/1959 Bottoms et al. ..................... 264/291
`54) METHOD OF MOLDING PLASTIC-BACKED
`2,939,179 6/1960 Pennan et al. ..................... 264/134
`CARPET
`2,986,777 6/1961 Carter ................................. 264/324
`s
`3, 15,678 12/1963 Keen et al.....
`... 264/322
`75) Inventor: Ronald R. Grace, Hamilton, Ohio
`3,328,839 7/1967 Treece et al......
`... 425/397
`irraa.
`A
`3,388,018 6/1968 Squier et al. ........................ 264/257
`73) Assignee: Nifty Products, Inc., Hamilton, Ohio
`4,432,716 2/1984 Kiss ..................................... 264/324
`(21) Appl. No.: 219,358
`Primary Examiner-Jeffery Thurlow
`(22
`Filed:
`Jul. 15, 1988
`Assistant Examiner-Mathieu Vargot
`Attorney, Agent, or Firm-Charles R. Wilson
`(i.
`51) Int. Cl. ...................... B29C 51/08;
`57
`ABSTRACT
`52) U.S. C. .................................... 264/163; 264/257;
`264/291; 264/322; 264/324; 264/325;
`264/DIG. 65; 425/186; 425/195; 425/510; A method of molding a plastic-backed carpet blank to a
`desired shape uses a minimum of work force and carpet
`425/397; 425/400; 425/403.1; 42.5/DIG. 39
`58) Field of Search ............... 26,333,291, material. The method utilizes a portable frame assembly
`264/292, 257, 258, 241, 243, 135, 136, 137, 134,
`haying an open rack with yieldable holding clamps. The
`DIG. 65, DIG. 73,320, 163; 425/400, 397, 501,
`holding clamps are used to suspend a plastic-backed
`502,327,339, 402,403.1, DIG. 38, DIG. 39,
`carpet blank in the rack. The frame assembly has a set of
`DIG. 41, DIG. 201, 388, 384, 186, 195,510;
`wheeled legs which allows it to be readily transported
`72/361, 364
`between work stations such as a heating zone and a
`molding zone. The yieldable holding clamps maintain
`the carpet under constant tension during the molding
`zone to result in a high quality molded carpet.
`
`(56)
`
`References Cited
`U.S. PATENT DOCUMENTS
`2,266,846 12/1941 Buff..................................... 264/324
`2,759,217 8/1956 Peterson .............................. 264/291
`
`23 Claims, 5 Drawing Sheets
`
`
`
`MacNeil Exhibit 2066
`Yita v. MacNeil IP, IPR2020-01139
`Page 1
`
`

`

`U.S. Patent
`
`Sheet 1 of 5
`
`5,207,963
`
`
`
`CUT OUT
`CARPET
`
`----
`
`2×
`
`C • ca º 3C,
`
`MacNeil Exhibit 2066
`Yita v. MacNeil IP, IPR2020-01139
`Page 2
`
`

`

`U.S. Patent
`
`May 4, 1993
`
`Sheet 2 of 5
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`5,207,963
`
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`
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`31
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`
`
`1-30
`
`R
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`to
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`MacNeil Exhibit 2066
`Yita v. MacNeil IP, IPR2020-01139
`Page 3
`
`

`

`U.S. Patent
`
`May 4, 1993
`
`Sheet 3 of 5
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`5,207,963
`
`
`
`MacNeil Exhibit 2066
`Yita v. MacNeil IP, IPR2020-01139
`Page 4
`
`

`

`U.S. Patent
`
`May 4, 1993
`
`Sheet 4 of 5
`
`5,207,963
`
`
`
`MacNeil Exhibit 2066
`Yita v. MacNeil IP, IPR2020-01139
`Page 5
`
`

`

`U.S. Patent
`
`May 4, 1993
`
`Sheet 5 of 5
`
`5,207,963
`
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`
`
`
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`to
`
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`
`MacNeil Exhibit 2066
`Yita v. MacNeil IP, IPR2020-01139
`Page 6
`
`

`

`5,207,963
`
`METHOD OF MOLDING PLASTC-BACKED
`CARPET
`
`5
`
`2
`SUMMARY OF THE INVENTION
`A method of molding a plastic-backed carpet to a
`contoured shape to fit a motor vehicle's interior floor
`surface area uses a minimum of carpet raw material and
`work force. The method comprises initially positioning
`and clamping a carpet blank in a frame assembly. The
`frame assembly comprises an open rack, a set of legs
`with wheels, and yieldable holding means mounted
`around the periphery of the open rack. The frame as
`sembly is portable in nature in that it can be readily
`moved from work station to work station by a single
`worker. The frame assembly with the carpet blank
`yieldably clamped in the open rack is initially moved
`into a heat zone to soften the plastic backing and then
`moved to a molding zone. A set of male and female
`molds are brought together with the heated carpet
`blank in the middle. The yieldable means holding the
`carpet blank in the open rack maintain a constant ten
`sion on the carpet as the molds draw together. The
`carpet blank can be suspended in the open rack
`throughout the complete sequence of steps of produc
`ing the molded carpet.
`BRIEF DESCRIPTION OF THE DRAWINGS
`FIG. 1 is a schematic diagram showing the various
`method steps which are carried out in accordance with
`this invention to produce a molded carpet.
`FIG. 2 is a view in perspective showing a frame as
`sembly used in the method of the invention.
`FIG. 3 is a view in perspective of a portion of the
`frame assembly of FIG. 2 showing yieldable holding
`e2S.
`FIG. 4 is a side view showing carpet blanks individu
`ally mounted in two of the frame assemblies of FIG. 2
`and positioned in a heating zone and a molding zone,
`respectively.
`FIG. 5 is a top view of the frame assembly of FIG. 2
`with a break-away end-rail shown in phantom in an
`open position.
`FIG. 6 is an end view of the frame assembly of FIG.
`5.
`FIG. 7 is a top view of an alternative yieldable hold
`ing means positioned in a portion of a frame assembly.
`FIG. 8 is a top view of a frame assembly used in
`another embodiment of the method of this invention
`wherein a carpet blank held in the frame assembly can
`be readily turned over for fast heating purposes.
`FIG. 9 is an end view of the frame assembly of FIG.
`8 showing an open rack with the carpet blank mounted
`therein in the process of being revolved.
`DETAILED DESCRIPTION OF THE
`INVENTION
`The description of the invention which follows is
`made with particular reference to the drawings. FIG. 1
`shows in schematic form the basic steps of the method
`while FIGS. 2-9 show the equipment used in the
`method steps.
`The method of the invention uses a plastic-backed
`carpet material. Such carpet materials are commercially
`available. The particular weight and color of the carpet
`are usually specified by the vehicle manufacturer for
`new vehicles or the vehicle's owner for those vehicles
`whose original carpet is being replaced. A carpet
`weight of at least about 8 oz., preferably from about 8
`oz. to about 30 oz. is generally used. A thermoplastic
`material which is tough, elastic and non-tacky is used as
`
`O
`
`20
`
`15
`
`METHOD OF MOLDING PLASTIC-BACKED
`CARPET
`This invention relates to a method of molding carpet.
`More particularly, the invention relates to a method of
`molding plastic-backed carpet to a shape which con
`forms to the irregular contour of a motor vehicle's in
`side floor surface.
`Most motor vehicles being produced today have their
`inside floor surface covered with a carpet. The carpet is
`primarily for appearance purposes and secondarily for
`comfort, acoustic and protective purposes. A problem
`with installing carpet in a motor vehicle results from the
`many varied shapes often found in the vehicle's floor
`surface. A center hump in the floor surface is often
`provided to accommodate a drive shaft. Protrusions
`and recesses are also often built into the floor area for
`aesthetic reasons and functional reasons. Protrusions for
`wheel wells can be quite pronounced. Any carpet in
`tended to cover such an irregular floor surface area
`must be able to conform to the irregular surface.
`25
`Carpets manufactured for use on the irregular floor
`surface of a motor vehicle are typically molded to the
`desired shape. A high quality carpet is provided with a
`backing of a thermoplastic material. The thermoplastic
`materials are capable of being softened by heat, molded
`30
`to a desired shaped, and finally cooled to set the shape.
`The resultant plastic-backed carpet has a shape which
`permits ready installation in the vehicle. The molded
`carpet is simply properly positioned and secured at its
`35
`edge portions. A minimum of cutting and manual shap
`ing is needed to achieve a smoothly carpeted floor area.
`Known methods of molding carpet are very labor
`intensive and have a substantial amount of carpet mate
`rial wastage. Thus, a plastic-backed carpet is initially
`cut to the same general shape as the floor area to be
`covered. The carpet blank is placed in a flattened state
`in an oven to soften the plastic backing. The heated
`carpet blank is then hand-carried to a set of male and
`female molds. The carpet blank must be held under
`45
`tension by at least two and up to six workers as the two
`molds with the main body of the blank between them
`are closed together. Sufficient tension must be exerted
`by those holding the carpet blank to keep the molds
`from pulling portions of the carpet within it and/or
`molding a permanent wrinkle into the carpet. Worker
`carelessness and fatigue are responsible for significant
`quality control problems.
`Attempts have been made to automate methods of
`molding carpet. A method as described in U.S. Pat. No.
`55
`2,939,179 to Penman et al is one example of such an
`attempt. A frame is designed to hold a carpet blank
`throughout the steps of carpet molding. The frame is
`built to move along fixed side rails to convey the carpet
`blank from an initial heating stage to a final cutting
`60
`stage. While successful to an extent, the method is in
`flexible in handling varied sizes and weights of carpet.
`As can be imagined, a large range of carpet sizes and
`carpet weights are required to meet vehicle manufactur
`ers' specifications. Still other more labor intensive and
`65
`/or capital intensive methods are used throughout in
`dustry to mold carpet. They all suffer in efficiency or
`flexibility to different degrees.
`
`MacNeil Exhibit 2066
`Yita v. MacNeil IP, IPR2020-01139
`Page 7
`
`

`

`5,207,963
`3
`4.
`the backing. Examples of such backings include poly
`their heights can be adjusted according to need. Thus, .
`mers of ethylenevinyl acetate, ethylene, and acrylic
`different molds will dictate the use of frame assemblies
`acid. The backings are applied to the carpet in any
`wherein the carpet blank is suspended at varying dis
`manner, e.g. from a dispersion or by extrusion. The
`tances from ground surface. Several means for adjusting
`thermoplastic backing material is preferably capable of 5
`the length of the legs are usable. For example, hollow
`being softened at a temperature of from about 300' F. to
`legs with a spring-loaded mechanism within each and
`about 500 F. to a sufficient degree to be readily
`an operably associated crank arm is usable. Telescoping
`legs with peg holding means is another example.
`molded.
`With reference to FIG. 1, the carpet to be molded is
`A wheel 17 secured at the lower extremity of each leg
`cut to a size which is sufficient to result in a complete 10
`renders the frame assembly portable and easily moved
`molded carpet piece, yet with as little excess as possible.
`from one treatment zone to the next. As most evident
`Obviously, excess carpet material which must later be
`from FIGS. 2 and 6the wheels have a V-groove in their
`periphery for the purpose of riding along floor rails 18.
`trimmed off the molded carpet and discarded is a waste.
`As discussed in the following paragraphs, the method of
`The floor rails are anchored to a floor surface and are
`this invention is able to use less carpet material without 15
`laid out to lead continuously through the treatment
`affecting the quality of the molded carpet product.
`ZOneS.
`Carpet blank 19 is movably suspended within the
`Interior floor surface areas of most motor vehicles are
`rectangular in shape; accordingly, the carpet blanks are
`open rack. A yieldable holding means comprised of
`also cut to this same general shape. The carpet's dimen
`elastic cord 20 and clamp means 22 is used for this pur
`sions approximate the outside dimensions of a mold
`pose. Elastic cord 20 which is secured by eye screws 21
`20
`used in a later stage of the method. Generally, the resul
`to the open rack extends completely around the inside
`tant carpet blank has an area of from about 10 square
`periphery of the open rack. A set of clamp means are
`feet to about 100 square feet.
`individually secured at one end to the elastic cord.
`The carpet blank is next placed within an open rack
`Clamp means 22 are conventional vise grips which have
`on a portable frame assembly and clamped by yieldable
`been modified by the addition of a screw attachment
`25
`holding means. The carpet blank remains clamped on
`means 23 at vise grip extremity 24. The screw attach
`the open rack throughout subsequent steps of the
`ment means 23 has a suitably dimensioned opening 25
`method. Thus, the frame assembly with the carpet blank
`which, if desired, allows it to freely move along the
`yieldably clamped within it is next moved into a heating
`elastic cord to a desired clamping position. A clip 26 is
`zone. The carpet blank remains in the heating zone
`preferably used for a more secure attachment to the
`30
`sufficiently long to soften the plastic-backing on the
`elastic cord. The degree of force exerted by gripping
`carpet blank. The carpet blank is promptly transported
`extremity 27 of the vise grip is controlled by adjusting
`by the frame assembly into a molding zone. While still
`screw means 29. Typically, at least ten clamp means are
`suspended within the open rack of the frame assembly,
`positioned on the elastic cord. The number of clamp
`male and female molds are forced together under con
`means needed is dependent on the carpet blank size and
`35
`trolled pressure. Shaped cavities in the molds tend to
`the cavities of the molds. The purpose of the yieldable
`draw outer portions of the carpet into them while the
`holding means is to suspend the carpet within the open
`yieldable holding means on the carpet exert tension to
`rack during processing in all steps and to hold all por
`keep the carpet free of wrinkles and uniform through
`tions of the carpet blank under controlled tension dur
`ing the molding operation. Generally speaking, deep
`out this step.
`40
`The molded carpet is finally cooled to set the thermo
`cavities in the molds tend to draw edges of the carpet
`plastic backing and trimmed. Typically, these steps
`blank more with the result being that extra clamp means
`occur while the carpet is still positioned between the
`are employed in areas of the carpet which are proximate
`molds, though can as well be done in separate steps and
`the cavities.
`in either order. The resultant molded carpet retains the
`The carpet blank is readily loaded in the open rack.
`45
`contour imparted by the mold due to the nature of the
`Most conveniently, the cut carpet blanks are stacked on
`plastic material. The molded carpet is ultimately
`a work table positioned between the rails 18. The height
`shipped and installed in a motor vehicle simply by prop
`of the table is about the same as the height of the open
`erly positioning it and securing the edges. The pre
`rack. By positioning the frame assembly and open rack
`formed carpet follows the contour of the vehicle's floor
`directly over the work table, a carpet blank is clamped
`to the yieldable holding means in a sequential manner
`surface area.
`With particular reference to FIGS. 2-6, there is
`until fully clamped. The frame assembly 10 with the
`shown a portable frame assembly used in the method of
`carpet blank suspended within the open rack is wheeled
`this invention. The frame assembly shown generally as
`along the rails to the next work station. A single worker
`10, comprises an open rack 11 of a generally rectangular 55
`is capable of loading the carpet blank and moving it
`shape with legs 12 at each corner. The open rack's
`along to the proper work station.
`dimensions are dependent on the particular carpet size
`The frame assembly and suspended carpet are ini
`being run. However, the nature of the holding means is
`tially moved into a heat zone 30. A bank of heaters (not
`such that one open rack will accommodate a range of
`shown) is suspended in the hood of oven 31. An ade
`carpet blank sizes. The rack itself has four rails each 60
`quate number of heaters are employed so as to overlap
`attached at its respective ends to an adjoining rail by
`the carpet edges to substantially evenly heat the carpet.
`conventional means, e.g. welds or bolts and nuts. Thus,
`Sufficient heat is imparted to the carpet to soften the
`plastic backing of the carpet to a pliable or moldable
`side rails 13 and 14 and end rails 15 and 16 form the
`open rack.
`state. The amount of heat and dwell time in the oven
`The legs 12 extend from the open rack and are dimen
`will depend on the particular plastic backing and its
`65
`sioned in accordance with the height requirements in
`thickness. Generally, the carpet blank is left in the heat
`posed by equipment found in subsequent steps. Prefera
`zone until a carpet surface temperature of from about
`bly, the legs on at least one end have means by which
`300' F. to about 500' F. is reached.
`
`MacNeil Exhibit 2066
`Yita v. MacNeil IP, IPR2020-01139
`Page 8
`
`

`

`15
`
`5,207,963
`5
`6
`Any conventional heat source is used in the heating
`frame assembly. One end of each tension spring is at
`zone. Nicrone coated wire heaters are preferred be
`tached to the open rack. A second end has gripping
`cause of the intense heat they are able to quickly gener
`surfaces for securely clamping onto the carpet blank.
`ate. Quartz heaters and forced air can as well be used to
`For example, the rail 51 of the frame assembly has lon
`accomplish the stated purpose.
`gitudinal slots 52 formed in its surface to accommodate
`The heated plastic-backed carpet blank is promptly
`a bolt 53 and nut 54. A tension spring 55, secured at one
`transferred by movement of the frame assembly 10
`end to the bolt 53, has a set of end clamps 56 and 57 for
`along the floor rails to molding zone 40. Optionally, the
`gripping and holding the carpet blank. If needed, the
`floor rails have pre-set stop means to aid in precisely
`tension in each spring is adjusted depending on its loca
`positioning the frame assembly for the molding opera
`tion on the rack and anticipated tension during the
`O
`molding operation.
`tion. Thus, each rail can have a stop such as a bracket
`which is hingably attached and activated simply by
`FIGS. 8 and 9 illustrate a frame assembly which is
`swinging it into engagement with a wheel. The pre-set
`most useful in this invention with carpet blanks having
`stops have the effect of speeding up the process and
`a thick plastic backing. In order to soften such plastic
`improving on the quality of the molded carpet. Prefera
`backings without singeing the fabric of the carpet it is
`bly each stage, or at least the molding stage, has such
`necessary that the plastic backing be heated directly.
`stops installed. Other stops such as air cylinders and
`That is, the plastic-backing should be directly opposite
`stationary blocks can as well be used.
`the heat source in the heating zone. For an overhead set
`of quartz heaters, this means the carpet must be clamped
`Male mold 41 and female mold 42 are contoured to
`impart the desired shape to the carpet. Such molds, of
`into the portable frame assembly so that its plastic back
`20
`course, are contoured according to the particular motor
`ing is facing upwards. However, after being heated, the
`plastic-backed carpet must be flip flopped so that the
`vehicle's floor surface area. The mold is fabricated from
`fiberglass reinforced resinous material or cast metal e.g.
`plastic-backing contacts the surface of the bottom mold.
`This is quite often necessary because of the usual,
`aluminum. The later molds are more durable and can be
`though optional, placement of felt pads in portions of
`further modified with water cooling, though are more
`25
`expensive. Pneumatic pressure means 45 are used to
`the bottom mold and their subsequent adherence to the
`force the molds together.
`molded carpet. The frame assembly 60 allows the
`The heated carpet blank is initially suspended by the
`clamped carpet blank to be positioned plastic-backing
`up for heating purposes and plastic-backing down for
`open-rack between the two molds 41 and 42. As the
`molds are forced together, the carpet blank follows the
`molding purposes in a convenient fashion.
`moving mold surfaces. The yieldable holding means are
`Frame assembly 60 has a fixed frame 61 and a pivota
`put under tension by the carpet being drawn into the
`bly mounted open rack 62 positioned within the frame
`mold. Certain of the holding means, such as those near
`61. Fixed frame 61 is generally rectangular in shape and
`est a deep mold cavity, are placed under a greater
`has four legs 63 attached at its four corners. The indi
`amount of tension. The tension exerted by the yieldable
`vidual rails 64-67 of fixed frame 61 are permanently
`holding means prevents any edge portion of the carpet
`attached at their extremities to one another. Open rack
`from completely entering into the mold area.
`62 is dimensioned to fit within fixed frame 61. The open
`Optionally, a felt pad underlay is placed between the
`rack is pivotably mounted by pivot pins 68 which ex
`heated carpet blank and the female mold prior to the
`tend from the rack into receiving fittings 69 on the fixed
`molds being forced together. The felt pad is to add a
`frame. The pivot points are located in the centers of side
`degree of durability and comfort to the carpet and is
`rails 65 and 67 and the height the frame assembly is such
`sometimes specified by the carpet installer. The porta
`that the open rack can revolve completely about its
`ble nature of the frame assembly used in the method of
`pivot points in either direction. Stop means 70 are found
`this invention allows the felt pad to be easily inserted at
`near at least one corner of the fixed frame to engage
`this stage.
`receiving means 71 found on the open rack so as to
`The molded carpet is preferably trimmed while still
`secure the open rack to the frame assembly and steady
`it during treatment stages.
`between the molds. At the same time, the carpet is being
`cooled by ambient temperature or refrigerated molds.
`The pivot points on the open rack 62 of frame assem
`After about one minute, the carpet is sufficiently cooled
`bly 60 can as well be positioned at mid-point of the end
`for the thermoplastic backing to be set to its molded
`rails if desired. Pivot points on the side rails, though, are
`configuration. The molds are then separated and the
`preferred in that this allows the end rail 66 to open in
`molded carpet set aside for shipment to the carpet in
`the manner above discussed.
`A crossbar 75 is movably mounted on the side rails of
`staller.
`In a preferred embodiment, at least one end rail has
`the open rack 62. It is moved according to the length of
`means by which the rail can be broken apart. As best
`the carpet blank being molded. The cross bar is an op
`55
`seen in FIGS. 2 and 5, end rail 16 is comprised of two
`tional feature which adds another measure of flexibility
`substantially equal lengths. Each length 46 is pivotably
`to the method herein described. An elastic cord with
`secured to end rail portions 47, which in turn extend
`yieldable holding means as described with reference to
`FIGS. 2-6 is positioned on the inside surfaces of rails 76,
`from the side rails. A hold means such as a slip collar 48
`is used to hold the two lengths together. When a carpet
`77 and 78 and cross bar 75. The elastic cord can as well
`blank is released from the holding means and the slip
`be positioned on all the rails 76-79 of the pivotably
`collar disengaged, the two end rail lengths pivot out
`mounted open rack 62. End rails 66 and 78 on the fixed
`wardly. This allows the frame assembly to be returned
`frame and pivotably mounted open rack, respectively
`to the initial loading stage while the carpet is left in the
`are constructed to open. End rail half lengths and slip
`molds to cool.
`collars similar to that described with reference to FIGS.
`An alternative yieldable holding means is shown in
`2 and 6 are used.
`In operation, a plastic-backed carpet blank of a prede
`FIG. 7. A set of tension means 50 are movably posi
`tioned around the inside surface of the open rack of a
`termined size is clamped into the open rack of the frame
`
`45
`
`30
`
`35
`
`MacNeil Exhibit 2066
`Yita v. MacNeil IP, IPR2020-01139
`Page 9
`
`

`

`5,207,963
`7
`8
`assembly by yieldable holding means. The assembly is
`4. The method of claim 3 wherein at least one clamp
`means is positioned on the open rack and clamped to the
`wheeled along floor rails into a heating zone to suffi
`plastic-backed carpet blank at a point approximately
`ciently soften the plastic backing and then into a mold
`opposite wherein a contoured shape in the molds is
`ing zone. Male and female mold close together with the
`heated plastic-backed carpet between them. The yield
`found so as to attain maximum tension at said point
`during the molding step.
`able holding means maintain a constant force or tension
`on the carpet during this molding operation. A single
`5. The method of claim 1 further wherein a set of
`worker is capable of loading the carpet in the frame
`floor rails secured to a floor surface is laid out to lead
`assembly and moving it throughout the various stages.
`continuously from a zone where the carpet blank is
`positioned and clamped in the frame assembly to the
`The yieldable holding means and open rack construc
`tion add a degree of flexibility in handling various car
`heating zone and then to the molding zone.
`pet sizes. A high quality carpet molded to specification
`6. The method of claim 2 further wherein a set of
`floor rails secured to a floor surface is laid out to lead
`results from the method.
`continuously from a zone where the carpet blank is
`While the invention has been described with particu
`positioned and clamped in the frame assembly to the
`15
`lar reference to the drawings, it should be understood
`heating zone and then to the molding zone.
`obvious variations and modifications may be made. For
`7. The method of claim 1 wherein the plastic-backed
`example, instead of wheels, slide blocks can be used. A
`pair of cross bars can also be positioned across two of
`carpet blank has a weight of at least about 8 oz.
`8. The method of claim 7 wherein the plastic-backed
`the frame assembly rails to reduce its area so as to ac
`carpet blank has a surface area of from about 10 square
`commodate smaller sized carpet blanks. Such changes 2O
`feet to 100 square feet when suspended in the open rack
`are within the scope of the following claims.
`prior to the molding step.
`What is claimed is:
`9. A method of molding a heavy weight plastic
`1. A method of molding a plastic-backed carpet to a
`backed carpet to a contoured shape designed to fit the
`contoured shape designed to fit the interior floor area of
`25
`a motor vehicle wherein the method requires a mini
`interior floor area of a motor vehicle wherein the
`mum of carpet material and work force, comprising the
`method requires a minimum of carpet material and
`steps of:
`work force, comprising the steps of:
`(a) positioning a plastic-backed carpet blank with a
`(a) positioning a plastic-backed carpet blank within a
`portable frame assembly, said frame assembly hav
`thick plastic-backing within a portable frame as
`30
`sembly, said frame assembly having a fixed frame
`ing a fixed open rack of rails attached together to
`form a shape approximating the carpet blank, a set
`of two side rails and two end rails in a shape ap
`of legs extending from the open rack with each of
`proximately the carpet blank, a set of legs extend
`said legs having a wheel mounted at a bottom ex
`ing from the fixed frame with each of said legs
`tremity for the purpose of moving the frame assem
`having a wheel mounted at a bottom extremity for
`35
`bly during treatment stages, and a yieldable hold
`the purpose of moving the frame assembly during
`treatment stages, an open rack of the approximate
`ing means mounted on the open rack for holding
`shape of the fixed frame pivotably mounted within
`the carpet blank at selected areas, said yieldable
`holding means having an elastic cord secured to an
`the fixed frame so as to be capable of revolving
`completely about its points of pivotable mounting
`inside surface of the rack and a set of clamp means
`wherein each clamp means is movably secured at
`and a set of yieldable holding means mounted on
`the open rack for holding the carpet blank at se
`one end to the elastic cord and at a second end to
`the plastic-backed carpet blank;
`lected areas;
`(b) clamping the plastic-backed carpet blank to the
`(b) clamping the plastic-backed carpet blank to the
`yieldable holding means mounted on the open rack
`yieldable holding means mounted on the open rack
`45
`so that the carpet blank is suspended under a sub
`so that the carpet blank is suspended under a sub
`stantially constant tension within the open rack of
`stantially constant tension with the open rack of the
`frame assembly and with its plastic-backing facing
`the frame assembly;
`upwards;
`(c) moving the frame assembly with the plastic
`(c) moving the frame assembly with the plastic
`backed carpet blank into a heating zone;
`(d) heating the plastic-backed carpet blank for a time
`backed carpet blank into a heating zone;
`(d) heating the plastic-backed carpet blank for a time
`and a temperature sufficient to soften the plastic
`backing so as to be moldable;
`and a temperature sufficient to soften the plastic
`(e) moving the frame assembly with the heated plas
`backing so as to be moldable;
`(e) revolving the open rack of the frame assembly a
`tic-backed carpet blank to a molding zone com
`55
`half-turn so that the plastic backing of the carpet
`prised of male and female molds;
`(f) molding the heated plastic-backed carpet blank to
`blank is facing downwards;
`(f) moving the frame assembly with the heated plas
`the contour of the molds by causing said male and
`female molds to come together under pressure such
`tic-backed carpet blank to a molding zone com
`that the shape defined by the molds is imparted to
`prised of male and female molds; and
`(g) molding the heated plastic-backed carpet blank to
`the plastic-backed carpet blank; and
`(g) cooling the molded plastic-backed carpet blank
`the contour of the molds by causing said male and
`sufficiently to set its molded configuration.
`female molds to come together under pressure such
`2. The method of claim 1 further comprising the step
`that the shape defined by the molds is imparted to
`the plastic-backed carpet blank.
`of trimming excess material from the plastic-backed
`carpet blank while still positioned between the molds.
`10. The method of claim 9 wherein the carpet blank
`remains in the molds until the plastic-backing has
`3. The method of claim 1 wherein at least ten clamp
`cooled sufficiently to set to its molded configuration.
`means are mounted on the elastic cord.
`
`50
`
`O
`
`65
`
`MacNeil Exhibit 2066
`Yita v. MacNeil IP, IPR2020-01139
`Page 10
`
`

`

`5
`
`10
`
`5,207,963
`10
`9
`mum of carpet material and work force, comprising the
`11. The method of claim 10 wherein the carpet blank
`steps of:
`is trimmed of excess material while positioned between
`(a) positioning a plastic-backed carpet blank within a
`the molds.
`portable frame assembly, said frame assembly hav
`12. The method of claim 10 wherein the yieldable
`ing a fixed open rack of rails attached together to
`holding means mounted on the open rack is an elastic
`form a shape approximating the carpet blank and
`cord secured to an inside surface of the rack and a set of
`wherein at least one end rail is capable of opening,
`clamp means, each movably secured at one end to the
`a set of legs extending from the open rack with
`elastic cord and at a second end to the plastic-backed
`each of said legs having a wheel mounted at a
`carpet blank.
`bottom extremity for the purpose of moving the
`13. The method of claim 12 wherein at least ten clamp
`frame assembly during treatment stages, and a set
`means are mounted on the elastic cord.
`of yieldable holding means mounted on the open
`14. The method of claim 10 wherein the yieldable
`rack for holding the carpet blank at selected areas;
`holding means is a set of spring clamps secured to an
`(b) clamping the plastic-backed carpet blank to the
`inside surface of the rack so as to be individually ad
`yieldable holding means mounted on the open rack
`15
`justed according to the degree of tension to be exerted
`so that the carpet blank is suspended under a sub
`on the plastic-backed carpet blank during the molding
`stantially constant tension with the open rack of the
`stage.
`frame assembly;
`15. The method of claim 10 wherein at least one end
`(c) moving the frame assembly with the pl