Vehicle floor covering with integral threaded drain tube and method of making same

• US 20020079621A1
• Filed: 11/05/2001
• Published: 06/27/2002
• Est. Priority Date: 06/25/1999
• Status: Active Grant

• Current Assignee: Auria Solutions Uk I Ltd.
• Original Assignee: Siemens AG
• Inventors: McIntosh, William Duncan, Haight, Dayne Stuart
• Granted Patent: US 6,905,650 B2
• Time in Patent Office: Days
• US Class Current: 264/544
• CPC Class Codes: B60N 3/04 of floor mats or carpets
• CPC Class Codes: Y10S 470/906 Nylon plug lock

Abstract

A molded floor covering for a vehicle floor includes a thermoplastic polymer layer with an integral, threaded drain tube extending therefrom. The drain tube is configured such that a distal end thereof can extend through a drain hole in a vehicle floor when the floor covering is installed within a vehicle. The drain tube includes a threaded bore that is configured to receive a correspondingly-threaded drain plug therein. A method of producing a molded floor covering having an integrally formed, threaded drain tube includes providing a mold having a contour of a vehicle floor with an outwardly projecting threaded member. A layer of thermoplastic polymer is vacuum formed over the mold and around the threaded member such that the layer follows the contours of the mold and threaded member to form an elongate tube extending therefrom.

Claims

1. A molded floor covering for a vehicle floor, wherein the vehicle floor includes a drain hole formed therethrough, the molded floor covering comprising:

a thermoplastic polymer layer having a nonplanar three dimensional contoured configuration adapted to conform to a contour of the vehicle floor, and opposite first and second surfaces; and

an elongate tube extending outwardly from the thermoplastic polymer layer, including an open proximate end and an open distal end, a threaded cylindrical bore defining an axial direction and extending from the open proximate end to the open distal end, wherein the open proximate end is integrally formed with the thermoplastic polymer layer, and wherein the elongate tube is configured such that the distal end thereof can extend through the vehicle floor drain hole.

2. A molded floor covering according to claim 1 further comprising a drain plug including a head and a threaded shank connected to the head, wherein the threaded shank is configured to threadingly engage the threaded cylindrical bore for moving the head of the drain plug along the axial direction toward and away from the proximate end when the drain plug is rotated about the axial direction in respective opposite directions.

3. A molded floor covering according to claim 1 wherein the drain plug head has a conical frustum shape and wherein the proximate end has a corresponding conical frustum shape that is configured to receive the drain plug head in countersunk relation therewith.

4. A molded floor covering according to claim 1 wherein the drain plug head comprises a tool engaging aperture for engagement with a tool for rotating the drain plug about the axial direction.

5. A molded floor covering according to claim 1 further comprising a carpet having a fibrous surface disposed on the floor covering first surface.

6. A molded floor covering according to claim 1 wherein the thermoplastic polymer layer is formed from an ethylene/vinyl acetate copolymer.

7. A molded floor covering for a vehicle floor, wherein the vehicle floor includes a drain hole formed therethrough, the molded floor covering comprising:

a thermoplastic polymer layer having a nonplanar three dimensional contoured configuration adapted to conform to a contour of the vehicle floor, and opposite first and second surfaces;

an elongate tube extending outwardly from the thermoplastic polymer layer second surface, including an open proximate end having a conical frustum shape and an open distal end, a threaded cylindrical bore defining an axial direction and extending from the open proximate end to the open distal end, wherein the open proximate end is integrally formed with the thermoplastic polymer layer, and wherein the elongate tube is configured such that the distal end thereof can extend through the vehicle floor drain hole; and

a drain plug including a head and a threaded shank connected to the head, wherein the drain plug head has a conical frustum shape that is configured to be received by the proximate end in countersunk relation therewith, wherein the threaded shank is configured to threadingly engage the threaded cylindrical bore for moving the head of the drain plug along the axial direction toward and away from the proximate end when the drain plug is rotated about the axial direction in respective opposite directions.

8. A molded floor covering according to claim 7 wherein the drain plug head comprises means for engaging a tool for rotating the drain plug about the axial direction.

9. A molded floor covering according to claim 7 further comprising a carpet having a fibrous surface disposed on the floor covering first surface.

10. A molded floor covering according to claim 7 wherein the thermoplastic polymer layer is formed from an ethylene/vinyl acetate copolymer.

11. A method of producing a molded floor covering for a vehicle floor, wherein the molded floor covering includes a drain tube integrally formed therewith, wherein the drain tube includes a threaded bore that is configured to receive a correspondingly-threaded plug, the method comprising the steps of:

providing a mold having a contour of the vehicle floor and an outwardly projecting threaded member, wherein the threaded member includes a head portion and an elongate threaded shank;

vacuum forming a layer of thermoplastic polymer over the mold and around the threaded member such that the layer follows the contours of the mold and threaded member to produce a molded floor covering having opposite first and second surfaces, and a drain tube extending outwardly therefrom, wherein the drain tube includes a threaded bore with an open proximate end and a closed distal end, wherein the open proximate end is integrally formed with the molded floor covering, and wherein the open proximate end has a configuration of the head of the threaded member;

rotating the threaded member to threadingly disengage the threaded member from the drain tube; and

forming an opening through the drain tube distal end.

12. A method according to claim 11 wherein the threaded member head portion has a conical frustum shape.

13. A method according to claim 11 wherein the thermoplastic polymer is an ethylene/vinyl acetate copolymer.

14. A method according to claim 11 further comprising the step of disposing a carpet having a fibrous surface on the first surface of the molded floor covering.

15. A method according to claim 11 further comprising the step of disposing padding on the second surface of the molded floor covering.

17. A molded floor covering according to claim 16 further comprising a drain plug including a head and a threaded shank connected to the head, wherein the threaded shank is configured to threadingly engage the threaded insert for moving the head of the drain plug along the axial direction toward and away from the elongate tube proximate end when the drain plug is rotated about the axial direction in respective opposite directions.

18. A molded floor covering according to claim 16 wherein the drain plug head has a conical frustum shape and wherein the elongate tube proximate end has a corresponding conical frustum shape that is configured to receive the drain plug head in countersunk relation therewith.

19. A molded floor covering according to claim 16 wherein the thermoplastic polymer layer is formed from an ethylene/vinyl acetate copolymer.

16. A molded floor covering for a vehicle floor, wherein the vehicle floor includes an aperture formed therethrough, the molded floor covering comprising:

a thermoplastic polymer layer having a nonplanar three dimensional contoured configuration adapted to conform to a contour of the vehicle floor, and opposite first and second surfaces;

an elongate tube extending outwardly from the thermoplastic polymer layer second surface, including an open proximate end and an open distal end, a cylindrical bore defining an axial direction and extending from the open proximate end to the open distal end, wherein the open proximate end is integrally formed with the thermoplastic polymer layer such that the cylindrical bore is in fluid communication with the aperture, and wherein the elongate tube is configured such that the distal end thereof can extend through the vehicle floor aperture; and

a threaded insert disposed within the cylindrical bore.

20. A molded floor covering for a vehicle floor, wherein the vehicle floor includes a drain hole formed therethrough, the molded floor covering comprising:

a thermoplastic polymer layer having a nonplanar three dimensional contoured configuration adapted to conform to a contour of the vehicle floor;

an elongate tube extending outwardly from the thermoplastic polymer layer second surface, including an open proximate end having a conical frustum shape and an open distal end, a cylindrical bore defining an axial direction and extending from the open proximate end to the open distal end, wherein the open proximate end is integrally formed with the thermoplastic polymer layer, and wherein the elongate tube is configured such that the distal end thereof can extend through the vehicle floor drain hole;

a cylindrical internally threaded insert disposed within the cylindrical bore; and

a drain plug including a head and a threaded shank connected to the head, wherein the drain plug head has a conical frustum shape that is configured to be received by the elongate tube proximate end in countersunk relation therewith, wherein the threaded shank is configured to threadingly engage the threaded insert for moving the head of the drain plug along the axial direction toward and away from the elongate tube proximate end when the drain plug is rotated about the axial direction in respective opposite directions.

21. A molded floor covering according to claim 20 wherein the thermoplastic polymer layer is formed from an ethylene/vinyl acetate copolymer.

22. A method of producing a molded floor covering for a vehicle floor, wherein the molded floor covering includes a drain tube integrally formed therewith, wherein the drain tube includes a bore that is configured to receive a removable plug, the method comprising the steps of:

providing a mold having a contour of the vehicle floor and an outwardly projecting threaded member, wherein the threaded member includes a head portion, an elongate threaded shank, and a cylindrical threaded insert threadingly engaged with the threaded member along a portion of the elongate threaded shank;

vacuum forming a layer of thermoplastic polymer over the mold and around the threaded member and threaded insert such that the layer follows the contours of the mold, threaded member and threaded insert to produce a molded floor covering having opposite first and second surfaces, and a drain tube extending outwardly therefrom, wherein the drain tube includes a bore with an open proximate end and a closed distal end, wherein the open proximate end is integrally formed with the molded floor covering, wherein the threaded insert is integrally formed within the cylindrical bore, and wherein the open proximate end has a configuration of the head of the threaded member;

rotating the threaded member to threadingly disengage the threaded member from the threaded insert within the drain tube; and

forming an opening through the drain tube distal end.

23. A method according to claim 22 wherein the threaded member head portion has a conical frustum shape.

24. A method according to claim 22 wherein the thermoplastic polymer is an ethylene/vinyl acetate copolymer.

25. A method according to claim 22 further comprising the step of disposing a carpet having a fibrous surface on the first surface of the molded floor covering.

26. A method according to claim 22 further comprising the step of disposing padding on the second surface of the molded floor covering.

28. A molded floor covering according to claim 27 wherein the fastener comprises a neck portion between the head and the threaded shank that has a conical frustum shape and wherein the proximate end of the elongate tube has a corresponding conical frustum shape that is configured to receive the neck portion in countersunk relation therewith.

29. A molded floor covering according to claim 27 wherein the fastener head comprises a tool engaging aperture for engagement with a tool for rotating the drain plug about the axial direction.

30. A molded floor covering according to claim 27 wherein the fastener head comprises a portion configured to be grasped by a user for manually rotating the drain plug about the axial direction.

31. A molded floor covering according to claim 27 wherein the thermoplastic polymer layer is formed from an ethylene/vinyl acetate copolymer.

27. A molded floor covering for a vehicle floor, wherein the vehicle floor includes an aperture formed therethrough, the molded floor covering comprising:

a thermoplastic polymer layer adapted to conform to a contour of the vehicle floor having opposite first and second surfaces;

an elongate tube extending outwardly from the thermoplastic polymer layer, including an open proximate end and a distal end, a cylindrical bore defining an axial direction and extending from the open proximate end to the distal end, wherein the open proximate end is integrally formed with the thermoplastic polymer layer, and wherein the elongate tube is configured such that the distal end thereof can extend through the vehicle floor aperture;

a cylindrical internally threaded insert disposed within the cylindrical bore; and

a fastener that compressively engages a portion of a mat disposed on the floor covering, comprising;

a head having a circumferentially extending shoulder that is configured to compressively engage a portion of the mat disposed on the floor covering; and

a threaded shank connected to the head, wherein the threaded shank is configured to threadingly engage the threaded cylindrical bore for moving the head of the fastener along the axial direction toward and away from the proximate end when the fastener is rotated about the axial direction in respective opposite directions.

32. A method of producing a molded floor covering for a vehicle floor, wherein the molded floor covering includes an elongate tube integrally formed therewith, wherein the elongate tube includes a bore that is configured to receive a removable fastener, the method comprising the steps of:

providing a mold having a contour of the vehicle floor and an outwardly projecting threaded member, wherein the threaded member includes a head portion, an elongate threaded shank, and a neck portion between the-head portion an threaded shank, and a cylindrical internally threaded insert threadingly engaged with the threaded member along a portion of the elongate threaded shank;

vacuum forming a layer of thermoplastic polymer over the mold and around the threaded member and threaded insert such that the layer follows the contours of the mold, threaded member and threaded insert to produce a molded floor covering having an elongate tube extending outwardly therefrom, wherein the elongate tube includes a bore with an open proximate end and a distal end, wherein the open proximate end is integrally formed with the molded floor covering, wherein the threaded insert is integrally formed within the cylindrical bore, and wherein the proximate end has a configuration of the neck portion of the threaded member; and

rotating the threaded member to threadingly disengage the threaded member from the threaded insert within the elongate tube.

33. A method according to claim 32 wherein the threaded member neck portion has a conical frustum shape.

34. A method according to claim 32 wherein the thermoplastic polymer is an ethylene/vinyl acetate copolymer.