United States Patent (19)
`Grace
`
`11) Patent Number:
`(45) Date of Patent:
`
`5,071,614
`Dec. 10, 1991
`
`(54 METHOD OF MOLDING A CARPET
`HAVING DEEP WELL AREAS
`75) Inventor: Ronald R. Grace, Hamilton, Ohio
`73) Assignee: Nifty Products, Inc., Hamilton, Ohio
`(21) Appl. No.: 542,969
`22 Filed:
`Jun. 25, 1990
`51) int. C. ....................... B29C 33/42; B29C 51/08
`52 U.S. Cl. ...................................... 264/322: 264/25;
`264/243; 264/324
`58 Field of Search .................. 264/322, 324, 25, 243
`(56)
`References Cited
`U.S. PATENT DOCUMENTS
`2,939, 79 6/1957 Penman et al. ..................... 264/34
`3, 15,678 2/1963 Keen et al. ..........
`... 264/322
`3,635,629 1/1972 Saladin ........
`... 425/173
`3,743,689 7/1973 Saladin ............
`... 264/322
`3,979,487 9/1976 Squier et al. ...
`... 264/225
`4,701,293 0/1987 Mead ...............
`... 264/258
`
`FOREIGN PATENT DOCUMENTS
`1580391 10/1970 Fed. Rep. of Germany ...... 264/322
`8733 5/1982 Japan ................................... 264/322
`Primary Examiner-James Lowe
`Attorney, Agent, or Firm-Charles R. Wilson
`57
`ABSTRACT
`Molded carpet for use in motor vehicles is made by a
`method which allows the molding of carpet having
`deep well areas. The method comprises the steps of
`heating a plastic backed carpet blank to a degree to
`make its backing pliable and thereafter molding the
`heated carpet in a set of specially constructed molds.
`The molds generally have the shape of the floor area to
`be covered. However, they are arch-shaped from edge
`to edge at those portions of the mold where draws are
`needed to accommodate specially contoured well areas
`of the motor vehicle's floor area.
`
`10 Claims, 3 Drawing Sheets
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`
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`MacNeil Exhibit 2067
`Yita v. MacNeil IP, IPR2020-01139
`Page 1
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`U.S. Patent
`
`Dec. 10, 1991
`
`Sheet 1 of 3
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`5,071,614
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`
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`FIG 2
`PRIOR ART
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`MacNeil Exhibit 2067
`Yita v. MacNeil IP, IPR2020-01139
`Page 2
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`U.S. Patent
`U.S. Patent
`
`
`
`5,071,614
`
`Dec. 10, 1991
`
`Sheet 2 of 3
`
`FIG. 4
`FIG. 4
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`MacNeil Exhibit 2067
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`Yita v. MacNeil IP, IPR2020-01139
`Page
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`MacNeil Exhibit 2067
`Yita v. MacNeil IP, IPR2020-01139
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`U.S. Patent
`
`Dec. 10, 1991
`
`Sheet 3 of 3
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`5,071,614
`
`
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`MacNeil Exhibit 2067
`Yita v. MacNeil IP, IPR2020-01139
`Page 4
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`1.
`
`METHOD OF MOLDING A CARPET HAVING
`DEEP WELL AREAS
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`O
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`This invention relates to a method of molding carpet. 5
`More particularly, the invention relates to a method of
`molding a plastic backed carpet blank to a contoured
`shape having abrupt angled well areas.
`Motor vehicles, especially automobiles and vans,
`typically have a carpet installed on a floor surface area.
`The carpet is primarily for aesthetic reasons, but addi
`tionally is used for comfort and noise reduction reasons.
`The carpet is often a plastic backed carpet which has
`been molded to impart a particular shape to the carpet.
`The floor areas of motor vehicles are very contoured to
`accommodate wheel wells, drive train humps and other
`functional and styling needs. Properly molded carpet
`will fit neatly into a contoured floor area without excess
`material or wrinkles.
`Molded carpets as used in motor vehicles are pro
`duced in a method involving the application of heat and
`pressure. Initially, a flat carpet blank with a thermoplas
`tic backing is cut to a length and width slightly larger
`than the planar dimensions of the floor area to be cov
`ered. The carpet blank is passed through an oven to
`25
`soften the plastic backing to a state sufficient to make it
`pliable. The heated carpet blank is then placed between
`complimentary male and female carpet molds having a
`desired shape and contour. Necessarily, the carpet
`molds are uniquely designed to produce molded carpet
`which fits into a prescribed vehicle make and model.
`The molds are closed under pressure. The carpet blank
`between the molds assumes the shape of the molds and,
`upon cooling, permanently retains that shape. Excess
`material is trimmed off the edges and ultimately the
`molded carpet is installed in the motor vehicle.
`A particular problem for the molded carpet manufac
`turer in recent years has been the need to supply molded
`carpet for use in wide bodied vans having a number of
`deeply contoured floor areas. It can be appreciated that 40
`carpet blanks are originally planar in shape. When the
`plastic backing is softened and pressure from a set of
`mating molds is applied, the carpet will stretch in cer
`tain directions while it will contract in other directions.
`There is only a limited amount of stretch obtainable 45
`from a small area of carpet blank. Excessive stretching,
`which can result from deep well areas, can cause the
`carpet to tear. This, of course, will cause the molded
`carpet to be rejected. Modern vans pose a problem
`because of their large floor areas and typical deeply 50
`contoured floor areas.
`In accord with a need, there has been developed a
`method to produce a molded carpet using a minimum of
`carpet material. Additionally, the method is able to
`handle deep well areas in a mold without tearing of the 55
`carpet.
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`5,071,614
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`of the molds is characterized in having a generally arch
`shape extending across its width in at least one area
`where an extensive draw of carpet is required because
`of the mold's design.
`BRIEF DESCRIPTION OF THE DRAWINGS
`FIG. 1 is a view in perspective of a prior art mold
`used to produce a molded carpet.
`FIG. 2 is an end view of the mold of FIG. 1.
`FIG. 3 is another perspective view of a part of the
`mold of FIG. 1 showing two deep well areas.
`FIG. 4 is an end view of a set of arch-shape molds
`used in the method of this invention.
`FIG. 5 is a view in perspective of the arch-shape
`Inolds of FIG. 4.
`FIG. 6 is another perspective view of a part of the
`molds of FIG. 4 showing a deep well area of a step well.
`FIG. 7 is a partial side view of the molds of FIG. 4.
`DETALED DESCRIPTION OF THE
`INVENTION
`The description of the invention which follows is
`made with particular reference to the drawings. FIGS.
`1-3 show a mold used in one step of a prior art method
`while FIGS. 4-7 show the molds used in the method of
`this invention. The method of the invention is first gen
`erally described and then specifically described with
`reference to the drawings.
`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 about 8 oz. to
`about 30 oz, is generally used. A thermoplastic material
`which is tough, elastic and non-tacky is used as the
`backing. Examples of such backings include polymers
`of ethylenevinyl acetate, ethylene, and acrylic acid. The
`backings are applied to the carpet in any manner, e.g.
`from a dispersion or by extrusion. The thermoplastic
`backing material is preferably capable of being softened
`at a temperature of from about 300 F. to about 500 F.
`to a sufficient degree to be readily molded.
`The carpet to be molded is cut to a size which is
`sufficient to result in a complete molded carpet piece,
`yet with as little excess as possible. Obviously, excess
`carpet material which must later be trimmed off the
`molded carpet and discarded is a waste. As discussed in
`the following paragraphs, the method of this invention
`is able to use less carpet material without affecting the
`quality of the molded carpet product. Interior floor
`surface areas of most motor vehicles are rectangular in
`shape; accordingly, the carpet blanks are also cut to this
`same general shape. The carpet's dimensions approxi
`mate the outside dimensions of a mold used in a later
`stage of the method. Generally, the resultant carpet
`blank is from about five feet to about seven feet in width
`and about eight feet to about fifteen feet in length to
`result in an area of from about 40 square feet to about
`100 square feet.
`The carpet blank is initially moved into a heating
`zone. Several transport means can be used. In one pre
`ferred method, a portable open rack is used for this
`purpose. The carpet blank is clamped into the open rack
`by yieldable holding means. The rack has a set of
`wheels to allow it to be moved into the heating zone and
`subsequent zones of the method. Other modes of trans
`
`35
`
`SUMMARY OF THE INVENTION
`The method of molding a substantially fiat arrow
`width plastic-backed carpet blank to a substantla.:y flat
`60
`carpet piece having a contoured shape with deep well
`area designed to fit the interior floor area of a motor
`vehicle, comprises the steps of: (a) heating the carpet
`blank to a temperature sufficient to soften the plastic
`until pliable; and (b) molding the carpet blank by posi
`tioning it between a set of male and female molds and
`thereafter closing said molds under pressure to impart
`the general shape of the molds to the carpet blank. Each
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`4.
`porting the carpet blank throughout the steps of the
`extend a carpet tear will result. Other more interior
`method can be used, including hand carrying, but the
`areas because of the distance involved will not be sub
`portable rack has proved most efficient.
`jected to the same tension.
`Any conventional heat source is used in the heating
`In accord with this invention, an arch-shaped set of
`zone. Nicrone coated wire heaters are preferred be
`molds is used in the molding stage which results in
`cause of the intense heat they are able to quickly gener
`carpet blank raw material savings and less quality con
`trol problems. The unique molds allow a fuller use of
`ate. Quartz heaters and forced air can as well be used to
`accomplish the stated purpose. An adequate number of
`the total carpet blank to accommodate the carpet mate
`heaters are employed so as to overlap the carpet edges
`rial demands occasioned by the deeply contoured well
`to substantially evenly heat the carpet. The carpet blank
`areas of the molds. The operating steps of heating and
`remains in the heating zone sufficiently long to soften
`molding as above discussed are used in the method of
`the plastic backing on the carpet blank to a pliable or
`this invention.
`moldable state. The amount of heat and dwell time in
`With reference to FIGS. 4 and 5, there is shown a set
`the oven will depend on the particular plastic backing
`of complimentary molds used in the method of this
`and its thickness. Generally, the carpet blank is left in
`invention. A male mold 20 and a female mold 21 gener
`the heat zone until a carpet surface temperature of from
`ally have the shape of a floor area of a motor vehicle.
`The molds are generally dimensioned and contoured
`about 300' F. to about 500 F. is reached. The heated
`carpet blank is promptly transported into a molding
`according to the particular motor vehicle's floor surface
`zone. Complimentary male and female molds are forced
`area to be covered with the molded carpet. The molds
`together under controlled pressure. Shaped wells in the
`are fabricated from fiberglass reinforced resinous mate
`molds tend to draw outer portions of the carpet into
`rial. The molds can as well be made from cast metal, e.g.
`them. Yieldable holding means are normally used on the
`aluminum, especially where water cooling in the molds
`carpet edges to exert tension where needed so as to keep
`is desired for faster cooling of the molded carpet. The
`the carpet substantially free of wrinkles and uniform
`male mold 20 is set on a platform 22 and is stationary.
`throughout this step.
`The female mold 21 is suspended by a movable rack 23
`25
`The molded carpet is finally cooled to set the thermo
`operably connected to a power source, such as a hy
`plastic backing and trimmed. Typically, these steps
`draulic cylinder 24.
`occur while the carpet is still positioned between the
`The description which follows is with respect to the
`molds, though once the carpet has cooled sufficiently to
`male mold 20. It should be understood the same criteria
`set the plastic backing, it can be removed for full cool
`and parameters exist for the female mold 21. A forward
`30
`ing and trimming in separate zones. The resultant
`area 25 is substantially flat from side to side of the mold
`molded carpet retains the contour imparted by the mold
`and from about mid length of the mold to a sloping front
`due to the nature of the plastic material. The molded
`foot area 26. The rear area 27 of the mold, however, is
`carpet is ultimately shipped and installed in a motor
`arch-shaped from side to side. The degree of arching is
`vehicle simply by properly positioning it and securing
`critical. Too little arching will approximate the prior art
`35
`the edges. The preformed carpet follows the contour of
`flat molds and give no noticeable improvement in the
`the vehicle's floor surface area. FIGS. 1-3 show a mold
`method while too much arching will result in a molded
`10 used by the prior art in the molding of plastic backed
`carpet which will retain the arch shape and not flatten
`carpet. Only the male mold is shown for illustration
`to properly lie in the motor vehicle's floor area. A de
`purposes. The mold is in effect a replica of a floor area
`gree of arching which results in a vertical distance from
`40
`of a particular motor vehicle. The main floor area 11 of
`the apex of the arch to an adjacent side edge of about
`the mold is generally flat, both length-wise and width
`one-half inch to about one and one-half inches per foot
`wise. The rear wheel wells 12 each have an inside wall
`of mold width has been found to be optimum. Prefera
`which is substantially perpendicular to the floor area 11.
`bly, a degree of arching which results in a vertical dis
`The side and top walls of the wheel wells are contoured
`tance from apex to side edge of about one inch per foot
`45
`to follow the outline of a wheel. Rear step wells 13 and
`of mold width is used. The rear wheel wells 30 and 31
`front step wells 14 at mid length on the mold also have
`are tilted outwardly to the horizontal, though the side
`side walls which are substantially perpendicular to the
`walls 32 and 33 of the respective wells are substantially
`floor area with a parallel foot portion. A post well 15 is
`perpendicular to the immediate arched portion of the
`also provided in the mold to accommodate interior
`mold from which they extend. It has been found deep
`styling of the particular vehicle. A shaped front foot
`draw areas as presented by the wheel wells must be so
`area 16 of the mold is gently sloped upwardly and is for
`configured to result in a molded carpet which lays
`the purpose of creating a foot rest area for driver and
`properly. The step well 35 as most evident in FIGS. 5
`front seat passengers. The front wheel wells 17 extend
`and 6 also is tilted outwardly and has a side wall 37
`off of the forward area 16 and are gently contoured
`which is substantially perpendicular from the immedi
`partially for comfort reasons.
`ate arched portion of the mold from which it extends. It
`It will be noted the wheel wells, step wells, and post
`should be understood all edge wells found on the mold
`well areas of the prior art mold are al very deeply con
`are similarly configured in accord with this invention.
`toured. These areas cause deep draws in the carpet
`That is, the side walls of the edge wells configured into
`blank during the molding stage and are areas where the
`the particular mold which are located in the arch
`carpet is likely to tear. In effect, carpet in the immediate
`shaped portion of the mold are all substantially perpen
`vicinity of the deep well areas is stretched into the well
`dicular to the portion of the mold from which the re
`areas by the action of the molds closing together. Ex
`spective side wall extends.
`cess carpet width allows a certain draw from the carpet
`The molds used in the method of this invention must
`blank edges, but, of course, results in excessive raw
`meet two important criteria. First, a portion of each
`65
`material usage and is not fully effective. A greater con
`mold is arch-shaped across the width of the mold. The
`cern is that the deep well areas will tend to draw carpet
`arch-shape of the mold is located in at least that area of
`from an adjacent interior portion of the blank to the
`the mold where the deepest carpet draws will be experi
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`enced in the molding method. This will typically be
`date a wheel well in the floor area of the motor
`vehicle and further being generally arch-shaped
`from the rear of the mold to about a mid-length point in
`across its width from a deep well on one side edge
`the mold. The arch shape can as well extend the entire
`to a deep well on an opposite side edge.
`length of the mold. Second, edge wells which are lo
`cated in the arch-shaped portion of the mold are config
`2. The method of claim 1 wherein each of the deep
`ured so that their side walls are substantially perpendic
`wells has a vertical wall approximately perpendicular to
`ular to that portion of the mold from which each ex
`the arch portion of the mold from which it extends.
`tends. Preferably, though not necessary, the side walls
`3. The method of claim 2 wherein the arch shape has
`of the edge wells located in that part of the mold which
`a degree of arching which results in a vertical distance
`is flat also are titled outwardly.
`from an apex of the arch to an adjacent side edge of
`In operation, a substantially flat carpet blank is heated
`about one-halfinch to about one and one-halfinches per
`to soften its plastic backing and is then positioned be
`foot of mold width.
`tween the arch-shaped male and female molds. As the
`4. The method of claim 3 wherein each of the molds
`molds are closed together under pressure, the carpet
`has the arch shape extending from a rear edge to about
`blank begins to assume the shape of the molds. Those
`its mid-point and has a substantially flat shape for the
`portions of the mold which contact first tend to fix that
`balance of its length.
`portion of the carpet blank in an immovable state. How
`5. The method of claim 4 wherein the degree of arch
`ever, the arch shape nature of the molds permits carpet
`ing is about one inch per foot of mold width.
`to be drawn more evenly from substantial portions of
`6. The method of claim 1 wherein the molded carpet
`the carpet blank to accommodate the deep well areas
`20
`piece has planar dimensions of about five feet to about
`which must draw carpet into them to form the continu
`seven feet in width and about eight feet to about fifteen
`ous molded carpet. In effect a better distribution of
`feet in length.
`forces is obtained. The result being a more uniform
`7. The method of molding a substantially flat narrow
`stretching of the carpet blank and less localized carpet
`width plastic-backed carpet blank to a substantially flat
`stretchinq and resultant tears. When the carpet is cooled
`carpet piece having a contoured shape with deep wells,
`to set its thermoplastic backing and removed from the
`said carpet piece designed to neatly fit the interior floor
`molds, it will assume a substantially flat shape. That is,
`area of a motor vehicle without substantial wrinkles,
`the arch-shape of the mold is not evident in the molded
`comprising the steps of:
`product. The molded carpet is readily installed in a
`(a) heating the substantially flat narrow width plastic
`vehicle for which it was intended.
`backed carpet blank to a temperature sufficient to
`While the invention has been described with particu
`soften the plastic until pliable; and
`lar reference to the drawings and preferred embodi
`(b) molding the carpet blank by positioning it be
`Inents, it should be understood various modifications
`tween a set of male and female molds and thereaf
`can be made, For example, a felt underlay or vinyl heel
`ter closing said molds under pressure to impart the
`pad can be positioned in the molds prior to molding the
`35
`general shape of the molds to the carpet blank,
`carpet blank. Such features in a molded carpet are con
`wherein each of said molds is characterized in
`ventional. These and other obvious changes and modifi
`being generally arch-shaped across its width in at
`cations are intended to be within the scope of the ap
`last one area where a deep draw of carpet is re
`pended claims.
`quired because of the mold's design, wherein the
`What is claimed is:
`arch shape has a degree of arching which results in
`1. The method of molding a substantially flat narrow
`a vertical distance from an apex of the arch to an
`width plastic-backed carpet blank to form a substan
`adjacent side edge of about one-half inch to about
`tially flat carpet piece having a contoured shape with
`one and one-half inches per foot of mold width.
`deep wells, said carpet piece designed to neatly fit the
`8. The method of claim 7 wherein each of the molds
`interior floor area of a motor vehicle without substantial
`has the arch shape extending from a rear edge to about
`wrinkles, comprising the steps of:
`its mid-point and has a substantially flat shape for the
`(a) heating the substantially flat narrow width plastic
`balance of its length.
`backed carpet blank to a temperature sufficient to
`9. The method of claim 8 wherein the degree of arch
`soften the plastic until pliable; and
`ing is about one inch per foot of mold width.
`(b) molding the carpet blank by positioning it be
`50
`10. The method of claim 7 wherein the molded carpet
`tween a set of male and female molds and thereaf
`piece has planar dimensions of about five feet to about
`ter closing said molds under pressure to impart the
`seven feet in width and about eight feet to about fifteen
`general shape of the molds to the carpet blank,
`feet in length.
`wherein each of said molds is characterized in hav
`ing a deep well near each side edge to accommo
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