Attorney Docket No. 31700.000322
`
`IN THE UNITED STATES PATENT AND TRADEMARK OFFICE
`
`Inventors:
`
`David F. MACNEIL et al.
`
`Title:
`
`Filed:
`
`VEHICLE FLOOR TRAY
`
`Herewith
`
`UTILITY PATENT APPLICATION TRANSMITTAL
`New nonprovisional application under 37 CFR l.53(b), Electronic Filing
`
`Specification, including claims and abstract
`
`[Total Pages
`
`Drawing(s)
`
`[Total Pages
`
`Declaration oflnventor(s)
`
`[Total Pages
`
`a. D Newly executed
`b. CR] Copy from a prior application (37 CFR 1.63(d))
`
`(for continuation/divisional with Box 15 completed)
`[Note Box 4 below]
`
`@]
`@]
`[I]
`
`i. D
`
`DELETION OF INVENTOR(S)
`Signed statement attached deleting inventor(s) named in the prior application
`(see 37 CFR 1.63(d)(2) and 1.33(b)).
`
`Incorporation By Reference (useable if Box 3b is checked). The entire disclosure of the prior
`application, from which a copy of the oath or declaration is supplied under Box 3b, is considered
`as being part of the disclosure of the accompanying application and is hereby incorporated by
`reference therein.
`
`Application Data Sheet
`
`CD-ROM or CD-R in duplicate, large table or Computer Program (Appendix)
`
`1.
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`2.
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`3.
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`0
`0
`0
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`4.
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`5.
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`6.
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`0
`D
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`9.
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`D
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`10.
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`8. D Assignment Papers (coversheet and documents, submitted for recordation via EPAS)
`D Power of Attorney
`
`DOCUMENTS ACCOMPANYING APPLICATION PARTS
`
`37 CFR 3.73(b) Statement and
`Power of Attorney
`(when there is an assignee)
`
`English Translation Document (if applicable)
`
`1/2
`
`0001
`
`EX1002
`Yita v. MacNeil
`IPR2020-01139
`
`

`

`Utility Patent Application Transmittal
`
`Attorney Docket No. 31700.000322
`
`rv, Copy of those listed references which
`LJ are not US patents or US patent
`application publications
`
`l"x7
`11. ~ Information Disclosure
`Statement (IDS)/PTO/SB/08A,B
`12. D Preliminary Amendment
`13. D Certified Copy of Priority Document(s) (if foreign priority is claimed)
`14. CR] Other:
`
`Form _SB/ 4 24 _ Certification_ and_ Request_ for Prioritized Examination
`
`------------------------------------ under 3 7_ CFR_§_l .17{c) --------------------------------------------------------------------
`
`15. If a CONTINUING APPLICATION, check the appropriate box
`and supply the requisite information.
`IX I Continuation D Division D Continuation-in-part (CIP)
`Examiner: Pinel Romain
`
`... of prior application No.: 12/879,899
`
`Art Unit: 3612
`
`ZIP CODE: 60532-4306
`FAX (630) 434 0444
`
`16. Correspondence Address: CUSTOMER NUMBER 64770
`
`Jefferson Perkins
`NAME:
`ADDRESS: MOMKUS MCCLUSKEY, LLC
`1001 Warrenville Road, Suite 500
`Lisle
`STATE: Illinois
`USA
`TELEPHONE: (630) 434 0414
`
`COUNTRY:
`
`CITY:
`
`17. SIGNATURE OF ATTORNEY FOR APPLICANT:
`
`NAME:
`
`SIGNATURE:
`
`REGISTRATION
`NUMBER:
`DATE
`
`Jefferson Perkins
`
`/Jefferson Perkins/
`
`31,407
`
`August 27, 2012
`
`2/2
`
`0002
`
`

`

`Attorney Docket No. 31700.000322
`
`APPLICATION FOR UNITED STATES PATENT
`
`INVENTOR:
`
`DAVID F. MACNEIL
`SCOTT A. VARGO
`
`ASSIGNEE:
`
`MACNEIL IP LLC
`
`TITLE:
`
`VEHICLE FLOOR TRAY
`
`MOMKUS MCCLUSKEY, LLC
`1001 Warrenville Road, Suite 500
`Lisle, IL 60532
`Attorneys
`Telephone: (630) 434-0400
`Facsimile: (630) 434-0444
`www.momlaw.com
`
`1
`
`0003
`
`

`

`Attorney Docket No. 31700.000322
`
`DESIGNING AND MANUFACTURING VEHICLE FLOOR TRAYS
`
`RELATED APPLICATIONS
`
`[0001] This application is a continuation of copending United States Nonprovisional Application
`
`No. 12/879,899 filed on September 10, 2010, which is in tum a continuation of United States
`
`Nonprovisional Application No. 11/463,203 filed on August 8, 2006, now abandoned, which is
`
`in tum a division of United States Nonprovisional Application No. 10/976,441 filed on October
`
`29, 2004, now United States Patent No. 7,316,847. The disclosures and drawings of those
`
`applications are fully incorporated by reference herein.
`
`BACKGROUND OF THE INVENTION
`
`[0002] 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, therefore, 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 solution to this has been to
`
`provide a vehicle floor mat which may be periodically removed by the owner and cleaned.
`
`[0003] 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
`
`2
`
`0004
`
`

`

`Attorney Docket No. 31700.000322
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`manufacturers has therefore been to provide a floor mat that will stay put and which will not
`
`adversely affect vehicle operation.
`
`[0004] The foot wells of cars, trucks and SUV s vary in size in shape from one model of vehicle
`
`to the next. Floor mat manufacturers have noticed that floor mats which at least approximately
`
`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 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 surfaces, as the designer only has to mark a two(cid:173)
`
`dimensional periphery of the mat in providing one which will fit reasonably well.
`
`[0005] More recently, vehicle floor trays have come onto the market. Most front-seat vehicle
`
`foot wells are actually three-dimensional concave shapes, typically with complex curved
`
`surfaces. Floor trays have sidewalls that offer enhanced protection 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-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-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 consumer acceptance because of their
`
`loose fit inside the foot well. There is often, and in many places, a considerable space between
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`the exterior wall of these conventional trays and the interior surface of the foot well. This causes
`
`3
`
`0005
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`

`

`Attorney Docket No. 31700.000322
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`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.
`
`[0006] 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 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, until the water evaporates or can be disposed of by 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 acceptable fit to the surface of a vehicle foot well has not yet been
`
`done, since there are problems in incorporating a three-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 surface, such as a vehicle floor tray, will exhibit
`
`more problems in keeping the collected fluid from sloshing about in a moving vehicle.
`
`[0007] Conventional vehicle floor mats and trays are molded from a single rubber or plastic
`
`material. The selection of this material 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
`
`4
`
`0006
`
`

`

`Attorney Docket No. 31700.000322
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`occupants' feet, with nonslipperiness (having a relatively 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.
`
`SUMMARY OF THE INVENTION
`
`[0008] According to one aspect of the invention, there is provided a vehicle floor cover, mat or
`
`tray which is removably installable by a consumer and which is formed of at least three 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 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.
`
`[0009] Preferably, a major portion of the central layer is a polyolefin. More preferably, the
`
`polyolefin is either a polypropylene 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-acrylonitrile copolymer (SAN) or an acrylonitrile-butadiene(cid:173)
`
`styrene (ABS) polymer blend.
`
`[0010] Preferably, a major portion of the top layer is a thermoplastic 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 an ABS polymer blend. Where ABS is used in both the top and central layers, it
`
`is preferred that the amount of the polybutadiene phase in the top layer be greater than the
`
`amount of this phase in the central layer.
`
`5
`
`0007
`
`

`

`Attorney Docket No. 31700.000322
`
`[0011]
`
`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.
`
`[0012] Preferably one or more of the layers is actually a polymer blend, in which a minor portion
`
`is preselected for its coextrusion compatibility with the adjacent layer(s ). Thus, a minor portion
`
`of the top and bottom layers can consist of a polyolefin, while a minor portion of the central
`
`layer can consist of a 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 polybutadiene preferably is
`
`decreased in the central layer relative to the top and bottom layers.
`
`[0013] 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 sublayers, such that
`
`the total number of sublayers in the resultant mat or tray can exceed three.
`
`[0014]
`
`In another embodiment, the thermoplastic elastomer constituent 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, acrylonitrile butadiene rubber (NBR) or ethylene
`
`propylene rubber (EPDM).
`
`[0015] 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
`
`6
`
`0008
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`

`

`Attorney Docket No. 31700.000322
`
`that a major portion of the central layer be a polyolefin 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
`
`polyethylene (HMPE). The thermoplastic elastomer can, for example, be SANTOPRENE®,
`
`GEOLAST® or VYRAM®, with VYRAM® being particularly preferred. It is also preferred
`
`that each of the layers be a polymer blend, with a minor portion of each layer being chosen for its
`
`coextrusion compatibility with adjacent layers. For example, the top and bottom layers can
`
`consist of a 3: 1 weight ratio of VYRAM®/HMPE, and the central layer of a 3: 1 weight ratio of
`
`HMPENYRAM®.
`
`[0016]
`
`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.
`
`[0017]
`
`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).
`
`[0018]
`
`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 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 strength at yield, a tensile stress at
`
`7
`
`0009
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`

`

`Attorney Docket No. 31700.000322
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`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 properties while at the
`
`same time affording an enhanced coefficient 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.
`
`[0019]
`
`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 has a greatly
`
`enhanced conformance to the surface of the vehicle foot well for which it is provided. At least
`
`two upstanding walls of the tray, both extending from the tray floor to a top margin, conform to
`
`respective surfaces of the vehicle foot well such that at least within that one-third of the area of
`
`the outer surface of these upstanding walls of the tray which is adjacent the top margin, 90% of
`
`that top third area departs by no more than about one-eighth of an inch from the foot well
`
`surfaces to which they mate.
`
`These upstanding tray surfaces may be opposed surfaces or
`
`adjacent surfaces, and preferably are both. In a preferred embodiment, the tray departs from a
`
`door sill surface of the vehicle foot well, and/or a sill curve of the vehicle foot well, by about
`
`0.025 inches. The upstanding sidewalls of the floor tray conform to the foot well surfaces which
`
`they cover, even where such foot well surfaces present both concave and convex surface
`
`elements.
`
`[0020]
`
`In a still further aspect of the invention, a top margm 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 continuous upstanding sidewalls.
`
`8
`
`0010
`
`

`

`Attorney Docket No. 31700.000322
`
`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 forwardly and upwardly tilted
`
`relative to a horizontal floor. This provides enhanced protection to the vehicle foot well
`
`precisely in the place where muddy footwear are likely to be, near the accelerator, brake and
`
`clutch pedals or the firewall. In a preferred embodiment, the tray is at least five inches deep at
`
`its deepest part.
`
`[0021]
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`In a further aspect of the invention, the above mentioned tight tolerances are made
`
`possible by a novel vehicle floor tray manufacturing method. In a first step according to the
`
`invention, points on a surface of the vehicle foot well are digitally measured with a coordinate
`
`measuring machine (CMM). These points are stored in a computer memory. A foot well surface
`
`is generated which includes these points, preferably by connecting linear groups of the points
`
`together by using B-splines, and lofting between the B-splines to create areal portions of the foot
`
`well surface. Using this typically complex three-dimensional, predominately concave surface,
`
`which may have several concavely and convexly curved portions, a corresponding substantially
`
`convex outer floor tray surface is built up such that in many regions, the distance between the
`
`outer surface of the tray and the surface of the foot well is no more than about one eighth of an
`
`inch, insuring a snug fit.
`
`[0022]
`
`In one embodiment of the invention, a reservoir is incorporated into the tray floor as a
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`collection and evaporation area for drip water from the feet and legs of the occupant.
`
`Combination baffles/treads are provided in the reservoir to impede lateral movement of the
`
`collected fluid. Longitudinal and transverse portions of these baffles are joined together.
`
`9
`
`0011
`
`

`

`Attorney Docket No. 31700.000322
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`Channels are cut into another portion of the central area of the tray to direct fluid to the reservoir,
`
`such that the bottom of the channels is beneath a general tray floor surface but above the bottom
`
`of the reservoir.
`
`In a preferred driver's side embodiment, the channels are omitted from a
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`portion of the floor tray upper surface to leave a blank space where the driver's heel will rest
`
`when operating the gas and brake pedals.
`
`[0023]
`
`In a further aspect, a vehicle floor tray has a central panel for placement on the floor of a
`
`vehicle foot well, and at least first and second upstanding panels, joined to respective
`
`longitudinal and transverse margins of the central panel, for substantial conformance to side
`
`walls of the vehicle foot well. The tray is thermoformed from a sheet of polymer material having
`
`substantially uniform thickness, and this means that the components of the tray after
`
`thermoforming will have a substantially uniform thickness. A reservoir is formed in the central
`
`panel for collection of snow melt and other fluid. Multiple treads/baffles are disposed in the
`
`reservoir. The treads/baffles each have at least two opposed ends and are elongate. Each
`
`tread/baffle is hollow and has a width, in any horizontal direction, which is more than twice its
`
`thickness as measured from the top surface thereof to the nearest point on the bottom surface
`
`thereof. The treads/baffles are adapted to elevate the foot or shoe of the occupant out of the fluid
`
`collected by the reservoir. At the same time they are adapted to impede lateral movement of the
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`collected fluid within the reservoir, as might occur when the vehicle turns, accelerates or brakes.
`
`The fluid is forced around ends of the treads/baffles in order to reach any remote portion of the
`
`reservoir. Since any portion of the reservoir is connected to any other portion of it, a large
`
`surface area of the reservoir is available for the collected fluid to spread out and evaporate.
`
`10
`
`0012
`
`

`

`Attorney Docket No. 31700.000322
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`[0024] Further aspects of the invention and their advantages can be discerned in the following
`
`detailed description, in which like characters denote like parts and in which:
`
`[0025] FIGURE 1 is an isometric view of one embodiment of a vehicle floor tray according to
`
`the invention;
`
`[0026] FIGURE 2 is a top view of the floor tray illustrated in FIGURE 1;
`
`[0027] FIGURE 3 is an isometric and transverse sectional view of the floor tray seen m
`
`FIGURES 1 and 2, the section taken substantially along line 3 -3 of FIGURE 2;
`
`[0028] FIGURE 4 is an isometric and longitudinal sectional view of the floor tray shown in
`
`FIGURES 1 and 2, the section taken substantially along line 4 - 4 of FIGURE 2;
`
`[0029] FIGURE 5 is a side view of the tray illustrated in FIGURE 1, taken from the outer side;
`
`[0030] FIGURE 6 is a highly magnified sectional view of a vehicle floor tray, showing
`
`triextruded layers;
`
`[0031] FIGURE 7 is a schematic block diagram showing steps in a design and manufacturing
`
`process according to the invention; and
`
`[0032] FIGURE 8 is an isometric and schematic view of a digitally acquired vehicle foot well
`
`floor surface from which the illustrated floor tray was made;
`
`11
`
`0013
`
`

`

`Attorney Docket No. 31700.000322
`
`[0033] FIGURE 9 is a partly transverse sectional, partly isometric view of both the floor tray
`
`illustrated in FIGURE 2 and the vehicle foot well surface illustrated in FIGURE 8, taken
`
`substantially along line 9 - 9 of FIGURE 2 and substantially along line 9 - 9 of FIGURE 8;
`
`[0034] FIGURE 10 is a partly transverse sectional, partly isometric view of both the floor tray
`
`illustrated in FIGURE 2 and the vehicle foot well surface illustrated in FIGURE 8, taken
`
`substantially along line 10 - 10 of FIGURE 2 and substantially along line 10 - 10 of FIGURE 8;
`
`[0035] FIGURE 11 is a detail of a firewall region of FIGURE 10;
`
`[0036] FIGURE 12 is a detail of a seat pedestal region of FIGURE 10;
`
`[0037] FIGURE 13 is a partly longitudinal sectional, partly isometric view of both the floor tray
`
`illustrated in FIGURE 2 and the vehicle foot well surface illustrated in FIGURE 8, taken
`
`substantially along line 13 - 13 of FIGURE 2 and substantially along line 13 - 13 of FIGURE 8;
`
`and
`
`[0038] FIGURE 14 is a detail of a kick plate region of FIGURE 13.
`
`DETAILED DESCRIPTION
`
`[0039] An isometric view of one commercial embodiment is shown in FIGURE 1. The
`
`illustrated vehicle floor tray indicated generally at 100 is preferably molded from a blank, in
`
`sheet form, of water-impervious thermoplastic polymer material having a uniform thickness,
`
`although the present invention could be fabricated from another process such as injection
`
`molding. The floor tray 100 is preferably formed of a triextruded thermoplastic material such
`
`that the properties of a central or core layer can be different than the properties of the external or
`
`12
`
`0014
`
`

`

`Attorney Docket No. 31700.000322
`
`jacket layers, and such that the triextrusion is tougher and stiffer per unit thickness than any of
`
`the layers from which it is made, as will be described in more detail below.
`
`[0040] The vehicle floor tray or cover 100 is meant to protect both the floor and at least the
`
`lower sides of a vehicle foot well, and thus takes on a much more three-dimensional shape than
`
`is typical of prior art floor mats. The floor tray 100 includes a floor or central panel 102, which
`
`in the illustrated embodiment includes a plurality of fore-to-aft or longitudinal parallel straight
`
`channels 104 that are disposed in a forward region 106 of the floor panel 102. Preferably these
`
`channels are about an eighth of an inch deep so that they will correctly channel runoff, and can
`
`be about one-quarter of an inch wide. In FIGURE 1, forward is a direction to the upper left,
`
`while rearward is the direction to the lower right, and the terms are used in conformance with the
`
`orientation of the vehicle in which the tray is designed to be placed. As used herein,
`
`"longitudinal" means for-and-aft or along the axis of vehicle travel, while "transverse" means at
`
`a ninety degree angle to such an axis, or side-to-side.
`
`[0041] A rearward or back region 108 of the floor panel 102 is largely occupied by a reservoir
`
`110, whose bottom is made up by a substantially planar general surface 112. General surface
`
`112 is situated to be below a general surface 114 of the forward region 106. Preferably, the
`
`general bottom reservoir surface 112 is also below the bottommost points of the respective
`
`channels 104, as by about one-eighth of an inch, so that fluid in the channels 104 will empty into
`
`the reservoir 110.
`
`[0042] The channels 104 are designed to channel liquid runoff from the user's feet or footwear
`
`to the reservoir 110. In many vehicles, the portion of the vehicle floor (not shown in this Figure;
`
`see FIGUREs 8 - 11) which underlies the forward region 106 slopes from front to rear, and thus
`
`13
`
`0015
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`Attorney Docket No. 31700.000322
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`the tray 100, by simply conforming to the contour of the underlying vehicle floor portion, will
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`channel fluid to the reservoir. For those vehicle designs in which the underlying vehicle floor is
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`not pitched in this manner, the tray 100 can advantageously be designed to create this fluid flow,
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`as by making the material thicker in portion 106 than in portion 108, or by giving the bottoms of
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`channels 104 a front-to-rear slope.
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`[0043] The channels 104 occupy most of the forward region 106, although in this and other
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`commercial embodiments a space 116 on the forward right hand side has been left open to
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`receive the foot of the driver that operates the accelerator and brake pedals. In the illustrated
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`embodiment, this space or clear area 116 is a delimited by a 180 degree arc of a circle of about
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`four inch radius (shown in dashed line). The clear area 116 is provided so that the relatively
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`deep channels 104 do not catch the heel of the driver's shoe. In other embodiments, the clear
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`area 116 can take other shapes or positions, so long as the heels of almost all drivers, while
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`operating the brake and accelerator pedals of the vehicle for which the particular tray is designed,
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`will rest within its confines.
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`[0044] The reservoir 110 has interspersed within it a plurality of tread surfaces or baffles 118,
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`which have two purposes. The first purpose is to elevate the shoe or foot of the occupant above
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`any fluid which may have collected in the reservoir 110. The second purpose is to prevent this
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`accumulated fluid from sloshing around. To this end, most of the tread surfaces/baffles 118 have
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`both fore-to-aft or longitudinal portions 120 and side-to-side or transverse portions 122. This
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`prevents large fluid movement in a forward or rearward direction, as would otherwise happen
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`during acceleration or braking of the vehicle, and also large fluid movement side-to-side, as
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`when the vehicle is turning. Preferably, each or at least most of the fore-to-aft portions 120 are
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`Attorney Docket No. 31700.000322
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`joined to respective side-to-side portions. This further compartmentalizes and restricts the
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`movement of collected fluid. Fluid in one portion of the reservoir 110 may make its way only
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`slowly and through a complicated path to another distant portion of the reservoir 110, through
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`channels 124 around the ends of the treads or baffles 118. The reservoir design thus creates a
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`large surface area which promotes evaporation of the fluid, while at the same time restricts fluid
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`movement prior to such evaporation.
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`[0045] Disposed around the central or floor panel 102 are a series of upstanding side panels,
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`which will vary in number and configuration from one vehicle model to the next.
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`In the
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`illustrated embodiment these upstanding panels include a back panel 130 that is disposed
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`adjacent the bottom of a vehicle front seat, or a vehicle pedestal for receiving same; an inner side
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`panel 132 that closely fits a transmission tunnel or "hump" in this vehicle; a forward panel 134
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`that closely conforms to a vehicle firewall; and an outer side panel 136. In most embodiments,
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`the outer side panel or kick plate panel 136 will only extend from its transition with panel 134 to
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`a comer 138, at which point there begins a door sill curve 208 which transitions into a door sill
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`panel 140. Unlike the other panels, the sill panel 140 is not generally upstanding but instead
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`conforms to the sill of a vehicle door and lies in a substantially horizontal plane. In this way
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`occupant ingress and egress is not occluded.
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`In many embodiments, including the illustrated
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`embodiment, the sill panel 140 is at an elevation below that of the general surface 114 of the
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`floor forward region 106 and even below the general surface (bottom) 112 of the reservoir 110.
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`Very large amounts of fluid (in excess of the reservoir capacity) may therefore flow right out of
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`the vehicle without having the opportunity to damage the vehicle interior. It should be noted that
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`in these FIGUREs, the lines dividing the panels are conceptual only and do not appear in the
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`Attorney Docket No. 31700.000322
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`final part. As will be described in further detail below, the tray 100 preferably is integrally
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`molded as a one-piece construction.
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`[0046]
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`In one important aspect of the invention, the tray 100 is closely fitted to the vehicle foot
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`well in which it is designed to be placed. Panels 130, 132, 134, 136 and 140 are all formed so as
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`to as closely conform to the vehicle surfaces against which they are positioned, to an extent not
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`found in prior art vehicle floor trays. In a preferred embodiment, at least throughout the top one(cid:173)
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`third of the areas of these panels that is adjacent a vehicle tray top margin 150, at least ninety
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`percent of the points on the outer surface of the peripheral or side panels 130-136 are no more
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`than about one-eighth of an inch from the corresponding points on the surfaces that they are
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`formed to mate with. This close conformance occurs even where the underlying vehicular
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`surface is complexly curved or angled. Certain portions of the vehicle foot well surface, such as
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`kick plate transition plate 214, can have both convexly and concavely curved elements. The
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`preferred tolerance of door sill curve 208 and sill plate 140 is even tighter, about 0.025 in.
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`[0047] The close conformance of the tray side panels to respective surfaces of the vehicle foot
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`well produces a protective tray which will not be horizontally displaced under lateral forces
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`created by the occupant's feet, or by the motion of the vehicle. Opposing pairs of the peripheral
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`panels "nest" or "cage" the tray 100, preventing its lateral movement. Thus, outer side panel or
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`kick plate panel 136, which closely conforms to a vehicle side wall at that position, has as its
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`counterpart a portion 142 of the inner side panel 132. Any tendency of the tray 100 to shift
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`leftward is stopped by panel 136; any tendency of the tray 100 to shift rightward is stopped by
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`panel portion 142. In a similar manner, the upstanding rearward and forward panels 130 and 134
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`cooperate to "cage" any forward or rearward motion of the tray 100 within the vehicle foot well.
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`Attorney Docket No. 31700.000322
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`[0048] The close c