FLOOR COVERING FOR A VEHICLE

Abstract: A covering (10) defines a recess (22) of extent smaller than that of the covering, and a mat (32) having a shape and size conforming to those of said recess. Preferably the covering is moulded to contour around a vehicle floor and moulded to further form at least one of the recesses (22) in an upper surface of the covering.

Description: FLOOR COVERING FOR A VEHICLE This invention relates to floor coverings, for example, to be used in vehicles. More particularly, this invention relates to moulded floor carpets for vehicles. Floor coverings for vehicles of the prior art are made of either carpet material (e.g. tufted or non-woven) or are rubber based combined with a backing layer of fibrous, cellular material. The floor coverings are moulded to a three dimensional shape to contour around the floor of the vehicle. Footwell areas where the vehicle passengers place their feet are subject to particular high wear and are particularly prone to becoming muddy and wet. For this reason, accessory mats have been developed which lie on top of the factory fitted floor covering of the vehicle in the footwell area and are generally sold separately. Floor coverings for trucks have been fabricated from a high quality wear resistant thin foil which is laminated onto a thicker low quality backing layer. Decoration is printed onto the high quality foil. According to a first aspect of the present invention, there is provided a covering defining a recess of extent smaller than that of the covering, and an accessory mat having a shape and size conforming to those of said recess. According to a second aspect of the present invention, there is further provided a floor covering for a vehicle, wherein said covering is moulded to contour around a vehicle floor and moulded to further form at least one recess in an upper surface of said covering. According to a third aspect of the present invention there is further provided an accessory mat for a vehicle, comprising a waterproof sheet with an edge, said edge being of greater thickness than the remainder of said sheet and said edge protruding from said sheet on both sides of said sheet. According to a fourth aspect of the present invention, there is further provided a method of moulding a floor covering for a vehicle comprising the steps of: providing a substantially flat covering material of a predetermined size and shape; moulding said covering material to a three dimensional shape to contour around a vehicle floor; and moulding said covering material to form at least one recess in an upper surface of said covering, said recess being dimensioned for locating an accessory mat. The hereinafter described embodiments have the advantage over the prior art that the accessory mats may be contained within the accurately dimensioned recess of the covering, thus maintaining for a vehicle covering the design level of the covering system and the correct floor covering to pedal height. This enhances both the safety and comfort of the driver. The preferred accessory mat as illustrated hereinafter is reversible and is particularly suited for use in extreme weather conditions where water and mud can be contained on the accessory mat. The mats may also be reversible. The hereinafter described embodiments can be used in trucks in which the low quality backing layer of the prior art forms the floor covering for regions of low wear and regions of high wear have a recess formed in them to receive a sacrificial mat. In this way, the expensive thin foil can be dispensed with and decoration can be printed directly onto the backing layer. Preferred embodiments of the present invention are now described with reference to the following drawings in which: Figure 1 shows a floor covering for a vehicle according to the present invention; and Figure 2 shows a cross-section of an embodiment of the floor covering of the present invention taken through line 2-2 in Figure 1. Inside floors of vehicles are usually covered with a covering material which is often a carpet or rubber. This improves both the look, comfort and even the acoustic properties of the inside of the vehicle. Figure 1 shows a floor covering 10 according to the present invention. Floor covering 10 is moulded to contour around the features on the floor of the vehicle. For example, in the illustrated embodiment, a central hump 12 has been moulded to form around a central structural member (e.g. transmission tunnel of a rear wheel drive vehicle) which runs along the floor of the vehicle. Similarly, the covering 10 has upturned edges 14 which contour around an inner side shelf of the covering 10 has upturned edges 14 which contour around an inner side shelf of the vehicle. As will be appreciated, the covering may be moulded to form around any other objects on the floor of the vehicle. The illustrated embodiment of a covering is designed for a car which has four footwells. The covering 10 has been moulded around the footwells in areas generally indicated 16, 17, 18 and 19. In the bottom of each of these footwells, a further recess, 20, 22, 24, 26 has been moulded. In each of the recesses is an accessory mat, 30, 32, 34, 36. The recesses 20, 22, 24, 26 are dimensioned such that the corresponding accessory mats 30, 32, 34,36 i.e. inside the recesses, are located such that they will not slide out of the recesses. Fixing the position of the accessory mats 30,32,34,36 ensures that the mats are positioned optimally for collecting water and mud which is brought into the vehicle on an occupant's feet. Also the mat is prevented from sliding underneath the pedals and thereby interfering with their operation. As can be seen from Figure 2, in the preferred embodiment, the recess 22 and accessory mat 32 are dimensioned such that the top surface of the accessory mat 32 and the top surface 11 of the covering 10 are at substantially the same height. This improves the driving comfort of the vehicle operator, as well as the driving safety since the height between the floor covering and any control pedals of the vehicle can be accurately maintained. As can be seen from Figure 2, the recess has sides 23,25 which are substantially perpendicular to the top surface 11 of the covering 10. The recess 22 also has a bottom surface 27 which is substantially parallel to the top surface 11 of the covering 10. The fit of the accessory mat 32 in the recess 22 is optimised for preventing the accessory mat 32 from sliding around. The accessory mat 32 comprises a waterproof sheet 40 which is moulded with an edge 42 of greater thickness than the remainder of the sheet 40. The edge 42 protrudes on both sides of the sheet to thereby form on both sides of the mat a recess which can be used to collect water and/or mud. Having a recess on both sides of the accessary mat allows the accessory mat 32 to be reversible. That is, the accessory mat may be used with either side facing away from the floor covering 10. In Figure 1, mats 30 and 36 are identical and so are fully interchangeable without needing to be reversible, while mats 32 and 34 are mirror images and must be reversed if their positions are to be exchanged. The accessory mat 32 further comprises a carpet 44 on one side of the sheet 40. The carpet may be of the same type as that used for the floor covering 10. In the preferred embodiment, the floor covering 10 is a tufted carpet with a backing which is moulded to fit a vehicle floor pan although there is no reason why it may not comprise a non-woven carpet or a moulded or thermoplastic rubber or linoleum. The floor covering 10 may form part of an acoustically designed automotive floor system. The covering of this invention may be used in other applications than motor vehicles. The carpet 44 may be provided on one or both sides of the sheet 40. If the carpet 44 is only on one side, the vehicle occupant can decide if the carpet 44 is to be visible or not. During summer use, the carpet could be visible and during winter, when water and mud are more likely to enter the vehicle, the waterproof sheet 40 could face upwards.

Claims: CLATMS 1. A covering defining a recess of extent smaller than that of the covering, and an accessory mat having a shape and size conforming to those of said recess. 2. A floor covering for a vehicle, wherein said covering is moulded to contour around a vehicle floor and moulded to further form at least one recess in an upper surface of said covering. 3. The floor covering of claim 2, wherein said at least one recess has sides which are substantially perpendicular to said upper surface of said floor covering. 4. The floor covering of claim 2 or claim 3, wherein said at least one recess has a bottom surface substantially parallel to said upper surface of said floor covering. 5. The floor covering of any one of the preceding claims, wherein said at least one recess is positioned to be, when said covering is in use in a vehicle, substantially beneath a vehicle occupant's feet. 6. The floor covering of any one of the preceding claims, wherein said covering further comprises at least one accessory mat. 7. The floor covering of claim 6, wherein said at least one accessory mat and said at least one recess are dimensioned such that said accessory mat can be located in said recess, said recess thereby substantially preventing relative sliding movement between said accessory mat and said floor covering. 8. The covering of claim 6 or claim 7, wherein said at least one recess has a depth and said mat a thickness which are substantially equal. 9. The covering of any one of claims 6 to 8, having a first recess and a second recess and a first accessory mat and a second accessory mat, the first and second recesses being mirror images of one another and the first and second mats being mirror images of one another. 10. The covering of any one of claims of claims 6 to 9, having a first recess and a second recess and a first accessory mat and a second accessory mat, the first and second recesses being the same shape and the first and second mats being the same shape. 11. The covering of any one of claims 6 to 10, wherein said accessory- mat comprises a waterproof backing member, said member having an edge of greater thickness than the remainder of the member. 12. The covering of claim 11, wherein said edge protrudes from said backing member on both sides of said backing member. 13. The covering of claim 11 or claim 12, wherein said backing member is made of a moulded rubber or plastics material. 14. The covering of any one of claims 11 to 13, wherein carpeting is attached on one side of said backing member of the accessory mat. 15. The covering of claim 14, wherein said floor covering and said accessory carpeting are made of the same material. 16. The covering of any one of proceeding claims, wherein said floor. covering forms part of an acoustically designed automotive floor system. 17. The covering of any one of the preceding claims, wherein said covering is made of a tufted carpet or a non-woven carpet. 18. The covering of any one of claims 1 to 16, wherein said covering is made of linoleum. 19. An accessory mat for a vehicle, comprising a waterproof sheet with an edge, said edge being of greater thickness than the remainder of said sheet and said edge protruding from said sheet on both sides of said sheet. 20. The accessory mat of claim 19, wherein said sheet is made of moulded rubber or plastics material. 21. The accessory mat of claim 19 or claim 20, wherein accessory carpeting is attached to a top surface of the said sheet. 22. A method of moulding a floor covering for a vehicle comprising the steps of: providing a substantially flat covering material of a predetermined size and shape; moulding said covering material to a three dimensional shape to contour around a vehicle floor; and moulding said covering material to form at least one recess in an upper surface of said covering, said recess being dimensioned for locating an accessory mat. 23. The method of claim 22 wherein said steps of moulding to a three dimensional shape and moulding to form at least one recess are performed at the same time. 24. A covering substantially as hereinbefore described with reference to and as illustrated in the accompanying drawings. 25. An accessory mat substantially as herein before described with reference to and as illustrated in the accompanying drawings. 26. A method of moulding a floor covering for a vehicle substantially as herein before described with reference to and as illustrated in the accompanying drawings.

Inventors: COOPER PHIL, TOMPSON GRAHAM, COOPER, PHIL, TOMPSON, GRAHAM
Applicants: COLLINS & AIKMAN AUTOM SYST, COOPER PHIL, TOMPSON GRAHAM, COLLINS & AIKMAN AUTOMOTIVE SYSTEMS LIMITED, COOPER, PHIL, TOMPSON, GRAHAM
Application year: 2001
Main classification: B60N3
IPC codes: B60N3