United States Patent (19)
`Bailey
`
`(11)
`45)
`
`Patent Number:
`Date of Patent:
`
`4,721,641
`Jan. 26, 1988
`
`56
`
`54 AUTO ACCESSORY FLOORMAT
`76 Inventor: Bob Bailey, R.D. #3, Maple Ave.,
`Ballston Lake, N.Y. 12019
`(21) Appl. No.: 730,192
`(22
`Filed:
`May 3, 1985
`51 Int. Cl'............................................... B05D 5/12
`52 U.S. C. ........................................ 428/88; 428/95;
`428/96; 428/158; 428/159; 428/160; 428/161;
`428/172; 428/192
`58 Field of Search ..................... 428/192, 88, 96, 95,
`428/158-161, 172; D12/203
`References Cited
`U.S. PATENT DOCUMENTS
`3,042,564 7/1962 Hankins ................................ 154/49
`3,804,699 4/1974 Johnson ................................ 161/39
`4,016,318 4/1977 Di Gioia et al. .
`... 428/95
`4,230,755 10/1980 Morris................................... 428/95
`4,382,986 5/1983 Reuben ................................. 428/88
`4,399,176 8/1983 Beil et al. .............................. 428/85
`4,465,720 8/1984 Bell et al. .................
`428/85
`4,529,639 7/1985 Peoples, Jr. et al.
`. 428/95
`4,579,764 4/1986 Peoples, Jr. et al. ................. 428/95
`FOREIGN PATENT DOCUMENTS
`2340496 4/1980 Fed. Rep. of Germany .
`2062861 9/1970 France .
`
`2547252 7/1983 France .
`OTHER PUBLICATIONS
`Volvo Accessories, All Models VPD 150-85.
`Primary Examiner-John E. Kittle
`Assistant Examiner-P. R. Schwartz
`Attorney, Agent, or Firm-Heslin & Rothenberg
`(57)
`ABSTRACT
`An accessory floor mat designed to overlie and protect
`a portion of the original carpeted floor of an automobile
`is preformed into a tray-like configuration which also
`conforms to the contours of the floor portion. The mat
`snugly fits into the carpeted floor well on a side of the
`vehicle and thereby resists mat sliding. The rigidity of
`the mat is such that it maintains its original position in
`the vehicle and also retains its shape when removed for
`cleaning. Raised borders of the matterminate in rolled
`edges which eliminate the need for surging or otherwise
`finishing these edges. Optionally the mat can be pro
`vided with a recessed heel pad. The composite carpet
`structure from which the mat is molded preferably
`includes a layer of carpet fibers tufted into a primary
`backing material which is bonded to a sheet of open
`celled foam by an extruded thermoformable copolymer
`of polyethylene and ethylene vinyl acetate.
`
`23 Claims, 6 Drawing Figures
`
`
`
`EX1053
`Yita v. MacNeil
`IPR2020-01139
`
`

`

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`US.Patent—Jan. 26, 1988 Sheet1 of 4 4,721,641
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`U.S. Patent Jan. 26, 1988
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`U.S. Patent
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`Jan. 26, 1988
`Jan. 26, 1988
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`US. Patent—Jan. 26, 1988 Sheet 3 of 4
`U.S. Patent Jan. 26, 1988
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`U.S. Patent
`US. Patent
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`Jan. 26, 1988
`Jan. 26, 1988
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`Sheet 4 of 4
`Sheet 4 of 4
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`4,721,641
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`A/G 6
`FIG. 6
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`1.
`1
`
`AUTO ACCESSORY FLOOR MAT
`AUTO ACCESSORY FLOORMAT
`
`10
`10
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`4,721,641
`4,721,641
`2
`2
`turing expense. Furthermore, these earlier mats appear
`turing expense. Furthermore, these earlier mats appear
`to be intended for generic use in all automobiles and,
`to be intended for generic use in all automobiles and,
`accordingly, are not especially well suited to accommo
`accordingly, are not especially well suited to accommo-
`date the particular cut-outs and contours of, and pro
`date the particular cut-outs and contours of, and pro-
`vide maximum protection to, the carpeted foot space of
`vide maximum protection to, the carpeted foot space of
`particular vehicle models.
`particular vehicle models.
`Molded mats made by injection molding of thermo
`Molded mats made byinjection molding of thermo-
`plastic materials and contoured for an exact fit to a
`plastic materials and contoured for an exact fit to a
`particular automobile floor have been commercially
`particular automobile floor have been commercially
`available. At least some of these thermoplastic mats
`available. At least some of these thermoplastic mats
`have featured raised borders and waffle patterns to trap
`have featured raised borders and waffle patterns to trap
`dirt, water and snow; rigid construction to permit fast,
`dirt, water and snow;rigid construction to permit fast,
`easy removal for cleaning; and a studded bottom sur
`easy removal for cleaning; and a studded bottom sur-
`face to prevent slipping. However, such mats lack the
`face to prevent slipping. However, such mats lack the
`plushness, fabric resiliency and water absorption capa
`plushness, fabric resiliency and water absorption capa-
`bility afforded by carpeted floor mats. Further, there is
`bility afforded by carpeted floor mats. Further, thereis
`a tendency with such thermoplastic mats for accumu
`a tendency with such thermoplastic mats for accumu-
`lated dirt to be ground into the occupant's shoes and/or
`lated dirt to be ground into the occupant’s shoes and/or
`for the shoes to sit in a puddle of water.
`for the shoes to sit in a puddle of water.
`For sometime, moldable carpeting has been used to
`For sometime, moldable carpeting has been used to
`cover the bare metal floor of automobiles; e.g. see U.S.
`cover the bare metal floor of automobiles; e.g. see U.S.
`Pat. No. 4,230,755. However, such original carpeting is
`Pat. No. 4,230,755. However, such original carpetingis
`generally adhesively secured to the underlying floor
`generally adhesively secured to the underlying floor
`and, accordingly, manufacturers thereof have not been
`and, accordingly, manufacturers thereof have not been
`concerned with the movement problem and other con
`concerned with the movement problem and other con-
`siderations associated with removable auto accessory
`siderations associated with removable auto accessory
`floor mats. To the best of Applicant's knowledge, here
`floor mats. To the best of Applicant’s knowledge, here-
`tofore no one has successfully developed an accessory
`tofore no one has successfully developed an accessory
`automotive floor mat which passively but positively
`automotive floor mat which passively but positively
`solves the mat shifting problem and at the same time
`solves the mat shifting problem and at the same time
`provides an easily removable, attractive carpeted sur
`provides an easily removable, attractive carpeted sur-
`face.
`face.
`
`BACKGROUNDOF THE INVENTION
`BACKGROUND OF THE INVENTION
`1. Field of the Invention
`1. Field of the Invention
`The present invention relates to mats for use in auto
`The present invention relates to mats for use in auto-
`mobiles and other motor vehicles and more particularly
`mobiles and other motorvehicles and moreparticularly
`to removable accessory mats designed to overlie and
`to removable accessory mats designed to overlie and
`protect carpeted automobile floors.
`protect carpeted automobilefloors.
`2. Background Information
`2. Background Information
`Floor mats of the "throw-in' or accessory type are
`Floor mats of the “throw-in” or accessory type are
`popularly used to protect the carpeted floor of automo
`popularly used to protect the carpeted floor of automo-
`biles. Such mats are generally manufactured with a
`biles. Such mats are generally manufactured with a
`planar configuration and are customarily made of an
`planar configuration and are customarily made of an
`15
`15
`elastomeric material sufficiently fexible to conform, in a
`elastomeric material sufficiently fexible to conform, ina
`general way, when placed in use, to the multiplicity of
`general way, when placed in use, to the multiplicity of
`shapes and contours characteristic of today's automo
`shapes and contours characteristic of today’s automo-
`bile floors. Sometimes, a carpet layer is secured to the
`bile floors. Sometimes, a carpet layer is secured to the
`top of the elastomeric material.
`top of the elastomeric material.
`20
`A primary concern with respect to such automobile
`20
`A primary concern with respect to such automobile
`floor mats is their tendency to shift or move from their
`floor matsis their tendency to shift or move from their
`intended position in response to lateral forces experi
`intended position in response to lateral forces experi-
`enced during occupant ingress egress and in the course
`enced during occupant ingress egress and in the course
`of normal driving operations. This can result in the
`of normal driving operations. This can result in the
`bunching gathering and general disarray of the mat on
`25
`bunching gathering and general disarray of the mat on
`the automobile floor; moreover, movement of the floor
`the automobile floor; moreover, movementof the floor-
`mat on the driver's side can present a significant safety
`mat on the driver’s side can present a significant safety
`hazardif the mat shifts so as to interfere with the accel-
`hazard if the mat shifts so as to interfere with the accel
`erator, brake pedal or other automobile controls. Auto
`erator, brake pedal or other automobile controls. Auto-
`30
`mobile manufacturers have experienced major liability
`30
`mobile manufacturers have experienced majorliability
`claims related to alleged floor mat movement, not to
`claims related to alleged floor mat movement, not to
`mention the toll in human suffering, property damage
`mention the toll in human suffering, property damage
`and increased insurance premiums arising from auto
`and increased insurance premiumsarising from auto
`accidents. Mat movement is, therefore, considered a
`accidents. Mat movement is, therefore, considered a
`serious and significant concern in relation to "throw-in'
`serious and significant concern in relation to “throw-in”
`35
`mats.
`Inats.
`To address this problem, attempts have been made in
`To address this problem, attempts have been madein
`the past to increase the coefficient of friction between
`the past to increase the coefficient of friction between
`the mat and the supporting carpeted automobile floor.
`the mat and the supporting carpeted automobilefloor.
`40
`Nibs or corrogations have been molded into the back of
`Nibs or corrogations have been molded into the back of
`40
`the elastomeric layer and/or an additional anti-skid
`the elastomeric layer and/or an additional anti-skid
`layer, such as a polyurethane coating, has been sprayed
`layer, such as a polyurethane coating, has been sprayed
`on the bottom ofthe elastomeric material. Others have
`on the bottom of the elastomeric material. Others have
`attempted to increase the staying power of their mats by
`attemptedto increase the staying powerof their mats by
`45
`embedding or securing rigidifying elements, e.g. rod
`embedding or securing rigidifying elements, e.g. rod-
`45
`like elements or thin, flat sheets, to the flexible elasto
`like elements or thin, flat sheets, to the flexible elasto-
`meric mat. See U.S. Pat. Nos. 4,399, 176 and 4,465,720.
`meric mat. See U.S. Pat. Nos. 4,399,176 and 4,465,720.
`Another approach (See U.S. Pat. No. 4,382,986) em
`Another approach (See U.S. Pat. No. 4,382,986) em-
`ploys a mat having a relatively stiff planar first section
`ploys a mat having a relatively stiff planarfirst section
`350
`adapted to contact a generally horizontal portion of an
`adapted to contact a generally horizontal portion of an
`50
`automobile floor and a second relatively flexible portion
`automobilefloor and a secondrelatively flexible portion
`hinged to said first portion and adapted to rest against
`hingedto said first portion and adapted to rest against
`an inclined firewall of the automobile. Other prior art
`an inclined firewall of the automobile. Other prior art
`efforts to reduce mat slippage have employed mechani
`efforts to reduce mat slippage have employed mechani-
`cal retaining means to fasten the accessory mat to the
`cal retaining means to fasten the accessory mat to the
`55
`underlying carpeted surface.
`underlying carpeted surface.
`U.S. Pat. No. 3,804,699 discusses a slip-resistant mat
`U.S. Pat. No. 3,804,699 discusses a slip-resistant mat
`in which agripping layer of resilient polymeric slit foam
`in which a gripping layerofresilient polymeric slit foam
`is bonded by a fused vinyl resin plastisol to a facing
`is bonded by a fused vinyl resin plastisol to a facing
`60
`layer of carpeted fabric. FIG.3 of this patent illustrates
`layer of carpeted fabric. FIG. 3 of this patentillustrates
`60
`application of the patented invention to an automotive
`application of the patented invention to an automotive
`mat in which flap sections are adapted to bend up
`mat in which flap sections are adapted to bend up-
`wardly (or downwardly) onto surfaces having slopes of
`wardly (or downwardly) onto surfaces having slopes of
`different angles and directions.
`different angles and directions.
`Although providing increased slip resistance, the
`65
`Although providing increased slip resistance,
`the
`65
`above described efforts have not been totally successful
`above described efforts have not been totally successful
`in eliminating mat slippage and, in some cases, have
`in eliminating mat slippage and, in some cases, have
`been accompanied by undue complexity and manufac
`been accompanied by undue complexity and manufac-
`
`SUMMARYOF THE INVENTION
`SUMMARY OF THE INVENTION
`The present invention answers this need by providing
`Thepresent invention answersthis need by providing
`an accessory floor mat of composite carpet structure
`an accessory floor mat of composite carpet structure
`molded or otherwise preformed into a tray-like shape
`molded or otherwise preformed into a tray-like shape
`which conforms to the contour of a portion of the car
`which conformsto the contour of a portion of the car-
`peted automobile floor. The mat is dimensioned and
`peted automobile floor. The mat is dimensioned and
`configured to nest within and abut against the sides of a
`configured to nest within and abut against the sides of a
`carpeted floor well of the vehicle. This snug fit in com
`carpeted floor well of the vehicle. This snug fit in com-
`bination with the rigidity of the mat prevents mat slid
`bination with the rigidity of the mat prevents matslid-
`ing. The mat is sufficiently rigid so that it not only
`ing. The mat is sufficiently rigid so that it not only
`maintains its original position within the vehicle and
`maintains its original position within the vehicle and
`withstands foot exerted lateral forces without shifting
`withstands foot exerted lateral forces without shifting
`but also retains its shape while being removed, thereby
`but also retains its shape while being removed, thereby
`facilitating cleaning. Raised borders of the mat advanta
`facilitating cleaning. Raised borders of the mat advanta-
`geously terminate in rolled or down turned edges which
`geously terminate in rolled or down turned edges which
`eliminate the need for serging or otherwise further fin
`eliminate the need for serging or otherwise further fin-
`ishing these edges.
`ishing these edges.
`The mat of the present invention is constructed in the
`The matof the present invention is constructed in the
`form of a laminated composite carpet structure from a
`form of a laminated composite carpet structure from a
`layer of carpet bonded to an open-celled foam sheet
`layer of carpet bonded to an open-celled foam sheet
`backing by a middle layer of extruded thermoformable
`backing by a middle layer of extruded thermoformable
`material. In the presently preferred embodiment, the
`material. In the presently preferred embodiment, the
`carpet comprises tufted carpet fibers secured to a
`carpet comprises tufted carpet
`fibers secured to a
`woven backing material by a coating of polyurethane;
`woven backing material by a coating of polyurethane;
`the foam sheet backing comprises flexible polyester
`the foam sheet backing comprises flexible polyester
`urethane; and the thermoformable polymer comprises a
`urethane; and the thermoformable polymer comprises a
`copolymer of polyethylene and ethylene vinyl acetate.
`copolymerof polyethylene and ethylene vinyl acetate.
`The carpet provides an attractive, resilient and absor
`The carpet provides an attractive, resilient and absor-
`bent top surface to the mat. The thermoformable poly
`bent top surface to the mat. The thermoformable poly-
`mer facilitates custom molding and affords appropriate
`mer facilitates custom molding and affords appropriate
`rigidity and water impregnability; while the foam back
`rigidity and water impregnability; while the foam back-
`ing provides an added measure of slip resistance as well
`ing provides an added measureofslip resistance as well
`as an attractive, printable rear surface. Together these
`as an attractive, printable rear surface. Together these
`constituents, constructed and arranged in accordance
`constituents, constructed and arranged in accordance
`
`

`

`15
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`4,721,641
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`The top of mat 10 comprises a layer of carpet 18
`with the teachings of this invention, provide a safer,
`The top of mat 10 comprises a layer of carpet 18
`with the teachings of this invention, provide a safer,
`which covers the base portion 12 as well as raised bor
`more attractive accessory floor mat than has heretofore
`which covers the base portion 12 as well as raised bor-
`moreattractive accessory floor mat than has heretofore
`ders 14. This top layer of carpet provides an extremely
`been available.
`ders 14, This top layer of carpet provides an extremely
`been available.
`attractive appearance, is resilient and moisture absor
`The invention further contemplates particular formu
`attractive appearance, is resilient and moisture absor-
`Theinvention further contemplates particular formu-
`bent. Although other types and grades of carpet may be
`lations and constructions of the components of the mat,
`bent. Although other types and grades of carpet may be
`lations and constructions of the components of the mat,
`used, most preferable is a tufted, cut pile carpet of syn
`an optional recessed heel pad, and a method of manufac
`used, most preferable is a tufted, cut pile carpet of syn-
`an optional recessed heel pad, and a method of manufac-
`thetic fibers in a woven, primary backing material, for
`turing the unique accessory floor mats.
`thetic fibers in a woven, primary backing material, for
`turing the unique accessory floor mats.
`example a 22 ounce nylon pile carpet may be employed.
`Accordingly, a principle object of the present inven
`example a 22 ounce nylon pile carpet may be employed:
`Accordingly, a principle object of the present inven-
`Also shown in FIG. 1 is a heel pad 20 which may be
`tion is to provide a carpeted accessory floor mat which
`Also shownin FIG. 1 is a heel pad 20 which may be
`tion is to provide a carpeted accessory floor mat which
`optionally incorporated into a floor mat for the driver's
`overcomes the problem of mat sliding and thereby re
`optionally incorporated into a floor matfor the driver’s
`10
`overcomes the problem of mat sliding and thereby re-
`side of the vehicle. The construction and a preferred
`side of the vehicle. The construction and a. preferred
`duces the safety risk associated therewith.
`duces.the safety risk associated therewith.
`method of securing heel pad 20 in the floor mat will be
`method ofsecuring heel pad 20 in the floor mat will be
`Another object is to provide such a mat which af.
`Another object is to provide such a mat whichaf-
`described hereinafter.
`described hereinafter.
`fords a passive solution to the mat sliding problem
`fords a passive solution to the mat sliding problem
`FIG. 2 illustrates. the bottom of floor mat 10 and
`FIG. 2 illustrates the bottom of floor mat 10 and
`thereby eliminating the need for vehicle operator/pass
`thereby eliminating the need for vehicle operator/pass-
`reveals how the underside of the base portion and the
`reveals how the underside of the base portion and the
`enger intervention by use of clips or other mat securing
`enger intervention by use ofclips or other mat securing
`raised borders of the mat are formed to follow the con-
`raised borders of the mat are formed to follow the con
`devices.
`devices.
`tourof a floor well in which the matis intended to nest.
`tour of a floor well in which the mat is intended to nest.
`Another object is to provide such a mat which does
`Another object is to provide such a mat which does
`The mat 10 preferably includes a bottom layer of open
`The mat 10 preferably includes a bottom layer of open-
`not require edge finishing, while being highly attractive
`not require edgefinishing, while being highly attractive
`celled foam 22 substantially coextensive with the top
`celled foam 22 substantially coextensive with the top
`in appearance.
`in appearance.
`20
`layer of carpet 18. The foam layer provides a finished
`layer of carpet 18. The foam layer provides a finished
`20
`A further object is to provide such a mat which af
`A further object is to provide such a mat. which af-
`appearance to the underside of the mat, additional slip
`appearanceto the underside of the mat, additionalslip
`fords maximum protection to the carpeted floor wells of
`fords maximum protection to the carpeted floor wells of
`resistance and a surface which may be readily printed
`resistance and a surface which maybereadily. printed
`particular vehicle models and is also easily removable
`particular vehicle models andis also easily removable
`upon, for example by the rotogravure method.
`upon, for example by the rotogravure method.
`for cleaning.
`for cleaning.
`Also shown in FIG.2, is the underside 24 of an inden
`Also shownin FIG.2, is the underside 24 of an inden-
`A still further object is to provide such a mat which
`A still further object is to. provide such.a mat which
`5 tation or recessed cavity which may be molded into the
`tation or recessed cavity which may be moldedinto the
`overcomes the problem, associated with conventional
`overcomes the problem, associated with conventional
`top of floor mat 10 to accommodate heel pad 20 in such
`top of floor mat 10 to accommodate heel pad 20.in such
`floor mats, of water and dirt spilling off the sides of the
`floor mats, of water and dirt spilling off the sides of the
`a way that the top of the heel pad is substantially flush
`a way that the top of the heel pad is substantially flush
`mat whenit is removed from the vehicle.
`mat when it is removed from the vehicle.
`with the top of the rest of the mat. Underside 24 may
`with the top of the rest of the mat. Underside 24 may
`- Yet another object is to provide such an accessory
`--Yet another object is to provide such an accessory
`extend slightly beyond the bottom surface of adjoining
`extend slightly beyond the bottom surface of adjoining
`floor mat which can be readily and economically manu
`. floor mat which can be readily and economically manu-
`30
`portions of the mat, e.g. 0.125 inches. Alternatively a
`30
`portions of the mat, e.g. 0.125 inches. Alternatively -a
`factured.
`factured.
`heel pad may be accommodated in the driver's side
`heel pad may be accommodated in the driver’s side
`A still further object is to provide such a mat which
`A still further object is to provide such a mat which
`floor mat, without recessing, as more fully described
`floor mat, without recessing, as more. fully described
`can accommodate various grades of carpeting including
`- can accommodatevarious grades of carpeting including
`hereinafter.
`hereinafter.
`a plush deep pile which conveys a sense of luxurious
`a plush deep pile which conveys a sense of luxurious-
`Mat 10 is molded or otherwise permanently pre
`Mat 10 is molded or otherwise permanently pre-
`ness, and/or one that matches and therefore blends with
`ness, and/or one that matches and therefore blends with
`formed from a composite carpet structure into the tray
`formed from a composite carpet structure into the tray-
`the original carpeted floor.
`the original carpeted floor.
`like, floor well contour matching configuration illus
`like, floor well contour matching configuration illus-
`trated in FIGS. 1 and 2. The molded composite carpet
`trated in FIGS. 1 and 2. The molded composite carpet
`BRIEF DESCRIPTION OF THE DRAWINGS
`BRIEF DESCRIPTION OF THE DRAWINGS
`structure described more fully hereinafter, has sufficient
`structure described more fully hereinafter, has sufficient
`. These and other objects, features and advantages of
`_ These and other objects, features and advantages of
`rigidity to retain this shape both when placed in use on
`rigidity to retain this shape both whenplaced in use on
`I the present invention will be more readily apparent
`40
`the present invention will be more readily apparent
`the carpeted floor of an automobile and when removed
`the carpeted floor of an automobile and when removed
`40
`from the following detailed description read in conjunc
`‘from the following detailed description read in conjunc-
`for cleaning purposes. The custom molding of each mat
`for cleaning purposes. The custom molding of each mat
`stion with the accompanying drawings in which:
`-+tion with the accompanying drawings in which:
`to snugly fit within the carpeted floor well of a particu
`to snugly fit within the carpeted floor well of a particu-
`FIG. 1 is a perspective view from above of an acces
`FIG.1 is a perspective view from aboveofan acces-
`lar model vehicle along with the waterproof nature and
`lar model vehicle along with the waterproof nature and
`sory floor mat constructed in accordance with the prin
`sory floor mat constructed in accordance with the prin-
`tray-like configuration of the mat provide for maximum
`tray-like configuration of the mat provide for maximum
`ciples of the present invention;
`45
`protection of the underlying original automobile carpet
`ciples of the present invention;
`protection of the underlying original automobile carpet-
`45
`FIG. 2 is a perspective view of the underside of the
`ing. The rigidity, contouring and dimensioning of the
`FIG.2 is a perspective view of the underside of the
`ing. The rigidity, contouring and dimensioning of the
`floor mat of FIG. 1;
`floor mat of FIG. 1;
`mat lend it a non-slip capability which can be supple
`mat lend it a non-slip capability which can be supple-
`FIG. 3 is a cross-sectional blowup of a composite
`FIG. 3 is a cross-sectional blowup of a composite
`mented by the gripping nature of the open-celled foam
`mented by the gripping nature of the open-celled foam
`carpet structure of the present invention;
`backing.
`carpet structure of the present invention;
`backing.
`FIG.4 is a cross-sectional view of a floor mat of the
`50
`FIG. 4 is a cross-sectional view of a floor mat of the
`FIG. 3 illustrates in blownup cross-sectional view the
`FIG.3 illustrates in blownup cross-sectional view the
`50
`present invention incorporating a heel pad;
`preferred construction of composite carpet structure 25
`present invention incorporating a heel pad;
`preferred construction of composite carpet structure 25
`FIG. 5 is a simplified schematic of a floor mat manu
`FIG.§ is a simplified schematic of a floor mat manu-
`from which the accessory floor mat of this invention is
`from which the accessory floor mat of this invention is
`facturing process of the invention; and
`manufactured. Composite carpet structure 25 is prefer
`facturing process of the invention; and
`manufactured. Composite carpet structure 25 is prefer-
`FIG. 6 is a perspective view illustrating the use of the
`rably a 3-ply laminate of carpeting 18 bonded to a sheet
`FIG.6 is a perspective view illustrating the use of the
`rably a 3-ply laminate of carpeting 18 bonded to a sheet
`accessory floor mat of FIG. 1 in a carpeted floor well.
`of open-celled foam 22 by extruded thermoformable
`accessory floor mat of FIG. 1 in a carpeted floor well.
`of open-celled foam 22 by extruded thermoformable
`material 32. As shown, carpet layer 18 preferably in
`material 32. As shown, carpet layer 18 preferably in-
`DETAILED DESCRIPTION
`DETAILED DESCRIPTION
`cludes carpet fibers 26, composed e.g., of nylon, tufted
`cludes carpet fibers 26, composed e.g., of nylon, tufted
`Referring now to FIG. 1, an accessory floor mat 10.
`into a primary backing material 28 which may be either
`Referring now to FIG. 1, an accessory floor mat 10.
`into a primary backing material 28 which maybe either
`constructed in accordance with the principles of this
`constructed in accordance with the principles of this
`woven or non woven. To increase tuft bind, a spray
`woven or non woven. To increase tuft bind, a spray
`invention, is illustrated. The mat includes a base portion
`coating 30 of polyurethane is applied to the tufted car
`invention,is illustrated. The mat includes a base portion
`coating 30 of polyurethane is applied to the tufted car-
`12 designed to rest upon, match in contour, and protect
`pet. Latex or other known materials exhibiting similar
`12 designed to rest upon, match in contour, and protect
`pet. Latex or other known materials exhibiting similar
`a generally horizontal portion of the carpeted floor well
`strong tuft binding qualities may also be used for this
`a generally horizontal portion of the carpeted floor well
`strong tuft binding qualities may. also be used for this
`of a motor vehicle, and raised borders 14 which follow
`of a motor vehicle, and raised borders 14 which follow
`purpose.
`purpose.
`the contours of the periphery of the floor well and
`The extruded thermoformable material 32 facilitates
`the contours of the periphery of the floor well and
`The extruded thermoformable material 32 facilitates
`provide a tray-like configuration to the mat. Raised
`65
`molding of the composite carpet structure into the de
`provide a tray-like configuration to the mat. Raised
`molding of the composite carpet structure into the de-
`65
`sired permanent configuration, lends appropriate struc
`borders 14 terminate in rolled or down turned edges 16
`borders 14 terminate in rolled or down turned edges 16
`sired permanent configuration, lends appropriate struc-
`which, as more fully explained hereinafter, provide an
`tural rigidity to the mat and serves as a water impervi
`which, as more fully explained hereinafter, provide an
`tural rigidity to the mat and serves as a water impervi-
`ous layer. Although other compositions exhibiting
`attractive edge finish and additional rigidity to the mat.
`attractive edge finish and additionalrigidity to the mat.
`ous layer. Although other compositions exhibiting
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`35
`55
`
`60
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`15
`15
`
`20
`20
`
`4,721,641
`4,721,641
`5
`6
`5
`6
`equivalent qualities may be employed, preferably the
`A method of manufacturing the improved floor mat
`equivalent qualities may be employed, preferably the
`A method of manufacturing the improved floor mat
`thermoformable material consists of a copolymer of
`of the present invention is illustrated in schematic form
`thermoformable material consists of a copolymer of
`of the present invention is illustrated in schematic form
`high density polyethylene and ethylene vinyl acetate
`in FIG. 5. As shown therein, carpet 18 from a supply
`high density polyethylene and ethylene vinyl acetate
`in FIG. 5. As showntherein, carpet 18 from a supply
`formulated from a combination of substantially 90 parts
`roll 40 and sheet foam 22 from a supply roll 42 are
`formulated from a combination of substantially 90 parts
`roll 40 and sheet foam 22 from a supply roll 42 are
`by weight of polyethylene and 10 parts by weight of 5
`brought into juxtaposition and thermoformable material
`by weight of polyethylene and 10 parts by weight of
`broughtinto juxtaposition and thermoformable material
`32 from extruder 44 is deposited uniformly therebe
`ethylene vinyl acetate. The latter is added to enhance
`32 from extruder 44 is deposited uniformly therebe-
`ethylene vinyl acetate. The latter is added to enhance
`tween to form the desired laminated composite carpet
`the adhesion between the carpet and foam layers. The
`tween to form the desired laminated composite carpet
`the adhesion between the carpet and foam layers. The
`structure. Extruder 44 may be any of the commercially
`thermoformable material layer preferably has a stiffness
`structure. Extruder 44 maybe any of the commercially
`thermoformable material layer preferably has a stiffness
`available extrusion devices which, in known manner
`of 67-3 as measured by a Shore D durometer. Typical
`available extrusion devices which,
`in known manner
`of 67:3 as measured by a Shore D durometer. Typical
`specifications for the ingredients of the preferred co- 10
`—0
`can, under heat and pressure soften the thermoformable
`can, underheat and pressure soften the thermoformable
`specifications for the ingredients of the preferred co-
`material and force it under control out of a die 45 at
`material and force it under control out of a die 45 at
`polymer thermoformable material follows:
`polymer th