a2) United States Patent
`US 8,910,995 B2
`(0) Patent No.:
`Dec. 16, 2014
`(45) Date of Patent:
`MacNeil et al.
`
`US008910995B2
`
`USPC iececescsseeseesstenscnsseneenees 296/97.23; 296/39.1
`(58) Field of Classification Search
`CPC..... B60R 21/02; B29D 99/0057; B60N 3/044
`USPC wees 296/97.23, 39.1; 29/527.1; 15/215;
`700/17, 98
`See application file for complete search history.
`
`(56)
`
`References Cited
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`
`2,188,342 A
`2,709,105 A
`
`1/1940 England
`5/1955 Kramer
`
`(Continued)
`
`FOREIGN PATENT DOCUMENTS
`
`CA
`CA
`
`1101016 A
`1198466 A
`
`5/1981
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`
`(Continued)
`OTHER PUBLICATIONS
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`Japanese Patent Office, Rejection issued in connection with Japanese
`Patent Application No. 2005-317635 dispatched on Jan. 5, 2011.
`
`(Continued)
`
`Primary Examiner — Pinel Romain
`(74) Attorney, Agent, or Firm — Perkins IP Law Group LLC;
`Jefferson Perkins
`
`(57)
`
`ABSTRACT
`
`Points on a surface of a vehicle foot well are digitally mea-
`sured with a coordinate measuring machine. A vehicle foot
`well surface model is recreated in an electronic memory to
`include these points. The foot well surface model is in turn
`used to construct a moldfor a vehicle floor tray, which ensures
`a snugfit.
`
`3 Claims, 12 Drawing Sheets
`
`(54)
`
`DESIGNING AND MANUFACTURING
`VEHICLE FLOOR TRAYS
`
`(71)
`
`Applicant: MacNeil IP LLC, Bolingbrook, IL (US)
`
`(72)
`
`Inventors: David F. MacNeil, Hinsdale, IL (US);
`Scott A. Vargo, Lombard, IL (US)
`
`(73)
`
`Assignee: MacNeil IP LLC, Bolingbrook, IL (US)
`
`(*)
`
`Notice:
`
`Subject to any disclaimer, the term ofthis
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`(21)
`
`Appl. No.: 13/773,706
`
`(22)
`
`Filed:
`
`Feb. 22, 2013
`
`(65)
`
`(60)
`
`Prior Publication Data
`
`US 2013/0161863 Al
`
`Jun. 27, 2013
`
`Related U.S. Application Data
`
`Continuation of application No. 13/595,703, filed on
`Aug. 27, 2012, now Pat. No. 8,382,186, which is a
`continuation of application No. 12/879,899, filed on
`Sep. 10, 2010, now Pat. No. 8,267,459, which is a
`continuation of application No. 11/463,203, filed on
`Aug. 8, 2006, now abandoned, whichis a division of
`application No. 10/976,441, filed on Oct. 29, 2004,
`now Pat. No. 7,316,847.
`
`(51)
`
`Int. Cl.
`
`BOON 3/04
`GO6F 17/50
`B6OR 21/02
`B29D 99/00
`US. Cl.
`
`(52)
`
`(2006.01)
`(2006.01)
`(2006.01)
`(2010.01)
`
`CPC wee B29D 99/0057 (2013.01); B6ON 3/048
`(2013.01); GO6F 17/5086 (2013.01); B6OR
`21/02 (2013.01); BOON 3/044 (2013.01)
`
`
`
`700
`
`701
`
`702
`
`703
`
`720
`
`722
`
`726
`
`705
`
`706
`
`
`
`
`
`
`
`
`
`IMPORT RESERVOIR,
`
`
`CHANNELS
`
`
`704
`
`
`[soewAs_|TRAYDATAFILE
`DRAW LINES BETWEEN LOCI
`724
`LOFT SIDEWALL AREAS
`
`TRIEXTRUSION
`SHEETS
`
`FIT CURVES
`
`
`
`
`
`
`ADJUST FOR SURFACE
`IRREGULARITIES
`
`CMM VEHICLE FOOT WELL
`POINT AQUISITION
`
`SPLINES
`
`VEHICLE FOOT WELL
`SURFACE MODEL
`
`TOP, BOTTOM SKETCH PLANES
`
`TOP SKETCH PLANE LOCUS
`
`BOTTOM SKETCH PLANE LOCUS
`
`EX1034
`Yita v. MacNeil
`
`IPR2020-01139
`
`EX1034
`Yita v. MacNeil
`IPR2020-01139
`
`

`

`(56)
`
`
`
`
`
`
`
`ADNNNDANAPANPNNESSANSSPASSPANSANESPANSSPASESPALPAPPPPPAPPSPSPPrEErPPY
`
`US 8,910,995 B2
`
`Page 2
`
`U.S. PATENT DOCUMENTS
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`References Cited
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`
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`Chen
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`9/2009 MacNeil
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`Reuben
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`CA
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`Dupontet al.
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`Morawski
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`Peoples,Jr. et al.
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`Tanaka
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`1863477 U
`DE
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`Peress
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`DE
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`9/1987
`Dresenetal.
`1/2001
`19928720 Al
`DE
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`1/1988
`3/1988
`0258162 A2
`EP
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`Bailey
`5/1989
`8/1990
`0379630 Al
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`Bailey
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`0968875 Bl
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`Thundercloud
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`Montalciniet al.
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`H3-47245
`JP
`5,019,993
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`McKendrick
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`406227305 A
`JP
`5,208,995
`10/1993
`Gordon
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`JP
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`1/1994
`Primeau
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`Thundercloud
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`JP
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`2/2000
`200052835
`JP
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`Woosley
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`Primeau
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`2002-362209 A
`JP
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`JP
`D372,011
`Tyler
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`MacNeil
`
`WO 95/34443 Al=12/1995
`D377,780
`3/1998
`5,725,926
`Wang
`4/1998
`Kraines
`D393,238
`5/1998
`Mauffette
`D394,037
`T/N998
`5,776,583
`Peyton
`Koa
`11/1998
`5,830,560
`1/1999
`5,856,828
`Letcher, Jr.
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`D408,342
`‘Yang
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`5,891,546
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`5,919,540
`Bailey
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`Jacobson
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`Tacovelli et al.
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`2/2000
`Hudkinsetal.
`6,022,503
`2/2000
`Sherman
`6,027,782
`Lu
`4/2000
`D422,256
`5/2000
`Rizvi
`D425,005
`5/2000
`6,058,618
`Hemmelgarnet al.
`Lu
`8/2000
`D429,204
`Lu
`10/2000
`D432,478
`12/2000
`Sherman
`6,155,629
`Lu
`5/2001
`D442,530
`7/2001
`6,261,667
`‘Yang
`Lu
`3/2002
`D454,323
`Lu
`3/2002
`D454,324
`5/2002
`Kraines
`D457,845
`8/2002
`6,431,629
`Emery
`3/2003
`Kraines
`D471,850
`Bl
`3/2003
`6,534,146
`Mentz,Jr.
`Bl
`Peterson
`6/2003
`6,578,896
`B2
`8/2003
`Ferreira et al.
`6,605,333
`Bl
`Lu
`1/2004
`6,677,027
`Ss
`5/2004
`Kraines
`D489 ,306
`B2
`Jones
`5/2004
`6,732,030
`B2
`5/2004
`Gebreselassieet al.
`6,736,442
`Ss
`6/2004
`Kraines
`D491,122
`Bl
`Buss
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`6,793,872
`Bl
`9/2004
`Tacovelli et al.
`6,794,013
`B1* 10/2004
`6,804,568
`Miyazaki et al. ww. 700/98
`Ss
`11/2004
`Lafleur
`D499,057
`Bl
`11/2004
`Stanesic
`6,817,649
`
`Canadian Intellectual Property Office, Requisition by the Examiner
`issued in connection with Canadian Patent Application No.
`2,672,095, Jan. 14, 2011.
`Photographs of Ford Windstar floor mat with unknown manufacture
`date, obtained by Applicant in 2010, and believed to be on sale and in
`public use prior to Oct. 29, 2003.
`Canadian Intellectual Property Office, Requisition by the Examiner
`issued in connection with Canadian Patent Application No.
`2,672,423, Dec. 14, 2010.
`US. Patent and Trademark Office, Office Action issued on U.S. Appl.
`No. 11/463,203 on Aug. 13, 2009.
`US. Patent and Trademark Office, Office Action issued on U.S. Appl.
`No. 11/934,320 on Jun. 10, 2009.
`US. Patent and Trademark Office, Office Action issued on U.S. Appl.
`No. 12/332,757 on Jun. 11, 2009.
`Canadian Intellectual Property Office, Requisition by the Examiner
`dated Dec. 17, 2009 on Canadian Patent Application No. 2,672,116.
`Canadian Intellectual Property Office, Requisition on CA 2,672,095,
`dated Jan. 14, 2011.
`German Patent and Trademark Office, Official Action on DE 10 2005
`063 533.4-21, dated Sep. 1, 2011.
`Canadian Intellectual Property Office, Requisition on CA 2,672,097,
`dated on Dec. 19, 2011.
`Photographsof a Highland Floor Guard with unknown date ofmanu-
`facture, obtained by Applicant in 2010, and believed to be onsale and.
`in public use prior to Oct. 29, 2003.
`American Specialty Equipment Corp., “Big Book”catalog for “Per-
`formance Parts, Truck Accessories, and Sport Compact Equipment,”
`2000, p. 366.
`Add-On 2002-2003 Automotive Accessory Catalog, 2002, pp. 192
`and 447.
`Floor Mat Comparison Chart, Stylinconcepts.com, Jun. 2, 2002.
`
`

`

`US 8,910,995 B2
`
`Page 3
`
`(56)
`
`References Cited
`OTHER PUBLICATIONS
`
`Advertisement for Highland’s Black ArmorFloor Guard,Stylin Con-
`cepts “Custom Truck Accessories” catalog, 2003, pp. 1, 2 and 109.
`Image
`from advertisement
`for Black Armor Floor Guard,
`Stylinconcepts.com; Apr. 3, 2002, recovered from http://webarchive.
`org/20020403 23023 1/stylinconcepts.com/Images/
`BlackArmorWLogojpg.
`List of “front custom auto floor mats”, etrailer.com (as downloaded
`by web.archive.org), Jun. 4, 2004.
`Description and illustration of “Front Custom Auto floor Mats”;
`etrailer.com (as downloaded by web.archive.org), Jun. 4, 2004.
`Advertisement for Highland floor guards, Counterman Info Pages,
`prior to Nov. 2002, p. 27.
`Highland Catalog and Jobber sheet; prior to 2004.
`Highland Application Guide, 2004.
`Volvo Accessories brochure, 1990, pp. | and 23.
`Volvo 760 GLE Accessories Brochure, 1983, pp. 1-3.
`Volvo Accessories brochure, 1981, pp. 1, 27.
`Volvo Accessories brochure, 1983, p. 1, 11, 16.
`Photographs of Volvo floor mat with unknown manufacture date,
`obtained by Applicant in 2010, and believed to be on sale and in
`public use prior to Oct. 29, 2003.
`Photographs of a Husky Liner floor tray with unknown manufacture
`date, obtained by Applicant in 2010, and believed to be on sale and in
`public use prior to Oct. 29, 2003.
`Husky Liners Product Catalog, 2001, pp. 1-2.
`Husky Liners Product Catalog, 2002, selected pages.
`Husky Liners Product Catalog, 200314, SEMA Show Edition,
`selected pages.
`Photographs of Winfield’s Husky Liner Model 3780 for 2000-2001
`BMW X-5 possessed by Applicant, believed to be on sale and in
`public use prior to Oct. 29, 2003.
`1998 Lund Product Catalog, p. 24, Lund SportMat Molded Floor
`Trays.
`Webadvertisement for Fox Weatherboots, foxweatherboots.com (as
`downloaded by web.archive.org), Mar. 3, 2000.
`Nifty Products Catalog, 2003-2004, selected pages.
`Advertisement of unknown publication date for Husky Liner 3D
`Molded Carpeted Front Floor Liners, obtained by Applicantin 2010,
`and believed to be on sale and in public use prior to Oct. 29, 2003.
`Photographs of Husky Liner 3D Floor Liners manufactured Aug.
`2010, in possession of Applicant, and believed to be on sale and in
`public use prior to Oct. 29, 2003.
`Geomagic Press Release, “Geomagic, Inc. Wins Second Computer
`Graphics World Innovation Award,” Dec. 10, 1998.
`Geomagic Press Release, “Geomagic to Introduce Unique Solution
`for 3D Content Creation at SIGGRAPH ’99,” Aug. 3, 1999.
`Geomagic Press Release, “Geomagic Announces Geomagic Studio
`2.0,” Jan. 14, 2000.
`Geomagic Press Release, “Geomagic, QTE Offer RevQuick, Auto-
`matic Surface Generation for Mastercam,” Sep. 25, 2000.
`Advertisement, “Third Party Options (Romer, A CimCore Com-
`pany),” 2000.
`Son, Seokbae; Park, Hyunpung; and Lee, Kwan; “Automated laser
`scanning system for reverse engineering and inspection,” Int. J.
`Machine Tools & Manufacture, 42, 889-897 (2002).
`“Competition Rising in Portable CMMs,” Quality Magazine, May 5,
`2003.
`Press Release by Brown and Sharpe, “Portable K Series Optical
`CMMs,”Sep. 1, 2002.
`“CAM2software,” as downloaded from http://web.archive.org/web/
`200402 150656 13/www.faro.com/Products on Nov.4, 2010.
`“Laser Scanner edges out CMM in the race to market,” Machine
`Design.com, Feb. 5, 2004.
`“Highres Delivers Complete Reverse Engineering Software Suite for
`SolidWorks 2001Plus,” Reverse Engineering.com, Apr. 25, 2002.
`
`“HighRes Provides 3D Reverse Engineering Software to Higher
`Education Learning Institutions”, ReverseEngineering.com, May 21,
`2002.
`“HighRes Reverse Engineering Software now Ships with Every
`Romer 3000i and Stinger II Portable CMM in North America,”
`ReverseEnginering.com, Oct. 14, 2002.
`Press Release, “FARO Debuts Affordable Advantage“ Line of Mea-
`surement Products,” Sep. 4, 2003.
`Canadian Intellectual Property Office, Requisition by the Examiner
`in connection with Canadian Patent Application No. 2,672,423 dated.
`Dec. 14, 2010.
`Husky Liner for 1999 Ford Super Duty, downloaded from http://
`www.huskyliners.com/superduty.html on Jan. 3, 2005.
`Autofomi Trunk Liner, English web page, downloaded from http://
`www.autoform.se/eng/products_trunk_liners.htm on Oct. 20, 2004.
`“Installation Instructions for Your F-150/F-250 Ford Truck Front
`Floor Liners”, Winfield Consumer Products, Feb. 1, 2001, down-
`loaded from http://www-huskyliners.com on Jan. 3, 2005.
`Husky Deep Tray Floor Liner, downloaded from http://www.
`truckstuffusa.com/cusfitdeeptr-html on Jan. 3, 2005.
`Webpagesfeaturing products from 3D Carpet Liners, Weatherboots,
`Nifty Products,
`Inc. and Husky, downloaded from http://www.
`premiermotoring.net on Aug. 11, 2004.
`WeatherTech Floor Mat and Cargo Liner Product Sheets, MacNeil
`Automotive Products Limited, Downers Grove, IL, Nov. 1994, 4 pp.
`Faro Laser ScanArm, downloaded from http://www.faro.com/Prod-
`ucts/ScanArm.asp on Sep. 23, 2004.
`Faro ScanArm Product Techsheet, downloaded. from http://www.
`faro.com/Products/Product_Techsheet.asp?techsheet_id=106
`on
`Oct. 11, 2004.
`“CMM Produces Bikes With Custom-Look”, downloaded from
`http://manufacturingcenter.com/man/articles/0604/0604CMM.asp
`on Oct. 11, 2004.
`“Stereolithography (SLA) for Rapid Precision Prototypes”, p. 1,
`downloaded from http://www.boedeker.com/sla.htm on Oct. 12,
`2004.
`“About Coordinate Measuring Machines (CMM)”, downloaded from
`http://emm.globalspec.com on Oct. 11, 2004.
`“Bagagerumsmattor’, downloadedfrom http://www.autoform.se/sv/
`produkter_bagagerumsmattor.htm on Oct. 20, 2004.
`Strictly Catalog for Explorer/Mountaineer/Expedition/Navigator.
`MacNeil Automotive Products Limited, Downers Grove, IL, 1999,
`pp. 1-2 and 4-7.
`British Patent Office, Search Report on GB Patent Appin. No. GB
`0522091.8, Claims 47-66, 77 and 78, Jun. 23, 2006.
`British Patent Office, Search Report on Patent Appin. No. GB
`052209 1.8, Claims 67-70, Jun. 26, 2006.
`British Patent Office, Search Report on Patent Appin. No. GB
`052209 1.8, Claims 71-73, Jun. 27, 2006.
`British Patent Office, Search Report on Patent Appin. No. GB
`052209 1.8, Claims 79-84 and 101-105, Jun. 23, 2006.
`British Patent Office, Search Report on Patent Appin. No. GB
`522091.8, claims 85-100, Jun. 27, 2006.
`British Patent Office, Search Report on Patent Appin. No. GB
`0522091.8, claims 1-46 and 74-76, Feb. 14, 2006.
`Canadian Intellectual Property Office, Requisition by Examiner
`issued on Canadian Application No. 2,524,795 on Apr. 23, 2008.
`US. Patent and Trademark Office, Office Action issued on U.S. Appl.
`No. 11/463,215 on Nov. 27, 2007.
`US. Patent and Trademark Office, Office Action issued on U.S. Appl.
`No. 11/463,215 on Jun. 6, 2007.
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`0625354.6 dated Nov.6, 2007.
`British Patent Office, Search Report on GB Appin. No. 0625354.6
`dated Mar. 3, 2008.
`
`* cited by examiner
`
`

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`l
`
`Cp
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`Dec. 16, 2014
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`
`
`a| l
`1
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`[
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`—
`
`™,
`
`%,
`
`\\N\\\\
`
`\
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`

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`U.S. Patent
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`Sheet 6 of 12
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`US 8,910,995 B2
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`100
`
`600
`
`604
`
`
`
`7 —t
`
`|
`_-
`|
`
`ff}
`
`606
`
`300
`
`FIG. 6
`
`700
`
`701
`
`702
`
`CMM VEHICLE FOOT WELL
`POINT AQUISITION
`
`SPLINES
`
`VEHICLE FOOT WELL
`SURFACE MODEL
`
`ADJUST FOR SURFACE|-707
`
`703“1Top, BOTTOM SKETCH PLANES IRREGULARITIES
`
`720[TOPSKETCHPLANELOCUSIMPORT RESERVOIR, 709
`
`
`
`
`TOP SKETCH PLANE LOCUS
`CHANNELS
`
`BOTTOM SKETCH PLANE LOCUS
`
`SHELL
`
`722
`
`704
`
`126 —_—
`
`711
`
`708
`
`SIO
`
`TRIEXTRUSION
`
`
`
`
`TRAY DATA FILE
`
`FIG. 7
`
`

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`US 8,910,995 B2
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`1
`DESIGNING AND MANUFACTURING
`VEHICLE FLOOR TRAYS
`
`RELATED APPLICATIONS
`
`2
`the products currently in the marketplace have limited con-
`sumer acceptance because oftheir loose fit inside the foot
`well. There is often, and in manyplaces, a considerable space
`between the exterior wall of these conventional trays and the
`interior surface of the foot well. This causes the wall to
`
`This application is a continuation of copending U.S. Non-
`provisional application Ser. No. 13/595,703 filed on Aug. 27,
`2012, which is in turn a continuation of U.S. Nonprovisional
`application Ser. No. 12/879,899 filed on Sep. 10, 2010, now
`USS. Pat. No. 8,267,459, which is in turn a continuation of
`US. Nonprovisional application Ser. No. 11/463,203filed on
`Aug. 8, 2006, now abandoned, whichis in turn a division of
`US. Nonprovisional application Ser. No. 10/976,441 filed on
`Oct. 29, 2004, now U.S. Pat. No. 7,316,847. The disclosures
`and drawings of those applications are fully incorporated by
`reference herein.
`
`BACKGROUND OF THE INVENTION
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`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
`fora floor tray that will have a more exactfit to the vehicle foot
`well for which it is provided, that stays in place onceit is
`installed, and that provides a moresolid andcertain feel to the
`occupants’ feet.
`Somevehicle floor mats that are now on the market have
`fluid reservoirs built into them. Particularly in cold or wet
`climates, dirty water has a tendencyto 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 matandstain the carpeting ofthe
`foot well that the mat was meant to protect. These reservoirs
`typically are recessed areas in the mats that provide the mats
`with an enhancedability to retain snow-melt and the like,
`until the water evaporates or can be disposed ofby the vehicle
`owner or user. One advanced design places treads in the
`middle of the reservoir, such that the feet of the occupant are
`held above any fluid that the reservoir collects. But including
`such a reservoir within a floor tray that otherwise has an
`acceptablefit to the surface of a vehicle foot well has not yet
`been done, since there are problemsin incorporating a three-
`dimensionalliquid-holding vessel into a product that ideally
`conforms, on its lower surface, to the surface ofthe foot well.
`Further, a reservoir which collects drip water from a large
`surface, such as a vehicle floor tray, will exhibit more prob-
`lems in keeping the collected fluid from sloshing aboutin a
`moving vehicle.
`Conventional vehicle floor mats and trays are molded from
`a single rubberorplastic material. The selection of this mate-
`rial is controlled by its cost, its resistance to shear forces, its
`tensile strength, its abrasion resistance, its ability to conform
`to the surface of the vehicle foot well, its sound-deadening
`properties and how slippery or nonslippery it is relative to the
`occupants’ feet, with nonslipperiness (having a relatively
`high coefficient of friction) being advantageous. Often the
`designer must make tradeoffs amongthese different design
`constraints in specifying the material from which the tray or
`matis to be made.
`
`SUMMARY OF THE INVENTION
`
`Motor vehicles are almost always operated in the out of
`doors and are frequently parked there. It is therefore very
`common for their occupants to have wet or muddy feet—if
`the occupants have not just finished an outdoor activity, at
`least they have had to walk across a possibly wet, snowy or
`muddy surface to access their vehicles. For decades, there-
`fore, vehicle owners have been attempting to protect the
`enclosed interiors of their vehicles (cars, trucks, SUVs) from
`whatthey themselvestrack into them. The conventional solu-
`tion to this has been to provide a vehicle floor mat which may
`be periodically removed by the owner and cleaned.
`Humanbeings have a tendency to movetheir feet around,
`and foot motion is an absolute requirementin operating most
`vehicles. This has caused a problem,in that the occupants of
`a vehicle have a tendency to push aroundthe floor mats with
`their feet. The floor mats end up not being centered on the area
`protected, or pushed up so as to occlude the gas, brake or
`clutch pedals, or bunched up or folded over—all undesirable
`conditions. One objective of floor mat manufacturers has
`therefore been to provide a floor mat that will stay put and
`which will not adversely affect vehicle operation.
`The foot wells of cars, trucks and SUVs vary in size in
`shape from one modelofvehicle to the next. Floor mat manu-
`facturers have noticed that floor mats whichat least approxi-
`mately conform to the shape of the bottom surface of the foot
`well stay in place better and offer more protection.It is also
`common for such floor mats, where provided for front seat
`foot wells, to have portions which are meantto lie against the
`firewalls or front surfaces of the foot wells. Even as so
`According to one aspect of the invention,there is provided
`a vehicle floor cover, mat or tray which is removably install-
`extendedit is not too hard to provide a floor mat of flexible
`able by a consumer and which is formed ofat least three
`material that will approximately conform to these two sur-
`layers that are bonded together, preferably by coextrusion.
`faces, as the designer only has to mark a two-dimensional
`Thethree layers include a central layer whose composition is
`periphery of the mat in providing one which will fit reason-
`distinct from a bottom layer and a top layer. Preferably,all
`ably well.
`three layers are formed of thermoplastic polymer materials.
`Morerecently, vehicle floor trays have comeonto the mar-
`In another aspect of the invention, the top layer exhibits a
`ket. Most front-seat vehicle foot wells are actually three-
`kinetic coefficient of friction with respect to a sample meant
`dimensional concave shapes, typically with complex curved
`to emulate a typical shoe outsole (neoprene rubber, Shore A
`surfaces. Floor trays have sidewalls that offer enhanced pro-
`Durometer 60) of at least about 0.82.
`tection to the surfaces surrounding the vehicle floor, as might
`Preferably, a major portion of the central layer is a poly-
`be needed against wearers with very muddy or snowy shoes.
`olefin. More preferably, the polyolefin is either a polypropy-
`Conventional vehicle floor trays try to fit into these three-
`dimensional cavities, but so far their fit to the surfaces that
`lene ora polyethylene. Mostpreferably, the polyolefin is high
`molecular weight polyethylene (HMPE) asherein defined. In
`they are supposed to protect has been less than optimum. A
`an alternative embodiment, the centrallayer can be a styrene-
`conventionalvehicle floor tray is typically molded ofa single-
`acrylonitrile copolymer (SAN)or an acrylonitrile-butadiene-
`ply rubberor plastic material, exhibits enough stiffness to
`retain a three-dimensional shape,butis also at least somewhat
`styrene (ABS) polymerblend.
`
`flexible. Fitting suchatray to the complex three-dimensional Preferably, a major portionofthe top layer is a thermoplas-
`surface of a vehicle foot well has proven to be difficult, and
`tic elastomer, such as one of the proprietary compositions
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`US 8,910,995 B2
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`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
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`shear strength per cross-sectional area, tensile strength per
`cross-sectional area and stiffness per cross-sectional area is
`greater than any oneofthe layers from whichthe tray or mat
`is composed.It has been foundthata triextruded vehicle mat
`or floor tray according to the invention exhibits a tensile
`strength at yield, a tensile stress at break, a tensile modulus, a
`shear strength and a flexural modulus (stiffness) which are
`superior to either a polyolefin-dominated single extrusion or
`a thermoplastic elastomer-dominated single extrusion. The
`triextrusion tray demonstrates these enhanced physical prop-
`erties while at the same time affording an enhanced coeffi-
`cient of friction to the feet of the occupant and improved
`tactile properties. By presenting such a surface to the shoe of
`the driver or passenger, the footing of the driver or passenger
`will be more sure and comfortable.
`Ina further aspect of the invention, a vehicle foot well tray
`is providedasa part of a system that has the vehicle foot well
`as its other main component. Thetray has a greatly enhanced
`conformanceto the surface of the vehicle foot well for which
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`sold under the trademarks SANTOPRENE®, GEOLAST®
`and VYRAM®. VYRAM® is particularly preferred.
`In
`another embodiment, a major portion of the top layer can be
`anABS polymerblend. Where ABSisused in both the top and
`central layers, it is preferred that the amountof the polybuta-
`diene phasein the top layer be greater than the amountofthis
`phasein the central layer.
`It is further preferred that a major portion of the bottom
`layer likewise be a thermoplastic elastomer, and conveniently
`it can be, but does not haveto be, of the same composition as
`the major portion of the top layer.
`Preferably one or moreofthelayers is actually a polymer
`blend, in which a minorportion 1s preselected for its coextru-
`sion compatibility with the adjacent layer(s). Thus, a minor
`portion of the top and bottom layers can consist of a polyole-
`fin, 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
`weightof eachlayer, or a weight ratio of 1:3. Where all three
`layers are preselected to be ABS blends, the amountofpolyb-
`utadiene preferably is decreasedin the central layer relative to
`the top and bottom layers.
`While the preferred embodimentofthe vehicle floor cover
`upstanding walls ofthe tray which is adjacent the top margin,
`consists of three integral layers, any one ofthe recited layers
`90% of that top third area departs by no more than about
`can in fact be madeup oftwo or more sublayers, such that the
`one-eighth of an inch from the foot well surfaces to which
`total number of sublayers in the resultant mat or tray can
`exceedthree.
`they mate. These upstanding tray surfaces may be opposed
`surfaces or adjacent surfaces, and preferably are both. In a
`In another embodiment, the thermoplastic elastomer con-
`preferred embodiment, the tray departs from a doorsill sur-
`stituent of the top, central and/or bottom layers described
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`face of the vehicle foot well, and/orasill curve of the vehicle
`above can be replaced with a natural or synthetic rubber,
`including styrene butadiene rubber, butadiene rubber, acry-
`foot well, by about 0.025 inches. The upstanding sidewalls of
`lonitrile butadiene rubber (NBR) or ethylene propylene rub-
`the floor tray conform to the foot well surfaces which they
`ber (EPDM).
`cover, even where such foot well surfaces present both con-
`cave and convex surface elements.
`According to a related aspect of the invention, a vehicle
`floor cover is provided that has three layers bonded together,
`In a still further aspect of the invention, a top margin of a
`preferably by coextrusion. Major portions of the top and
`vehicle floor tray is substantially coplanar on at least two
`bottom layer consist of thermoplastic elastomer(s). The top
`upstanding sidewalls thereof. Preferably, the top margin of
`and bottom layers have compositionsdistinct from the central
`the tray is substantially coplanar through three or even four
`layer, which can be chosenforits relatively low expense.It is
`continuous upstanding sidewalls. This eases the design ofthe
`preferred that a major portion of the central layer be a poly-
`floor tray,
`increases hoop strength and assures that all
`olefin and that major portions of the top and bottom layers be
`upstanding surfaces of the vehicle foot well will receive
`one or more thermoplastic elastomers. The polyolefin may be
`adequate protection from muddy footwear. In a particularly
`selected from the group consisting of polypropylene and
`preferred embodiment, the plane of the top margin is for-
`polyethylene, and preferably is a high molecular weightpoly-
`wardly and upwardlytilted relative to a horizontal floor. This
`ethylene (HMPE). The thermoplastic elastomer can, for
`provides enhanced protection to the vehicle foot well pre-
`example, be SANTOPRENE®, GEOLAST® or VYRAM®,
`cisely in the place where muddy footwearare likely to be,
`with VYRAM®beingparticularly preferred. It is also pre-
`near the accelerator, brake and clutch pedals or the firewall. In
`ferred that each ofthe layers be a polymerblend, with a minor
`a preferred embodiment, the tray is at least five inches deepat
`portion of each layer being chosen for its coextrusion com-
`its deepestpart.
`patibility with adjacent layers. For example, the top and bot-
`In a further aspect of the invention, the above mentioned
`tom layers can consist of a 3:1 weight ratio of VYRAM®/
`tight tolerances are made possible by a novelvehicle floortray
`HMPE,andthe central layer of a 3:1 weight ratio of HMPE/
`manufacturing method.In a first step according to the inven-
`VYRAMB®.
`tion, 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
`portionsofthe foot well surface. Usingthis typically complex
`three-dimensional, predominately concave surface, which
`may haveseveral concavely and convexly curved portions, a
`corresponding substantially convex outerfloortray surfaceis
`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 snugfit.
`In one embodiment of the invention, a reservoir is incor-
`porated into the tray flooras a collection and evaporation area
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`In an embodimentalternative to the one above, the top and
`bottom layers can consist of ABS polymer blends and the
`central layer can consist of SAN or an ABS in which the
`polybutadiene phase is present in a smaller concentration
`than in the top and bottom layers.
`In yet another embodiment, the thermoplastic elastomer
`recited in this aspect of the invention may be replaced with a
`natural or synthetic rubber, such as styrene butadiene rubber
`(SBR), butadiene rubber, acrylonitrile butadiene rubber
`(NBR) or ethylene propylene rubber (EPDM).
`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
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`US 8,910,995 B2
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`5
`for drip water from the feet and legs of the occupant. Com-
`bination baffles/treads are providedin the reservoir to impede
`lateral movement of the collected fluid. Longitudinal and
`transverse portionsofthese baffles are joined together. Chan-
`nels are cut into another portion ofthe 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 ofthe reservoir. In a preferred driver’s side embodi-
`ment, the channels are omitted from a portion ofthe floortray
`upper surface to leave a blank space where the driver’s heel
`will rest when operating the gas and brake pedals.
`In a further aspect, a vehicle floor tray has a central panel
`for placementon the floor of a vehicle foot well, andat least
`first and second upstanding panels, joined to respective lon-
`gitudinal and transverse margins of the central panel, for
`substantial conformanceto side walls ofthe 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 andhas a width, in any
`horizontal direction, which is more than twiceits thickness as
`measured from the top surface thereofto 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 movementof the collected fluid within the
`reservoir, as might occur when the vehicle turns, accelerates
`or brakes. The fluid is forced around endsofthe tre