Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
1998-12-01
2001-10-02
Silbaugh, Jan H. (Department: 1732)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C156S312000, C264S243000, C264S322000, C264S327000
Reexamination Certificate
active
06296733
ABSTRACT:
TECHNICAL FIELD
The invention relates to floor covering systems, such as floor mats, having a plurality of projections extending from the underside thereof to enhance the stability of the mats when placed on a carpeted surface such as a carpeted floor of an automobile. The invention further relates to a method of making such floor covering systems.
BACKGROUND ART
Floor carpets are in common use in homes, businesses and transportation vehicles such as automobiles, buses, trains, aircrafts and marine crafts. It is common for certain areas of such carpets to receive substantially more foot traffic and, thus, more wear as compared with other areas. In order to accommodate such uneven wear, floor coverings such as floor mats are frequently placed on such carpets in high traffic areas. A common problem in the use of floor mats, however, is the tendency of the floor mats to slip on the underlying carpet. To minimize the slippage of floor mats on, for example, cut-loop pile carpets in automobiles, floor mats have been designed with a plurality of downwardly extending cone-shaped projections known as “bristles,” “nubs,” or “nibs.” Such cone-shaped projections typically have maximum diameters in the range of 2.5 to 6 millimeters (mm), and minimum diameters in the range of 1.5 to 2 mm. Furthermore, the density of such projections is typically in the range of 8 to 13 projections per square inch. Efforts by automotive manufacturers to reduce weight and cost of their products, however, have resulted in a shift away from cut-loop pile for floor carpet constructions to lighter-weight, less costly non-woven needle punched constructions.
Other known means of minimizing slippage of a floor mat include attaching mating fastening means to the underside of the floor mat and the top surface of a particular floor carpet. U.S. Pat. No. 4,968,548, for example, discloses a removable floor cover having a plurality of one of the elements of a hook and loop fastening system attached thereto, for use with a floor surface having a plurality of the other elements of a hook and loop fastening system attached thereto. Because of the high cost of hook and loop fastening systems and the additional labor required to attach the fastening elements to both the cover layer and the floor surface, this design is relatively costly to manufacture and install.
SUMMARY OF THE INVENTION
The present invention overcomes the shortcomings of the prior art by providing a low cost floor covering, such as a floor mat, that effectively minimizes slippage on carpeted floor surfaces, and functions especially well on non-woven, needle punched carpets. Furthermore, a method for manufacturing such a floor covering is also provided.
A floor mat according to the invention for covering a motor vehicle flooring system having a plurality of fibers comprises a thermoplastic layer having first and second surfaces and a plurality of projections extending from the second surface. Each of the projections includes an elongated body portion and an enlarged tip for engaging the fibers.
In one embodiment of the invention, the tips are button-shaped and function as one of the elements of a fastening system. Advantageously, such a configuration grips especially well to a carpet having a non-woven, needle punched construction. Such a carpet functions as the other element of the fastening system.
The method according to the invention of making a removable floor covering for covering a flooring system comprises forming a thermoplastic layer having first and second surfaces and at least one projection extending from the second surface, the at least one projection having an elongated body portion and an enlarged tip that is engageable with the flooring system.
A more specific expression of the method according to the invention of making a removable floor covering for covering a flooring system comprises forming a thermoplastic layer having first and second surfaces and at least one projection extending from the second surface, the projection having an elongated body portion. The method further includes heating the at least one projection to sufficiently soften the at least one projection, and compressing the thermoplastic layer sufficiently so as to form an enlarged tip on the at least one projection, the enlarged tip being engageable with the flooring system.
The at least one projection is preferably heated by positioning the projection adjacent to and in heat transfer relationship with a heated surface. Furthermore, the compressing step preferably involves compressing the at least one projection against the heated surface.
According to one aspect of the invention, the heated surface is a thermally regulated platen. According to another aspect of the invention, the heated surface is a thermally regulated roller. Such surfaces provide a cost-effective and efficient means for forming the enlarged tip.
While an exemplary floor covering and method for making the same are illustrated and disclosed, such disclosure should not be constructed to limit the claims. It is anticipated that various modifications and alternative designs may be made without departing from the scope of the invention.
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Hammond Steven P.
Hudkins Patrick E.
Thompson Mark W.
Brooks & Kushman PC
Eashoo Mark
Lear Corporation
Silbaugh Jan H.
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