Abstract:
An improved floor mat with inlays made out of wood, aluminum, carbon fiber or other decorative materials for automobiles. The floor mat has strategically placed inlays to increase durability, while also complimenting the decorative nature of the mats. The inlays are beveled in a way as to add to the aesthetic look of the floor mat. The bevel of the inlay creates seamless transition between inlay and the untrimmed carpet fibers

Description:
BACKGROUND 
       [0001]    1. Field of the Invention 
         [0002]    The present invention claims priority to and incorporates herein its parent U.S. Utility patent application Ser. No. 12/271759, filed on Nov. 14, 2008. 
         [0003]    The present invention relates to an improved automobile floor mat. Standard floor mats are primarily made of carpeting or rubber. Usually, standard factory supplied floor mats are not aesthetically pleasing. Nor do standard, factory supplied floor mats match or coordinate with the various interior trims used in modern vehicles, such as wood, aluminum or carbon fiber to name a few. Furthermore, certain areas of the mats are prone to accelerated wear. 
         [0004]    It would be desirable to have an aftermarket automobile floor mat that provides better aesthetics and coordination with different vehicle trims, such as wood, aluminum or carbon fiber to name a few, but also improved wear and longer life. 
         [0005]    2. Description of the Related Art 
         [0006]    Automobile floor mats, whether factory installed or acquired in the after market, are either single pieces of carpeting or single pieces of rubber or plastic. They are made to increase comfort, and, in the case of after market mats, protect the floor from dirt and wear and for aesthetics. 
       SUMMARY OF THE INVENTION 
       [0007]    In a preferred embodiment of the present invention, a piece of wood, faux wood, aluminum, steel, carbon fiber, or any other aesthetically pleasing material is affixed to a floor mat otherwise made of carpet. The material can be affixed to a substrate layer by screws, adhesive, grommets, or a combination of such. 
         [0008]    The novel features which are characteristic of the invention, both as to structure and method of operation thereof, together with further objects and advantages thereof, will be understood from the following description, considered in connection with the accompanying drawings, in which the preferred embodiment of the invention is illustrated by way of example. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only, and they are not intended as a definition of the limits of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is a perspective view of an embodiment of a method in preparing a floor mat of the present invention; 
           [0010]      FIG. 2  is a top view of an embodiment of a method in preparing a floor mat; 
           [0011]      FIG. 3  is a cross-section view of an embodiment of a method in preparing the floor mat; 
           [0012]      FIG. 4  is a cross-section view of a preferred embodiment of the floor mat; 
           [0013]      FIG. 5  is a perspective view of an embodiment of a method of preparing the floor mat; 
           [0014]      FIG. 6  is a cross-section view of an embodiment of a floor mat with an inlay; 
           [0015]      FIG. 7  is a magnified view of a portion of  FIG. 6 ; 
           [0016]      FIG. 8  is a cross-section of an embodiment of a floor mat; 
           [0017]      FIG. 9  is a cross-section of an embodiment of a floor mat; 
           [0018]      FIG. 10  is a cross-section of an embodiment of a floor mat; 
           [0019]      FIG. 11  is a cross-section of an embodiment of a floor mat; 
           [0020]      FIG. 12  is a cross-section of an embodiment of a floor mat; 
           [0021]      FIG. 13  is a cross-section of an embodiment of a floor mat; 
           [0022]      FIG. 14  is a cross-section of an embodiment of a floor mat; 
           [0023]      FIG. 15  is a cross-section of an embodiment of a floor mat; 
           [0024]      FIG. 16  is an exploded perspective view of an embodiment of a floor mat; 
           [0025]      FIG. 17  is a cross-section view of the embodiment displayed in  FIG. 16 ; 
           [0026]      FIG. 18  is a perspective view of an additional embodiment of the floor mat with an inlay; 
           [0027]      FIG. 19  is a cross-section view of the embodiment displayed in  FIG. 18 ; 
           [0028]      FIG. 20  is a top plan view of an additional embodiment of the floor mat and a plurality of inlays; 
           [0029]      FIG. 21  is a cross section of the embodiment displayed in  FIG. 20 ; 
           [0030]      FIG. 22  is a perspective view of an attachment to the outer edge of any floor mat embodiment; 
           [0031]      FIG. 23  is a top plan view of the embodiment displayed in  FIG. 22  where the attachment is attached to the body of the mat. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0032]    A preferred method of preparing a floor mat  100  is shown in  FIG. 1 . The floor mat  100  is shaped in a way to not add extra material or bulk to any of the side panels, pillars, drive shaft or any interior panels present and protruding in the seating/floor area in the automobile. This specific embodiment in  FIG. 1  is made in a shape so that it does not intrude or interfere with the driver&#39;s side pedals or foot placement. It is specifically tailored to the shape of the area in the automobile in which it is to be placed. 
         [0033]    Most automobiles have carpeting in the floor area and this floor mat is intended to be placed on top of that carpeting. The carpet layer  102  is located on the top surface of the floor mat  100 . The carpet layer may also be made of other textile materials. The floor mat  100  can have various shapes and/or tapers depending on the automobile application in which it is used. A matching mat could be supplied for the passenger side as well. Also, matching mats could be supplied for the rear seats. Additionally, a matching mat could be supplied for the trunk. 
         [0034]    A template  110  is placed over the carpet layer  102 . The template  110  may be used for cutting away the carpet layer  102  within the cut out sections  108 . Cutting away the carpet layer  102  may include removing the carpet fibers, cutting the carpet fibers, or shaving the carpet fibers. The shape of the cut out sections  112  substantially conforms to the shape of the inlays. 
         [0035]    The template  110  may have an outer perimeter dimension that conforms to at least part of the outer perimeter dimensions of the floor mat  100 . Other embodiments of the template may have any other outer perimeter dimensions. 
         [0036]    The floor mat  100  may have other types of surfaces such as non-slip surface and such surfaces may be used in combination with carpeting or other types of materials(not shown). 
         [0037]    The carpet layer  102  is cut by a cutter  103  to trim or remove the carpet fibers of that section. The cutter may be any means known in the art for trimming or removing fibers. The cut carpet fibers  104  are then at a length at least less than the carpet fibers at their original length. Once the carpet fibers have been trimmed or removed, an inlay  105  may be bonded to the cut carpet fibers  104 . In one exemplary embodiment, the inlay  105  may have a beveled edge  107  where inlay is bonded to the cut carpet fibers  104  in such a way that the beveled edge of the inlay  107  overlaps with the uncut carpet fibers  108 . The bonding of the inlay  105  to the cut carpet fibers  104  may be achieved in a number of ways including using an adhesive  106  as displayed in  FIG. 5 . 
         [0038]    An exemplary method for cutting the carpet layer  102  is displayed in  FIG. 3 . Said means for cutting the carpet layer  102  may be accomplished using a variety of tools including, but not limited to, a razor blade  103  and a template layer  110 . The template layer  110  may be positioned atop the carpet layer  102  to allow access to the portion of the fibers that are intended to be trimmed or removed.  FIG. 4  shows a method of preparing the mat where the carpet layers  102  have been trimmed or removed in a specific section of the floor mat  100  and the template layer  110  remains on top of the untrimmed areas of the carpet layer  102 . 
         [0039]    Some inlays  105  may have a beveled edge  107  at the edges of the inlay as shown in exemplary embodiment of  FIG. 7 . When the inlay  105  is positioned atop of the section of trimmed or removed carpet fibers  104 , the beveled edge of the inlay  107  is positioned in a way where the beveled portion extends over the uncut carpet fibers  108 . By extending the beveled portion  107  over the longer uncut carpet fibers  108 , the beveled portion of the inlay  107  pushes the longer fibers tighter together and creates a seamless effect  108  where there is no visible seam to the viewer of the mat. 
         [0040]      FIG. 8  displays another exemplary embodiment where a beveled inlay  205  is affixed to the cut carpet layer  204  using a staple or nail. The exemplary embodiment may be staples  209 . The base portions of the staples  209  are embedded in the substrate layer  200  and extend upward into the lower portion of the inlay  205 . 
         [0041]    Another preferred embodiment may use a tongue and groove  309  to attach the inlay to the trimmed or removed portion of the carpet layer  304 . The groove portion of the tongue and groove  309  may be affixed to the substrate layer  300  and the tongue portion may be affixed to the inlay  305 . The tongue and groove  309  may snap into place when applying pressure of the inlay on to the cut carpet fiber  304 . 
         [0042]      FIG. 10  provides an additional method of attaching said beveled inlay portion  405  atop of the cut carpet layer  404 . The preferred embodiment may use a hook and loop  409  (or Velcro) to attach the inlay  405  to the uncut carpet layer  404 . 
         [0043]    Another embodiment is a floor mat  500  with a holding structure  510  having an overhang  509  as shown in  FIG. 11 . The inlay  505  is placed adjacent to the holding structure. An edge of the inlay  505  may be tucked under the overhang  509  to secure the inlay  505  atop of the cut carpet portion  504 . Other means to affix the inlay may be used in combination with this method. The holding structure  510  may be an entire frame around one or more edges of the inlay. The vertical arm of the holding structure may also be positioned at an angle such that the end of the holding structure is positioned over carpet fibers in a manner that is similar to embodiments with the beveled edges. 
         [0044]    As shown in  FIG. 12 , an inlay portion  605  is placed atop uncut carpet layer  604 . In this method of preparing a floor mat, an outcropping  609  which is affixed to the substrate layer  600 , extends into a groove within the inlay. This embodiment may also be used in combination with other means of attachment including but not limited to adhesives or nails. 
         [0045]      FIG. 13  is another embodiment where the inlay  705  is attached to the cut carpet layer  704  using one or more screws  709 . The one or more screws  709  are mounted in or through the substrate layer  700  extending through the cut carpet fibers  704  and into at least a portion of the beveled inlay  705 .  FIG. 14  displays an additional method of attaching said beveled inlay  805  atop of the trimmed or removed carpet layer  804 . In this method of preparing a floor mat a form of one or more nails  809  are used to attach the inlay to the trimmed or removed portion of the carpet layer  804 . The one or more nails  809  are mounted in or through the substrate layer  800  extending through the trimmed or removed carpet fibers  804  and into at least a portion of the beveled inlay  805 . 
         [0046]      FIG. 15  is another embodiment where the beveled edge inlay  905  may have one or more rods  909  to be used for decorative purposes or provide a non-slip surface. The rods may be made of similar materials to the inlay or other materials such as rubber. The rods are not limited to having a circular diameter but may have any other shape such as oblong, rectangular, etc. 
         [0047]      FIGS. 16 and 17  show an additional method for attaching the beveled inlay  1005  atop of the trimmed or removed carpet layer  1004  wherein the inlay comprises a tray  1010  with a beveled edge or curved edge. The dimensions of the tray are configured to fit the beveled inlay  1005 . The tray may be mounted using any attachment method such as those previously described as well as with grommets  1009 . The grommets  1009  in this method of preparing a floor mat are mounted in or through the substrate layer  1000  extending through the cut carpet layer  1004  and at least partially into the beveled tray  1010 . The said beveled tray  1010  may extend partially upon and over the uncut carpet fibers  1011  creating the unique seamless effect desired. Said inlay may be mounted against the tray using a form of adhesive or through any method previously described. 
         [0048]      FIGS. 18 and 19  show an additional embodiment of attaching the inlay  1105  to the trimmed or removed carpet fiber portion  1104  of the floor mat. In this method of preparing a floor mat there is a carved out design portion  1112  that aligns with an untrimmed portion  1102  of the carpet fibers. The cut and uncut carpet fibers within this region may be cut to substantially match the shape of the design portion  1112 . The design portion  1112  may have beveled edges that may overlap some of the uncut carpet fibers  1102 . 
         [0049]      FIGS. 20 and 21  show an additional method and embodiment of attaching the beveled inlay portion  1205  where there is a plurality of inlays attached to the uncut carpet fibers. The beveled edges may be angled in an opposite manner than previously described. Here, the beveled edges may also allow for flexing of the car mat between each of the inlays. 
         [0050]      FIGS. 22 and 23  show a corner attachment piece  1313  that fits around the corners of the mat. The said attachment piece  1313  may also wrap around the top, bottom, and side edges of the mat. The attachment piece  1313  may be used for protection, prevent sliding of the mat, and for various other reasons. Additionally, said attachment piece  1313  may vary in size and thickness. 
         [0051]    Others skilled in the art can provide yet other embodiments employing the concepts of the present invention. Accordingly, the breadth of the invention should only be limited by the scope of the claims appended hereto.