(12) United States Patent
`McIntosh et al.
`
`I 1111111111111111 11111 111111111111111 IIIII IIIII 1111111111 1111111111 11111111
`US006361099Bl
`US 6,361,099 Bl
`Mar.26,2002
`
`(10) Patent No.:
`(45) Date of Patent:
`
`(54) VEHICLE FLOOR COVERING WITH
`INTEGRAL THREADED DRAIN TUBE AND
`METHOD OF MAKING SAME
`
`(75)
`
`Inventors: William Duncan McIntosh, Ontario
`(CA); Dayne Stuart Haight, Rochester
`Hills, MI (US)
`
`(73) Assignee: Collins & Aikman Products Co, Troy,
`MI (US)
`
`4/1985 Peoples, Jr. et al. .......... 428/95
`4,508,771 A
`4/1986 Peoples, Jr. et al. .......... 428/95
`4,579,764 A
`4,958,743 A * 9/1990 Hatton et al. ............... 220/288
`4,978,004 A * 12/1990 Silverstein et al.
`......... 206/224
`5,322,335 A
`6/1994 Niemi ..................... 296/97.23
`5,518,679 A
`5/1996 Junk .......................... 264/318
`5,527,081 A * 6/1996 Rauch et al.
`............... 296/186
`5,673,956 A * 10/1997 Emery ....................... 296/39.2
`5,957,154 A * 9/1999 Olaker ....................... 137/296
`
`FOREIGN PATENT DOCUMENTS
`
`( *) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by O days.
`
`JP
`JP
`JP
`
`03 284 432
`07 010 039
`08 156 669
`
`12/1991
`1/1995
`6/1996
`
`OTHER PUBLICATIONS
`
`(21) Appl. No.: 09/344,394
`
`(22) Filed:
`
`Jun. 25, 1999
`
`Int. Cl.7 ................................................ B62D 25/20
`(51)
`(52) U.S. Cl. ................... 296/97.23; 220/235; 52/302.7;
`470/906
`(58) Field of Search ........................ 296/38, 39.1, 39.3,
`296/97.23, 208; 220/235, 288; 52/302.1,
`302.7; 470/906
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`* 10/1909
`11/1927
`6/1930
`3/1936
`10/1941
`12/1943
`9/1953
`7/1962
`8/1962
`11/1962
`3/1963
`8/1964
`9/1964
`11/1966
`6/1969
`1/1978
`7/1981
`
`Gillon ........................ 220/288
`Roberts et al.
`. ... ... ... ... 156/221
`Tomlin ....................... 264/255
`Blair et al.
`. . . . . . . . . . . . . . . . 180/90.6
`Collins ....................... 156/156
`Rieser ........................ 264/318
`Peirce ..................... 296/97.23
`Gerstenmaier et al.
`..... 264/552
`Pagan ..................... 296/97.23
`Wadham ..................... 264/437
`Stata ....................... 296/97.23
`Fordyce ................. 296/107.01
`Stata ....................... 296/97.23
`Ioppolo ....................... 15/313
`Stata ....................... 296/97.23
`Hack et al. ................. 296/208
`Von Holdt .................. 264/152
`
`936,444 A
`1,649,734 A
`1,764,662 A
`2,032,832 A
`2,258,238 A
`2,336,423 A
`2,650,855 A
`3,042,974 A
`3,050,329 A
`3,061,888 A
`3,082,032 A
`3,143,373 A *
`3,149,875 A
`3,284,836 A
`3,450,429 A
`4,071,273 A *
`4,280,976 A
`
`International Search Report, European Patent Office, Oct.
`2000, PCT/US00/40112.
`
`* cited by examiner
`
`Primary Examiner-Stephen T. Gordon
`Assistant Examiner-Paul Chenevert
`(74) Attorney, Agent, or Firm-Myers Bigel Sibley &
`Sajovec
`
`(57)
`
`ABSTRACT
`
`A molded floor covering for a vehicle floor includes a
`thermoplastic polymer layer with an integral, threaded drain
`tube extending therefrom. The drain tube is configured such
`that a distal end thereof can extend through a drain hole in
`a vehicle floor when the floor covering is installed within a
`vehicle. The drain tube includes a threaded bore that is
`configured to receive a correspondingly-threaded drain plug
`therein. A method of producing a molded floor covering
`having an integrally formed, threaded drain tube includes
`providing a mold having a contour of a vehicle floor with an
`outwardly projecting threaded member. A layer of thermo(cid:173)
`plastic polymer is vacuum formed over the mold and around
`the threaded member such that the layer follows the contours
`of the mold and threaded member to form an elongate tube
`extending therefrom.
`
`5 Claims, 4 Drawing Sheets
`
`I I Ob
`
`/
`
`110
`
`162
`160
`
`EX1013
`Yita v. MacNeil
`IPR2020-01139
`
`

`

`U.S. Patent
`
`Mar. 26, 2002
`
`Sheet 1 of 4
`
`US 6,361,099 Bl
`
`FIG. I.
`
`12
`
`FIG. 2.
`
`22
`
`18
`
`FIG. 3.
`
`

`

`U.S. Patent
`
`Mar.26,2002
`
`Sheet 2 of 4
`
`US 6,361,099 Bl
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`/' 100
`
`,,.I 02
`
`f IG. 4.
`
`PROVIDE MOLD HAVING
`CONTOUR Of VEHICLE f LOOR AND
`OUTWARDLY PROJECTING
`THREADED MEMBER
`+
`VACUUM FORM LAYER OF
`THERMOPLASTIC POLYMER OVER
`MOLD AND AROUND THREADED
`MEMBER SUCH THAT LAYER
`FOLLOWS CONTOURS OF MOLD
`AND THREADED MEMBER
`+
`,,.104
`ROTATE THREADED MEMBER TO
`THREADINGLY DISENGAGE FROM
`DRAIN TUBE
`!
`FORM OPENING THROUGH
`DRAIN TUBE DISTAL END
`!
`POST-FORMING OPERATIONS
`
`,106
`
`r108
`
`f IG. 5.
`
`

`

`U.S. Patent
`
`Mar.26,2002
`
`Sheet 3 of 4
`
`US 6,361,099 Bl
`
`FIG. 6.
`
`18
`
`FIG. 78.
`
`FIG. 7 A.
`
`

`

`U.S. Patent
`U.S. Patent
`
`Mar. 26,2002
`Mar. 26, 2002
`
`Sheet 4 of 4
`Sheet 4 of 4
`
`US 6,361,099 B1
`US 6,361,099 Bl
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`174
`
`I I Ob
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`/
`
`110
`
` rtsat
`LILLLLLLLLLf110
`
`
`f IG. 8.
`
`ys
`
`N
`gn
`S
`Safere
`
`122
`
`
`162
`160
`
`FIG. 9.
`
`1s
`
`

`

`US 6,361,099 Bl
`
`1
`VEHICLE FLOOR COVERING WITH
`INTEGRAL THREADED DRAIN TUBE AND
`METHOD OF MAKING SAME
`
`FIELD OF THE INVENTION
`
`The present invention relates generally to floor coverings
`and, more particularly, to floor coverings for vehicles.
`
`BACKGROUND OF THE INVENTION
`
`10
`
`2
`drain tube. The threaded shank is configured to threadingly
`engage the threaded cylindrical bore such that the drain plug
`can be inserted and removed via rotation about the axial
`direction. Preferably, the drain plug head and the drain tube
`5 proximate end have respective conical frustum shapes such
`that the drain plug head can be received by the proximate
`end in countersunk relation therewith. Furthermore, it is
`preferable that the drain plug head include a portion that can
`be engaged by a tool or grasped by a user to rotate the drain
`plug about the axial direction.
`According to another aspect of the present invention, a
`method is provided for producing a molded floor covering
`for a vehicle floor that includes a drain tube integrally
`formed therewith. Arnold having a contour of a vehicle floor
`is provided with an outwardly projecting threaded member.
`15 The threaded member includes a head portion and an
`elongate threaded shank. A layer of thermoplastic polymer is
`vacuum formed over the mold and around the threaded
`member such that the layer follows the contours of the mold
`and threaded member to produce a molded floor covering
`20 having opposite first and second surfaces, and a drain tube
`extending outwardly therefrom. The drain tube includes a
`threaded bore that is configured to receive a
`correspondingly-threaded drain plug. The drain tube
`includes an open proximate end and a closed distal end. The
`25 open proximate end is integrally formed with the molded
`floor covering.
`According to another embodiment of the present
`invention, a fastener may threadingly engage an elongate
`threaded tube integrally formed with a floor covering
`30 according to the above described method to removably
`secure a mat to the floor covering.
`
`Vehicle manufacturers typically provide some type of
`covering for vehicle floors. Vehicle floor coverings are
`typically configured to provide a resilient and decorative
`wearing surface with heat insulating and sound deadening
`qualities. For example, the use of carpet as a vehicle floor
`covering is well known. Carpeting used to cover a vehicle
`floor is typically molded into a contoured configuration that
`conforms to the contour of a vehicle floor so as to fit
`properly. U.S. Pat. No. 4,579,764 to Peoples, Jr., et al.
`discloses an exemplary molded foam-backed carpet for use
`as a vehicle floor covering.
`The use of molded thermoplastic polymer compositions
`as floor coverings for vehicles known as sport utility
`vehicles (SUVs), which recently have found growing popu(cid:173)
`larity among consumers, is also known. U.S. Pat. No.
`5,322,335 to Niemi discloses an exemplary molded floor
`covering for an SUV.
`It is known that water can accumulate on the floors of
`passenger and cargo compartments of vehicles, particularly
`during inclement weather. Because of the potential for
`corrosion and other damage that may be caused by such
`water accumulation, drain holes are conventionally provided
`within vehicle floors to enable any collected water to drain
`out. In order to prevent the infiltration of noise and dirt
`within a vehicle during vehicle operation, these drain holes 35
`are conventionally fitted with removable plugs.
`Many conventional floor coverings, particularly floor
`coverings for SUVs, are formed from material that is imper(cid:173)
`vious to water. As a result, water that accumulates on a
`vehicle floor covering may be prevented from draining from
`the vehicle via drains provided within the vehicle floor.
`Accordingly, there is a need for providing a mechanism that
`allows water to drain directly through vehicle floor cover(cid:173)
`ings.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`The accompanying drawings, which are incorporated in
`and constitute a part of the specification, illustrate embodi(cid:173)
`ments of the invention and, together with the description,
`serve to explain principles of the invention.
`FIG. 1 is a perspective view showing an exemplary
`molded floor covering assembly for a vehicle incorporating
`40 an integral drain in accordance with the invention.
`FIG. 2 is an exploded, cutaway view of a portion of the
`floor covering of FIG. 1 having an integral drain and plug
`therein according to the invention.
`FIG. 3 is a side section view of a portion of the floor
`45 covering of FIG. 1 illustrating the plug in a secured position
`within the drain tube.
`FIG. 4 illustrates method steps for producing molded floor
`coverings according to the present invention.
`FIG. 5 is a side section view of a layer of thermoplastic
`polymer being vacuum formed over a mold and around a
`threaded member in accordance with the present invention.
`FIG. 6 is a side section view of a molded vehicle floor
`covering wherein water is shown draining through the drain
`55 tube.
`FIG. 7 A is a side section view of a layer of thermoplastic
`polymer being vacuum formed over a mold and around a
`threaded member having a threaded insert in accordance
`with another embodiment of the present invention.
`FIG. 7B illustrates the plug of FIG. 7A in a secured
`position threadingly engaged with the threaded insert within
`the drain tube.
`FIG. 8 is a side section view of a molded floor covering
`for a vehicle floor according to another embodiment of the
`65 present invention wherein the floor covering includes an
`elongate tube and a fastener for securing a mat to the floor
`covering.
`
`SUMMARY OF THE INVENTION
`
`50
`
`In view of the above, it is an object of the present
`invention to facilitate drainage of water from within a
`vehicle directly through a vehicle floor covering.
`It is another object of the present invention to provide a
`method of producing vehicle floor coverings having drains
`integrally formed therewith.
`These and other objects of the present invention are
`provided by a molded floor covering for a vehicle floor that
`includes a thermoplastic polymer layer with a contoured
`configuration adapted to conform to the contour of a vehicle
`floor and an integral, threaded drain tube extending out(cid:173)
`wardly therefrom. The drain tube extends outwardly from
`the thermoplastic polymer layer and includes an open proxi- 60
`mate end, an open distal end and a threaded cylindrical bore.
`The open proximate end is integrally formed with the
`thermoplastic polymer layer and the distal end is configured
`to extend through an aperture in a vehicle floor when the
`floor covering is installed within a vehicle.
`A drain plug including a head and a threaded shank
`connected to the head is configured to be inserted within the
`
`

`

`US 6,361,099 Bl
`
`3
`FIG. 9 is a perspective view of a drain plug having a
`handle that facilitates removal of the drain plug by hand.
`
`DETAILED DESCRIPTION OF IBE
`INVENTION
`
`The present invention now will be described more fully
`hereinafter with reference to the accompanying drawings, in
`which preferred embodiments of the invention are shown.
`This invention may, however, be embodied in many different
`forms and should not be construed as limited to the embodi(cid:173)
`ments set forth herein; rather, these embodiments are pro(cid:173)
`vided so that this disclosure will be thorough and complete,
`and will fully convey the scope of the invention to those
`skilled in the art. Like numbers refer to like elements
`throughout.
`Referring now specifically to FIG. 1, reference character
`10 generally indicates a vehicle floor covering incorporating
`a drain 15 in accordance with the invention. The floor
`covering 10 illustrated in FIG. 1 has a nonplanar three
`dimensional molded configuration adapted to fit the front 20
`seat compartment floor of a vehicle and includes a raised
`medial portion 11 adapted to conform to the transmission
`hump, generally vertically extending side portions 12
`adapted to fit beneath each door opening, and a front portion
`13 adapted to fit along the inclined floorboard and vertical 25
`firewall areas of a vehicle. Various openings or cut-outs are
`provided, as indicated at 14, to receive air conditioning
`equipment, the steering column, pedals and the like. Drains
`15 having removable plugs 16 secured therewithin accord(cid:173)
`ing to the invention are provided in selected low point areas 30
`17 of the floor covering 10. It is to be understood that the
`particular three dimensional configuration illustrated is
`merely for purposes of illustration. Vehicle floor coverings
`incorporating drains according to the present invention may
`have various configurations and shapes depending on the 35
`floor configuration of a vehicle.
`Referring now to FIG. 2, an exploded, cutaway view of a
`portion of the floor covering 10 having a drain 15 and plug
`16 therein, according to the invention, is illustrated. The
`floor covering 10 includes an exposed surface 10a and an
`opposite underside surface 10b. When the floor covering 10
`is installed in a vehicle, the underside surface 10b is con(cid:173)
`figured to make contacting relationship with the vehicle
`floor 18. As would be understood by one of skill in the art,
`the floor covering 10 may be secured to the floor 18 via
`adhesives and/or fasteners.
`The illustrated drain 15 includes a drain tube 20 that is
`integrally formed with the floor covering 10 and that extends
`downwardly from the underside surface 10b of the floor
`covering 10. The drain tube 20 is configured to extend
`through an aperture 19 formed within the vehicle floor 18
`when the floor covering 10 is installed within a vehicle.
`The drain tube 20 includes a cylindrical inner wall 21 that
`defines a cylindrical bore 22 that extends along an axial 55
`direction A The cylindrical bore 22 extends from an open
`proximate end 20b to an open distal end 20a, as illustrated.
`The illustrated proximate end 20b has a conical frustum
`shape that is configured to receive a correspondingly-shaped
`head of the plug 16 in countersunk relation therewith. The 60
`drain tube cylindrical inner wall 21 includes a set of threads
`25 which are configured to threadingly receive a correspond(cid:173)
`ingly threaded shank 31 of the plug 16.
`Still referring to FIG. 2, the plug 16 has a head portion 30
`with an aperture 34 configured to receive a tool for applying 65
`torque thereto and a circular, threaded shank portion 31. It is
`understood that the head portion 30 may have various
`
`4
`configurations. For example, the head portion 30 may
`include a handle (35, FIG. 9) that facilitates removal of the
`plug 16 by hand, without the need for a tool. Also, projec(cid:173)
`tions extending from the head portion 30, as well as
`5 apertures, may serve as means for engaging a tool that is
`configured to rotate the drain plug 16. The plug 16 may be
`formed from various materials including, but not limited to,
`metals, plastics and rubber. Preferably, the plug 16 is formed
`from plastic or rubber to facilitate easy removal by hand
`10 without the need for a removal tool.
`The head portion 30 has a conical frustum shape and
`includes a substantially flat end portion 30a. Accordingly,
`when the plug 16 is secured within the drain 15, the plug
`head portion 30 is countersunk within the proximate end 20b
`15 such that the end portion 30a is substantially flush with the
`exposed surface 10a of the floor covering, as illustrated in
`FIG. 3.
`The threads 32 on the shank are configured to threadingly
`engage with the threads 25 in the drain tube cylindrical inner
`wall 21 such that when torque is applied to the plug head
`portion 30, the plug 16 moves along the axial direction A
`within the drain tube 20. Preferably, rotation of the plug 16
`in a clockwise direction causes the plug 16 to move along
`the axial direction A so that the plug head portion 30 moves
`towards the proximate end 20b. Conversely, rotation of the
`plug 16 in a counter-clockwise direction causes the plug 16
`to move along the axial direction A so that the, plug head
`portion 30 moves away from the proximate end 20b.
`FIG. 3 illustrates the plug 16 in a secured position within
`the drain tube 20. To remove water that has accumulated on
`the floor covering exposed surface 10a, the plug 16 is rotated
`in a counter-clockwise direction which threadingly disen(cid:173)
`gages the threaded shank 31 from the threaded bore 22,
`thereby allowing the plug 16 to be removed from the drain
`15. The accumulated water can then drain from the vehicle
`through the drain tube 20. After the water is drained from the
`vehicle, the plug 16 is returned to a secured position within
`the drain 15 as illustrated in FIG. 3.
`Referring now to FIGS. 4 and 5, a method of producing
`a molded floor covering for a vehicle floor, wherein the
`molded floor covering includes a drain tube integrally
`formed therewith according to the present invention is
`illustrated. A mold having a contour of a vehicle floor is
`provided with an outwardly projecting threaded member
`(Block 100). A metal bolt is preferably utilized as the
`threaded member. FIG. 5 is a section view of a mold 40
`having a contour of a vehicle floor. An outwardly projecting
`threaded member 16 is also provided, as illustrated. The
`50 illustrated threaded member 16 has a head portion 30 with
`a conical frustum shape and an elongate threaded shank 31.
`A layer of thermoplastic polymer is then vacuum formed
`over the mold and around the threaded member such that the
`layer follows the contours of the mold and threaded member
`(Block 102). Various polymers or copolymers may be suit(cid:173)
`ably employed as the thermoplastic polymer such as, for
`example, polymers or copolymers of ethylene with ethyl(cid:173)
`enically unsaturated monomers; fillers; polyolefin polymers
`such as polyethylene or polypropylene; polyvinyl chloride;
`styrenebutadiene mixed polymers and mixtures of these
`materials with other thermoplastic polymers. A preferred
`thermoplastic polymer is ethylene/vinyl acetate copolymer.
`The polymer may include conventional fillers, plasticizers,
`processing aids, flame retardants, etc., the selection of which
`is within the skill of one in the art.
`As illustrated in FIG. 5, the layer of thermoplastic poly(cid:173)
`mer 45 has been formed via mold 40 to produce a molded
`
`45
`
`40
`
`

`

`US 6,361,099 Bl
`
`5
`floor covering 10 having opposite first and second surfaces
`10a, 10b and a drain tube 20 extending outwardly therefrom.
`The drain tube 20 includes a threaded bore 21 with an open
`proximate end 20b and a closed distal end 20a. The open
`proximate end 20b is integrally formed with the molded
`floor covering 10. In the illustrated embodiment, the open
`proximate end 20b has a conical frustum configuration
`matching that of the head 30 of the threaded member 16.
`Next, the threaded member is rotated to threadingly
`disengage the threaded member from the drain tube (Block
`104). An opening is then formed through the drain tube
`distal end (Block 106). Accordingly, fluid, such as water 50,
`can drain from the molded floor covering first surface 10a by
`flowing into the open proximate end 20b, through the drain
`tube 20, and out the open distal end 20a, as illustrated in
`FIG. 6. Preferably, a plastic threaded bolt is threadingly
`engaged with the drain tube to serve as the drain tube plug.
`Preferably, the plastic threaded bolt has a handle (35, FIG.
`9) to allow users to manually rotate the plastic bolt in order
`to threadingly disengage the plastic bolt from the drain tube.
`Additional post-forming operations may be performed on 20
`the floor covering (Block 108). Such operations may
`include, but are not limited to, the addition of padding to the
`underside surface 10b of the molded floor covering 10 for
`providing cushioning, sound deadening, and thermal
`insulation, and the addition of carpeting to the exposed 25
`surface 10a of the molded floor covering 10.
`As would be known to one of skill in the art, padding may
`be formed from relatively inexpensive fibers such as jute or
`recycled waste fibers, and may be precut into predetermined
`desired shapes and bonded to the underside surface 10b of 30
`the floor covering 10. carpeting added to the exposed surface
`may suitably be of tufted, woven, knitted, or nonwoven
`construction in accordance with known methods of carpet
`manufacture.
`Referring now to FIGS. 7A and 7B, another embodiment 35
`of the present invention is illustrated. A threaded sleeve 60
`is threadingly engaged with the threaded member 16 prior to
`forming the molded floor covering 10. The purpose of the
`threaded sleeve 60 is to eliminate the potential for stripping
`and other thread damage during and after the molding 40
`process. In the illustrated embodiment, the layer of thermo(cid:173)
`plastic polymer 45 has been formed via mold 40 to produce
`a molded floor covering 10 having opposite first and second
`surfaces 10a, 10b and a drain tube 20 extending outwardly
`therefrom. The drain tube 20 includes an open proximate
`end 20b and a closed distal end 20a. The threaded insert 60
`is integrally formed with the layer of thermoplastic polymer
`45. The threaded insert 60 may include outwardly projecting
`members, such as ribs or threads, on the outer surface
`thereof to facilitate bonding with the floor covering 10 50
`during formation of the elongate tube 20. FIG. 7B illustrates
`the plug 16 in a secured position threadingly engaged with
`the threaded insert 60 within the drain tube 20.
`Referring now to FIG. 8, a molded floor covering 110 for
`a vehicle floor, according to another embodiment of the 55
`present invention is illustrated. The floor covering 110 has
`opposite first and second surfaces 110a, 110b, and an
`elongate tube 120 extending outwardly therefrom, as illus(cid:173)
`trated. The elongate tube 120 includes a distal end 120a and
`an open proximate end 120b with a cylindrical inner wall 60
`121 that defines a cylindrical bore 122 having an axial
`direction A extending from the open proximate end 120b to
`the distal end 120a. The open proximate end 120b is
`integrally formed with the floor covering 110 and the
`elongate tube 120 is configured such that the distal end 120a 65
`can extend through an aperture (not shown) within a vehicle
`floor.
`
`6
`Preferably, a threaded insert 160 is integrally formed with
`the cylindrical inner wall 121 within the cylindrical bore 122
`as illustrated. The threaded insert 160 may include out(cid:173)
`wardly projecting members, such as ribs or threads, on the
`5 outer surface 162 thereof to facilitate bonding with the floor
`covering 110 during formation of the elongate tube 120. A
`fastener 170 that is configured to compressively engage a
`portion of a mat 180 disposed on the floor covering 110 is
`threadingly engaged with the threaded insert 160. The
`10 fastener 170 includes a head 171 having a circumferentially
`extending shoulder 172 that is configured to compressively
`engage a portion of the mat 180 disposed on the floor
`covering 110. The fastener 170 also includes a threaded
`shank 173 that is connected to the head 171 and that is
`15 configured to threadingly engage the threaded insert 160.
`In the illustrated embodiment, the fastener 170 also
`includes neck portion 174 between the head 171 and the
`threaded shank 173. The fastener neck portion 174 has a
`conical frustum shape. The proximate end 120b of the
`elongate tube 120 has a corresponding conical frustum shape
`that is configured to receive the neck portion 174 in coun-
`tersunk relation therewith, as illustrated. The fastener 170
`allows a mat to be quickly secured to and removed from the
`floor covering 110.
`The foregoing is illustrative of the present invention and
`is not to be construed as limiting thereof. Although a few
`exemplary embodiments of this invention have been
`described, those skilled in the art will readily appreciate that
`many modifications are possible in the exemplary embodi(cid:173)
`ments without materially departing from the novel teachings
`and advantages of this invention. Accordingly, all such
`modifications are intended to be included within the scope of
`this invention as defined in the claims. Therefore, it is to be
`understood that the foregoing is illustrative of the present
`invention and is not to be construed as limited to the specific
`embodiments disclosed, and that modifications to the dis(cid:173)
`closed embodiments, as well as other embodiments, are
`intended to be included within the scope of the appended
`claims. The invention is defined by the following claims,
`with equivalents of the claims to be included therein.
`That which is claimed is:
`1. A molded floor covering for a vehicle floor, wherein the
`vehicle floor includes an aperture formed therethrough, the
`molded floor covering comprising:
`a thermoplastic polymer layer adapted to conform to a
`contour of the vehicle floor having opposite first and
`second surfaces;
`an elongate tube extending outwardly from the thermo(cid:173)
`plastic polymer layer, including an open proximate end
`and a distal end, a cylindrical bore defining an axial
`direction and extending from the open proximate end to
`the distal end, wherein the open proximate end is
`integrally formed with the thermoplastic polymer layer,
`and wherein the elongate tube is configured such that
`the distal end thereof can extend through the vehicle
`floor aperture;
`a cylindrical internally threaded insert disposed within the
`cylindrical bore; and
`a fastener that compressively engages a portion of a mat
`disposed on the floor covering, comprising:
`a head having a circumferentially extending shoulder
`that is configured to compressively engage a portion
`of the mat disposed on the floor covering; and
`a threaded shank connected to the head, wherein the
`threaded shank is configured to threadingly engage
`the threaded cylindrical bore for moving the head of
`
`45
`
`

`

`US 6,361,099 Bl
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`7
`the fastener along the axial direction toward and
`away from the proximate end when the fastener is
`rotated about the axial direction in respective oppo(cid:173)
`site directions.
`2. A molded floor covering according to claim 1 wherein s
`the fastener comprises a neck portion between the head and
`the threaded shank that has a conical frustum shape and
`wherein the proximate end of the elongate tube has a
`corresponding conical frustum shape that is configured to
`receive the neck portion in countersunk relation therewith. 10
`3. A molded floor covering according to claim 1 wherein
`the fastener head comprises a tool engaging aperture for
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`8
`engagement with a tool for rotating the drain plug about the
`axial direction.
`4. A molded floor covering according to claim 1 wherein
`the fastener head comprises a portion configured to be
`grasped by a user for manually rotating the drain plug about
`the axial direction.
`5. A molded floor covering according to claim 1 wherein
`the thermoplastic polymer layer is formed from an ethylene/
`vinyl acetate copolymer.
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`* * * * *
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