United States Patent (19)
`Grace
`
`Patent Number:
`11
`(45) Date of Patent:
`
`5,034,258
`Jul. 23, 1991
`
`(54 CARPET MAT WITH IMPROVED GRIPPING
`SURFACE
`(75) Inventor: Ronald R. Grace, Hamilton, Ohio
`73) Assignee: Nifty Products, Inc., Hamilton, Ohio
`21 Appl. No.: 468,610
`22 Filed:
`Jan. 22, 1990
`
`(56)
`
`51
`
`Int. Cl...............................'s so a n e o a s s r. so as a s B32B 3/30
`
`52 U.S. Cl. ........................................ 428/78; 428/88;
`428/95; 428/99: 428/120; 156/290
`58) Field of Search ....................... 428/78, 88, 95, 99,
`428/120; 16/4, 8; 15/217; 156/290
`References Cited
`U.S. PATENT DOCUMENTS
`4,588,628 5/1986 Roth ...................................... 428/85
`4,748,063 5/1988 Reuben ................................. 428/78
`Primary Examiner-Alexander S. Thomas
`
`Attorney, Agent, or Firm-Charles R. Wilson
`57
`ABSTRACT
`A carpet mat is produced for use on a floor carpet. The
`carpet mat is comprised of a carpet component with at
`least one gripping member of its underside. The grip
`ping member is a thin plate having a first set of verti
`cally extending protrusions which extend into a fibrous
`portion of the carpet component. Substantially all the
`tips of the protrusions are distorted in a random fashion
`to interlock with the fibrous portion of the carpet com
`ponent to cause a permanent attachment thereto. A
`second set of vertically extending protrusions extend
`from an opposite side of the thin plate and are for the
`purpose of interacting with the floor carpet to prevent
`a shifting of the carpet mat when placed onto the floor
`carpet.
`
`20 Claims, 2 Drawing Sheets
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`EX1055
`Yita v. MacNeil
`IPR2020-01139
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`U.S. Patent
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`July 23, 1991
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`Sheet 1 of 2
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`5,034,258
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`U.S. Patent
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`July 23, 1991
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`Sheet 2 of 2
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`5,034,258
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`1.
`
`CARPET MAT WITH IMPROVED GRIPPING
`SURFACE
`
`O
`
`This invention relates to a carpet mat. More particu- 5
`larly, the invention relates to a carpet mat with an in
`proved gripping member on its underside for retaining a
`position on an underlying carpet.
`BACKGROUND OF THE INVENTION
`Carpets are found in the home, commercial establish
`ments, and motor vehicles such as automobiles, vans
`and even some trucks. The carpet provides a pleasing
`appearance, but also adds comfort, warmth and im
`proved acoustic characteristics. It can be subjected to 15
`constant foot traffic. It is quite usual for a small area of
`the carpet to receive substantially more wear and
`tear than other areas. For instance, a carpeted room in
`a house will usually have a certain traffic pattern de
`pending on where doors and other entrance ways are 20
`located. A hallway will receive much more traffic than
`an edge of a room away from doors and windows.
`Rooms and hallways in commercial establishments also
`will have certain established traffic patterns. Carpets in
`motor vehicles will have developed a localized heavy 25
`usage also, particularly in the foot well of the driver's
`side of the vehicle.
`It is possible to even-out wear on a carpet by rotating
`it or even shifting its room locale if feasible. Wall to
`wall carpet and motor vehicle carpet, however, are 30
`permanently installed in one position. When one area of
`the carpet shows excessive wear and tear, it is necessary
`to discard the whole carpet.
`Carpet mats of various shapes have been designed to
`provide a measure of protection to those areas of an 35
`underlying carpet which receive the most traffic. Thus,
`floor runners have been used in hallways. Foot mats
`have been used near an outside door. Car mats have
`been used for placement in the vehicle's front foot wells
`and even in the rear foot wells. The mats are typically 40
`made of a low quality carpet material which is itself
`discarded and replaced when necessary.
`A problem inherent with a carpet mat used on a car
`pet is its tendency to slip. A carpet mat often has a
`smooth backing. The carpet will have a fibrous surface. 45
`The smooth backing of the mat on the fibrous surface of
`the carpet is very conducive to slippage during use. The
`problem is well recognized. Different solutions have
`been used. For instance, a mat with a roughened back
`side has been used. A mat with a low slip backing such 50
`as a foam layer has been used. Double-sided carpet
`tapes have also been used.
`One carpet mat which has met with limited success
`has a backing with a set of vertically extending protru
`sions. The protrusions extend into the fibrous portion of 55
`the carpet being protected. They physically interact to
`prevent the mat from moving in a lateral direction. A
`particular problem with this type of gripping member is
`the initial positioning of the protrusions on the mat's
`underside. If the mat has a heavy plastic backing, the 60
`protrusions are simply included in the backing's mold
`design. This represents an added cost. Additionally,
`many carpet mats of various qualities are designed with
`out a plastic backing and necessarily present no eco
`nomical means for inclusion of the protrusions.
`65
`There has now been developed a carpet mat with an
`improved gripping member on its underside. The carpet
`mat of the invention is produced in an economical fash
`
`5,034,258
`2
`ion without extensive capital costs or labor needs. The
`mat is capable of retaining its position when used on
`different carpets without damaging the carpet.
`SUMMARY OF THE INVENTION
`A carpet mat is comprised of a carpet component
`with a fibrous portion and at least one gripping member
`permanently positioned on the carpet component's un
`derside. The gripping member is a thin plate having on
`one side a first set of vertically extending protrusions
`which extend into the fibrous backing and having on an
`opposite side a second set of vertically extending pro
`trusions. The first set of protrusions has substantially all
`its tips distorted in a random fashion to interlock with
`the fibrous portion. The second set of protrusions inter
`act with the floor carpet when placed thereon to pre
`vent a shifting.
`BRIEF DESCRIPTION OF DRAWINGS
`FIG. 1 is a view in perspective showing a carpet mat
`of this invention.
`FIG. 2 is a view in perspective showing a gripping
`member prior to its attachment to a carpet component.
`FIG. 3 is a partial side view in section of the carpet
`mat of FIG. 1 showing in detail one gripping member.
`FIG. 4 is a view in perspective of a molded carpet
`mat of this invention.
`FIG. 5 is a partial side view in section of the carpet
`mat of FIG. 4 showing in detail a gripping member.
`DETAILED DESCRIPTION OF THE
`INVENTION
`With reference to the drawings, there is shown in
`FIG. 1 a carpet mat 10 of this invention intended for use
`as an inside door mat. The invention will be described
`with particularity for this use. Such a mat is generally
`about one foot to about six feet in length and about one
`foot to about three feet in width. It should be readily
`apparent a carpet mat of different shapes and dimen
`sions would have use on other carpeted floor surfaces,
`such as in the home, office or motor vehicle.
`The carpet mat 10 is comprised of a tufted carpet
`component 11 and gripping members 12. Specifically, as
`best seen in FIG. 3, the tufted carpet component 11
`includes a woven fabric backing 13 and pile yarns 14
`which are secured to the backing and extend therefrom
`to form a pile surface on its upperside. The pile yarns
`may be made from natural material such as wool, but
`more often is made from a synthetic material such as
`polyester or nylon. A binder coating (not shown) is
`used to adhere and lock the pile yarns into the backing.
`Other carpet constructions including woven, knitted or
`non-woven constructions of a one-piece or composite
`design can be used in this invention. Any carpet con
`struction having a fibrous portion whether as a backing,
`a mid-portion or the total carpet is useful herein.
`In accord with this invention a gripping member is
`permanently attached to the underside of the carpet
`component. For purposes of fully understanding the
`invention the gripping member 12 is shown in FIG. 2
`before its attachment to the carpet component and con
`sequent structural changes. The gripping member 12 is
`a thin plate 15 of a polymeric material having sets of
`vertically extending protrusions on each side. One set of
`protrusions 16 is used to permanently hold the gripping
`member to the carpet component while the second set
`of protrusions 17 is used to hold the carpet mat in posi
`tion when placed on a floor carpet. The size of the
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`4.
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`purpose, a hydraulic press is preferably provided. A
`gripping member is not critical. It can have a length and
`stationary platen has a set of receiving holes to match
`width sufficient to substantially cover the carpet com
`the second set of protrusions extending from the grip
`ponent's underside. Maximum holding power would be
`ping member. A force platen mounted in the press di
`attained in this instance, though is more than is needed
`rectly above the stationary platen has a flat surface. The
`under normal use circumstances. Preferably, small car
`carpet component with the gripping member temporar
`pet mats such as the mat 10 of FIG. 1 use gripping
`ily in position is placed in the press. The second set of
`members 12 ranging in size from about five inches to
`vertically extending protrusions are fitted into the re
`about ten inches in length and width near each corner.
`ceiving holes in the stationary platen to ensure that no
`Carpet mats such as a hallway runner will use a series of
`force is exerted on them. The upper flat force platen is
`similarly shaped and dimensioned gripping members
`caused to contact the carpet component with sufficient
`placed strategically in the corners and along the edges
`force that the tips of the first set of vertically extending
`of the runner's underside. A small carpet mat will re
`protrusions are forced downwardly. The tips will dis
`quire only one gripping member position in an approxi
`tort in a random set of directions depending on a num
`mate center location.
`ber of factors such as force deflections, uneven platen
`The first set of vertically extending protrusions 16 on
`surface, uneven initial protrusion tilt, etc.
`the gripping member 12 covers one surface. They are
`The degree of force needed in the press is determined
`preferably uniformly spaced over the surface to provide
`by routine experimentation. Too little force will not
`about one to about forty protrusions per square inch,
`give the requisite degree of distortion with a resultant
`preferably about five to about fifteen protrusions per
`carpet mat wherein the gripping member is not securely
`square inch. Each protrusion is about one-eighth to
`20
`attached. Too great a force will cause all the protru
`about one-half inches in length, preferably about one
`sions to mushroom and, here also, the resultant carpet
`eighth to about one-fourth inches in length before any
`mat's gripping member may not be able to withstand
`distortion when attached to the carpet mat. The protru
`lateral forces in all directions without being dislodged
`sions 16 are conical-shaped, though other shapes can be
`from the fabric backing of the carpet component. Ex
`used.
`cessive force during this stage of manufacture can, of
`After the gripping member is attached to the carpet
`course, also damage the carpet component.
`component, and as best seen in FIG. 3, the protrusions
`As should be apparent, the carpet mat of this inven
`16 are distorted at their tips 18 in a random fashion.
`tion can be economically produced. The gripping mem
`Some of the protrusions are bent in essentially right
`ber is inexpensive and the equipment needed to secure
`angles to the base portions of the protrusions while
`attachment to the carpet component is not excessively
`other tips are "mushroomed'. The random distortions
`great. Additionally, assembly of the carpet mat is not
`of the tips are responsible for the permanent attachment
`labor intensive.
`of the gripping member to the carpet component. The
`FIGS. 4 and 5 show a molded carpet mat 20 intended
`protrusion tips interlock with the component's fabric
`for use in an automobile. The mat uses a tufted carpet
`backing so that vertical as well as lateral forces in any
`component 21 with a plastic layer 22 underside. The
`direction will be resisted by several protrusion tips
`tufted carpet has a fabric backing 23 and pile yarns 24.
`which are bent in the same direction as the force and
`The tufted carpet component of the nat is the same as
`thus are locked against a part of the fabric backing.
`used with the mat described with reference to FIGS. 1
`The second set of vertically extending protrusions 17
`and 2. The plastic layer 23 covering the underside of
`cover the opposite side of the gripping member 12.
`tufted carpet component 21 is a thermoplastic material.
`They too, are preferably uniformly spaced over the
`The layer is adhered firmly to the fabric backing 23 and
`surface to provide about one to about forty protrusions
`covers the entire surface. The primary function of the
`per square inch, preferably about one to about thirty
`thermoplastic layer is to impart stiffness and moldability
`protrusions per square inch. The protrusions are about
`to the carpet component so that it can be molded to a
`oneeighth to about three-eighths inches in length, pref
`45
`desired contour designed to fit a particular vehicle's
`erably about one-eighth to about one-fourth inches in
`foot well area. Examples of suitable thermoplastics
`length. These protrusions are used to interact with an
`include polymers of ethylene and propylene, copoly
`underlying floor carpet to prevent shifting of the mat
`mers of ethylene with ethylenically unsaturated mono
`when placed thereon. The protrusions are conical
`mers, e.g. ethylenevinyl acetate, acrylates, polyvinyl
`shaped for best structural strength and holding power.
`chlorides and styrene-butadiene polymers. The thermo
`They can as well be peg-shaped or any of several other
`plastic layer will cause the carpet component to retain
`shapes, though such shapes provide no real advantage
`its contour throughout its useful life. The layer is added
`and are less preferred.
`to the fabric backing by extrusion coating or laminating
`The gripping member used in this invention is prefer
`ably produced from a thermoplastic polymeric material
`in known fashion.
`55
`Carpet mat 20 covers only a portion of the automo
`by conventional molding techniques. Initially, the grip
`bile's carpeted floor area. However, the driver's foot
`ping member is positioned on the underside of the car
`well receives by far the most wear and accordingly will
`pet component where it is to be permanently attached.
`be the first area to show any wear or soiling. The carpet
`The tips of the first set of protrusions extend into the
`mat 20 itself is shaped to smoothly fit into the irregular
`fibrous portion of the carpet component a sufficient
`shaped foot well.
`distance that when they are ultimately distorted, the
`A single gripping member 25 is permanently attached
`bent tips will interlock with the fibrous material. The
`to the underside of plastic layer 22 of the tufted carpet
`exact distance will be based on the particular carpet,
`component. It is positioned in the approximate center of
`protrusion length and degree of distortion. Routine
`the mat and extends from edge to edge. Additional
`experimentation will readily determine the proper ex
`65
`gripping members can as well be placed in other areas,
`tension for optimum gripping member retention.
`e.g. the sloped foot rest area for added stability. The
`A force is applied to the first set of vertically extend
`gripping member 25 is of the same construction as that
`ing protrusions to cause their tips' distortions. For this
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`cally extending protrusions is from about one-eighth
`used on the carpet mat 10 of FIG. 1. It comprises a thin
`inches to about one-fourth inches in length.
`plate 26 with a first set of vertically extending protru
`7. The carpet mat of claim 5 wherein the second set of
`sions 27 on one side and a second set of vertically ex
`vertically extending protrusions are conical-shaped.
`tending protrusions 28 on an opposite side. The protru
`8. The carpet mat of claim 6 wherein the gripping
`sions 27 extend through the thermoplastic layer with
`member is formed from a polymeric material.
`their distorted tips 29 interlocking with the fabric back
`9. The carpet mat of claim 6 wherein a set of gripping
`ing of the carpet component.
`members are placed around the periphery of the carpet
`In use, the carpet mat is simply placed on the floor
`component's underside.
`carpet to be protected and a slight downward pressure
`10. The carpet mat of claim 9 wherein the carpet mat
`10
`exerted to cause the protrusions on the underside of the
`ranges from about one foot to about six feet in length
`gripping member to interact with the floor carpet. The
`and about one foot to about three feet in width.
`carpet mat will remain in place under normal use. The
`11. The carpet mat of claim 1 wherein the carpet
`unique gripping member remains permanently attached
`component is a tufted carpet having a fabric backing
`to the carpet component due to the first set of vertically
`and pile yarns extending therefrom.
`extending protrusions and remains in place on the floor
`12. The carpet mat of claim 11 wherein the carpet
`carpet due to the second set of vertically extending
`component further has a thermoplastic layer covering
`protrusions. In due course, the carpet mat is readily
`the fabric backing.
`removed simply by lifting it vertically from the carpet.
`13. The carpet mat of claim 12 wherein the carpet
`The underlying carpet is not damaged to any noticeable
`mat is contoured to fit a foot well of a motor vehicle.
`degree.
`14. The carpet mat of claim 1 wherein the carpet
`The invention has been described with particularity
`component is a one-piece non-woven fibrous material.
`and with reference to the drawings. Obvious variations
`15. The method of claim 1 wherein the carpet compo
`and modifications can be made. Such changes are
`nent is a one-piece non-woven fibrous material.
`within the scope of the appended claims.
`16. A method of producing a carpet mat for overlay
`What is claimed:
`ment on a carpet, comprising the steps of:
`1. A carpet mat intended for overlayment on a floor
`(a) positioning a gripping member on the underside of
`carpet, comprising:
`a carpet component having a fibrous portion, said
`(a) a carpet component having a fibrous portion; and
`gripping member comprised of a thin plate having
`(b) at least one gripping member permanently posi
`a first set of vertically extending protrusions and
`30
`tioned on the underside of the carpet component,
`having on an opposite side a second set of verti
`said gripping member being a thin plate having on
`cally extending protrusions;
`one side a first set of vertically extending protru
`(b) placing the carpet component with the gripping
`sions which extend into the fibrous portion of the
`member positioned on its underside in a press
`carpet component with substantially all tips of the
`wherein the press has a stationary platen with re
`35
`protrusions distorted in a random fashion to inter
`ceiving holes to receive the second set of vertically
`lock with the fibrous portion so as to cause a per
`extending protrusions to prevent a force being
`manent attachment thereto and having on an oppo
`transmitted thereto and an oppositely positioned
`site side a second set of vertically extending protru
`force platen; and
`sions which interact with the floor carpet to pre
`(c) forcing the platens of the press together under
`40
`vent shifting of the carpet mat when placed
`sufficient force that the first set of vertically ex
`tending protrusions are distorted in a random fash
`thereon.
`2. The carpet mat of claim 1 wherein the vertically
`ion to interlock with the fibrous portion of the
`extending protrusions on the plate are uniformly spaced
`carpet component so as to produce the carpet mat.
`on each side of the plate.
`17. The method of claim 16 wherein the vertically
`45
`extending protrusions on the gripping member are uni
`3. The carpet mat of claim 2 wherein the first set of
`vertically extending protrusions are spaced to provide
`formly spaced on each side thereof.
`from about one to about forty protrusions per square
`18. The method of claim 17 wherein the first set of
`vertically extending protrusions are spaced to provide
`inch and the second set of vertically extending protru
`sions are spaced to provide about one to about forty
`from about one to about forty protrusions per square
`protrusions per square inch.
`inch and the second set of vertically extending protru
`sions are spaced to provide about one to about forty
`4. The carpet mat of claim 3 wherein each protrusion
`of the first set of vertically extending protrusions is
`protrusions per square inch.
`19. The method of claim 18 wherein each protrusion
`from about oneeighth inches to about one-half inches in
`of the first set of vertically extending protrusions is
`length.
`5. The carpet mat of claim 4 wherein each protrusion
`from about one-eighth inches to about one-halfinches in
`length and each protrusion of the second set of verti
`of the second set of vertically extending protrusions is
`cally extending protrusions is from about one-eighth
`from about oneeighth inches to about three-eights
`inches to about three-eights inches in length.
`inches in length.
`20. The method of claim 16 wherein the carpet com
`6. The carpet mat of claim 5 wherein each protrusion
`ponent is a tufted carpet having a fabric backing and
`of the first set of vertically extending protrusions is
`pile yarns extending therefrom.
`from about oneeighth inches to about one-fourth inches
`in length and each protrusion of the second set of verti
`
`SO
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