Patent Description:
Vehicle mats are used in vehicles to protect the floor of vehicles under the feet of vehicle occupants. Frequently, the mats become soiled, or full of mud and dirt, and must be cleaned. To do so, a user typically will remove the mats from the vehicle, affix them to holder, and spray them with water, sometimes pressurized water if the user has access to a pressure washer. If not, the user will also use a brush and manually brush the mat to remove any stubborn dirt and debris on the mat. While this manual method of washing mats works, it is time consuming and labor intensive. Reference may be made to <CIT> which discloses a method and apparatus for cleaning a vehicle mat. The disclosed process receives a user identifier, such as a phone number and/or PIN, at a mat cleaner from a user. The mat cleaner then accepts a mat, such as a yoga mat, from the user and conveys the mat through the mat cleaner. Various guides and sensors are employed to facilitate straight insertion and smooth conveyance of the mat through the mat cleaner. As the mat is conveyed, the mat is illuminated with ultraviolet light and sprayed with a recirculated cleaning solution. The mat cleaner includes a sensor, such as a float switch, to facilitate determination of the circulated cleaning solution level. Specifically, the method comprises receiving a user identifier, receiving the mat, conveying the mat via a plurality of rollers in response to receiving the user identifier, illuminating the mat with ultraviolet radiation while conveying the mat, spraying the mat with a recirculated cleaning solution while conveying the mat, determining if the recirculated cleaning solution requires refilling using a sensor, transmitting a signal indicative of a recirculated cleaning solution level, and rolling up the mat after illuminating and spraying the mat.

Accordingly, there remains room for improvement in the field of washing vehicle mats, and in particular three dimensional vehicle mats.

An apparatus is provided to automatically clean a vehicle mat, and can include one or more compliant rollers that cooperatively grab and advance the vehicle mat toward one or more brushes that scrub debris from above and/or below the mat.

In one embodiment, the vehicle mat can be a semi-rigid, three-dimensional mat including a floor substantially conforming to a floor of a vehicle foot well and at least one wall integrally formed with the floor and extending upward from the floor at a first angle. In some cases, the wall can be a forward wall integrally formed with the floor extending upward from the floor at the first angle. In other cases, the wall can be a side wall integrally formed with the floor extending upwardly from the floor along a side of the mat, substantially conforming to a foot well wall. One or more walls can be joined with the floor of the mat by a curved transition. Due to one or more of these features, the mat can have a bulky, abnormal and/or contoured shape.

In another embodiment, the one or more compliant rollers can deform a distance radially toward an axis of rotation when contacting the mat to accommodate the contoured three dimensional shape of the mat and still grab the mat for advancing, optionally altering the first angle to a second angle different from the first angle and/or flattening the curved transition.

In still another embodiment, the apparatus can include first and second brushes that rotate in opposite directions. The mat can be fed between these brushes so they simultaneously engage the mat from above the vehicle mat and below the vehicle mat, to scrub debris from the vehicle mat while moving along a first pathway, optionally altering the first angle to a second angle different from the first angle and/or flattening the curved transition.

In yet another embodiment, the apparatus can include a deflector that deflects the vehicle mat downstream of the brushes to a second pathway different from first pathway. The deflector engages the vehicle mat to bend at least one of the floor and the wall, optionally altering the first angle to a second angle different from the first angle and/or flattening the curved transition.

In even another embodiment, the apparatus can include a holding pan that receives and supports the mat so it is accessible through a second opening below the brushes and a first opening of a frame that supports the rollers and brushes. The deflector can be included to reroute the mat downstream of the brushes along a pathway toward the pan.

In a further embodiment, the one or more brushes can rotate at a greater RPM than the compliant rollers to exert a tension on a first portion of the vehicle mat between the brushes and the compliant rollers. A second portion of the vehicle mat beyond the brushes is not under the tension. The tension can allow the brushes to rotate relative to the surfaces of the mat to provide a scrubbing action, rather than simply move at the same tangential speed as the surfaces, which may not provide any scrubbing action to those surfaces.

In still a further embodiment, a method of washing a vehicle mat is provided. The method can include providing a vehicle mat including a floor substantially conforming to a floor of a vehicle foot well and a wall integrally formed with the floor of the mat and extending rigidly upward from the floor at a first angle; advancing the vehicle mat with a plurality of compliant rollers that are rotating under power, at least one of the compliant rollers deforming radially toward an axis of rotation when contacting and grabbing the vehicle mat; engaging the vehicle mat with a first brush to scrub debris from the vehicle mat while moving along a first pathway; and bending at least one of the floor and the wall so that the first angle changes to a second angle different from the first angle.

In yet a further embodiment, the method can include deflecting the vehicle mat downstream of the first brush to a second pathway different from first pathway. The bending can occur during the deflecting, or interaction with the rollers or brushes.

In even a further embodiment, the method can include depositing the vehicle mat on a holding pan below the first brush. The vehicle mat can include an upper surface and a lower surface. The lower surface can face upward when the vehicle mat is advanced with the compliant rollers. The lower surface can face downward when the vehicle mat is supported on the holding pan.

The current embodiment provides an apparatus and method for quick and consistent cleaning of a three-dimensional, contoured vehicle mat via an automatic system. The apparatus can effectively pull and advance the mat through the system, accommodating the various different contours and walls of the mat. The brushes can clean upper and lower surfaces of the mat simultaneously, to provide complete cleaning. The apparatus also can prevent inadvertent bunching of the mat downstream of the brushes, and can deposit the mat in a holding pan if included for easy retrieval by a user.

These and other objects, advantages, and features of the invention will be more fully understood and appreciated by reference to the description of the current embodiment and the drawings.

Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following detailed description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of "including" and "comprising" and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components.

A current embodiment of the vehicle mat washer is shown in <FIG> and generally designated <NUM>. The mat washer <NUM> can include a frame <NUM> and enclosure <NUM>, one or more sets of compliant rollers <NUM> and <NUM>, and one or more brushes <NUM> and <NUM>. The compliant rollers <NUM> and <NUM> can intake the vehicle mat <NUM> described below, advance the mat toward the one or more brushes <NUM> and <NUM>, and can operate in conjunction with the brushes to satisfactorily feed the vehicle mat through the brushes to remove debris from the vehicle mat <NUM>, for example, both the upper 100U and lower surfaces <NUM> as described below. The rollers can grab the mat <NUM> and pull it into the washer <NUM>, advancing it toward the brushes. Optionally, the brushes can spin at a faster rate than the rollers <NUM> and <NUM> and scrub debris from the upper and/or lower surfaces of the mat <NUM>, due to the mat advancing at a slower rate than the tangential speed of the outermost surfaces of one or more of the brushes.

In advancing from the rollers to the brushes, the mat <NUM> can travel on a first pathway P1, which can generally be a linear pathway between those elements. Optionally, the mat washer <NUM> can be constructed to fit within a confined space, where it can be placed up against a wall WL (<FIG>) that is part of a larger structure, such as a building. As such, the washer <NUM> can be configured to deflect the mat along a second pathway P2 and/or a third pathway P3 back toward the user after cleaning along a first pathway P1. For example, that washer <NUM> can include the enclosure <NUM>, in which the user initially places the mat <NUM>. The mat can proceed through the rollers, brushes and deflectors, as described below, to be deposited on a holding pan <NUM> as described below. The holding pan <NUM> can be accessible through the second opening <NUM> so that a user can retrieve the clean mat <NUM> through the opening <NUM>. Further optionally, the first opening <NUM> can be disposed above the second opening <NUM>. Of course, in other applications, where the washer <NUM> includes a more singular or linear pathway, the openings <NUM> and <NUM> can be aligned with one another but on opposite sides of the closure <NUM>. The enclosure <NUM> can be constructed from multiple panels which conceal the internals and the frame <NUM> of the mat washer <NUM>.

Generally, the mat washer <NUM> can clean, wash, treat, scrub, modify or otherwise modify (all referred to as scrub herein) a vehicle mat <NUM> to remove debris from that mat. The vehicle mat <NUM> optionally can be a three-dimensional, contoured vehicle mat that is designed or configured to fit within a vehicle floor well. The vehicle mat <NUM>, as shown in <FIG>, can include a floor <NUM> upon which a vehicle occupant's feet can be disposed when the vehicle mat <NUM> is in a vehicle foot well. The floor can substantially conform to that vehicle foot well and can be of a similar shape and outline. The vehicle mat <NUM> can include a forward wall <NUM> integrally formed with the floor <NUM> and extending upwardly from it. The forward wall <NUM> can be disposed at an angle A1 relative to the floor <NUM> when the mat <NUM> is in a normal, uncompressed or un-tensioned state, for example, when the mat is in a vehicle foot well or generally sitting on a flat surface removed from the vehicle. The first angle A1 can be a static angle that is maintained in the mat without any outside forces acting on the mat, due to the mat's rigidity and contours molded into it. The angle can be optionally between <NUM>° and <NUM>°, inclusive, between <NUM>° and <NUM>°, inclusive, between <NUM>° and <NUM>°, inclusive, between <NUM>° and <NUM>°, inclusive, or other angles, depending on the vehicle well into which the mat is to be placed. The forward wall can be configured to be disposed under one or more brake or acceleration pedals of the vehicle and can be disposed generally forwardly of the floor <NUM>. The forward wall <NUM> as shown can be split into one or more different individual walls or panels that are separated or spaced from one another as shown, but that optionally can be contiguous and integrally formed with one another.

The forward wall <NUM> can transition to the floor <NUM> at a curved transition 102C, which can be rigid enough to retain the angle A1 between the remainder of the floor <NUM> and the wall <NUM>. The mat <NUM> optionally can include one or more side walls <NUM> integrally formed with the floor <NUM> and extending upwardly from the floor <NUM>, distal from at least a portion of the forward wall <NUM> and substantially conforming to a foot well wall. The side wall <NUM> can be joined with the floor <NUM> via a curved transition 103C. The side wall <NUM> can project forwardly and can transition to a portion of the forward wall <NUM>. In some cases, the mat can include additional sidewalls, for example, and opposing sidewall <NUM> that lays across the longitudinal axis LA of the mat. The mat <NUM> can include a rear sidewall or rear wall <NUM> distal and opposite from the forward wall <NUM>, which can lay in a position, when installed in the vehicle, behind an occupant's feet. In some applications, the forward wall, sidewalls and rear walls and floor can form a tray that can capture and retain dirt, mud, snow, water and other debris from a user's feet therein, preventing it from leaking to a vehicle foot well and any carpet or other material disposed therein.

The mat <NUM> can be constructed from a polymer, and can be semi-rigid and can hold its shape in a three-dimensional form when removed from the vehicle well. Each of the walls can extend upward from the floor and can be disposed in a non-planar orientation relative to the floor. The walls can be generally self-supporting due to the semi rigid or rigid character of the mat. Due to the various walls extending upward from the floor, the mat can be difficult to process or wash due to its unwieldy, bulky and irregular shape and size. The mat washer <NUM> herein can be configured so that the mat is not permanently deformed, torn or damaged so that it no longer fits the vehicle foot well.

With reference to <FIG>, the particular components of the mat washer <NUM> will now be described in further detail. The washer <NUM> can include a frame <NUM>. The frame <NUM> can include multiple upright vertical supports in corners that support horizontal support bars which will not be described in detail here. The frame <NUM> can support a motor <NUM> which can drive and rotate the various rollers, brushes and deflectors as described below. The particular drive mechanism as shown can include multiple belts 23B1, 23B2, etc., which engage multiple pulleys, for example pulleys 43P, 53P, 73P, 91P, 92P to rotate the respective first and second compliant rollers <NUM>, <NUM>, as well as the second brush <NUM> and rollers <NUM>, <NUM> as described below. As shown in <FIG>, the motor <NUM> can include a direct drive shaft <NUM> that rotates the first brush <NUM>, but of course, that brush and other elements could be driven in other manners, depending on the application.

Optionally, the first brush <NUM> can rotate at a faster RPM than the compliant rollers <NUM> and <NUM> to promote or exert a tension T in the mat <NUM> when located between the compliant rollers <NUM> and <NUM>, the first brush <NUM>, and optionally the second brush <NUM>. This can be shown in with reference to <FIG>. There, a tension T is exerted and the portion 100P1 of the mat <NUM> that is between the compliant rollers <NUM> and <NUM> as well as the brushes <NUM> and <NUM>. That portion 100P1 can be under a tension T optionally of at least <NUM> N/m2 (<NUM>/<NUM> pound per square inch), at least <NUM> N/m2 (<NUM>/<NUM> pound per square inch), <NUM> N/m2 (<NUM> pound per square inch) or other tensions depending on the application and the desired scrubbing of the mat <NUM>. Between the respective rollers <NUM> and <NUM>, and the brushes <NUM> and <NUM>, the portion 100P1 can be substantially planar, as it is being stretched out in a linear manner between the points of contact at the rollers and the brushes. That portion 100P1 optionally does not curve, dip or sag between those elements.

As mentioned above, the frame <NUM> can support the first set <NUM> and second set <NUM> of compliant rollers. These rollers can be supported on a bar <NUM> and <NUM> that extend across the width W of the frame. The rollers can grab and advance the mat <NUM> when the mat <NUM> is placed adjacent to the opening <NUM>. Each of the compliant rollers <NUM>, <NUM> can be in sets of individual rollers or roller units. For example, the first set of rollers <NUM> can include a first roller <NUM>, a second roller <NUM> and a third roller <NUM>, also respectively referred to as a primary roller, an intermediate roller, and a secondary roller of the first set. The second set of rollers <NUM> can include a first roller <NUM>, a second roller <NUM> and a third roller <NUM>, also respectively referred to as a primary roller, an intermediate roller and a secondary roller of the second set. Optionally, the number of independent and separate rollers can vary depending on the application and the grip to be applied to the mat <NUM>.

The rollers of each of the respective sets can be separated respective distances D1 and D2 from one another. For example, the primary roller <NUM> can be separated from the intermediate roller <NUM> by the distance D1, and the intermediate roller <NUM> can be separated from the secondary roller <NUM> by the distance D2. The distances D1 and D2 can be equal. The same can be true for the primary, intermediate and secondary rollers of the second set of rollers <NUM>. By separating the independent roller units <NUM>, <NUM> and <NUM> from one another along the bar <NUM>, each of the independent roller units <NUM>, <NUM> and <NUM> can independently grip and dynamically compress, collapse or react relative to the interaction of that individual roller unit with the contours and shapes of the three-dimensional mat <NUM>. Each of the rollers optionally can be aligned vertically with one another. For example, the primary rollers <NUM> and <NUM> of the different roller sets can be aligned one above the other to provide a pinching or gripping action therebetween on the mat <NUM>. Likewise, the intermediate and secondary rollers also can be aligned from one set to the next.

Optionally, the rollers <NUM> and <NUM> are not formed of a continuous roller unit that extends across the entire width of the mat <NUM>. Instead, the rollers form an interrupted and discontinuous force application zone FAZ that applies pressure via each of the separate rollers units <NUM>, <NUM>, <NUM> and <NUM>, <NUM>, <NUM> separately and independently to the mat. With this type of separated and discontinuous force application zone FAZ, the rollers optionally can conform more easily to the varying contours of the mat. Of course, in some alternative applications, the rollers can be constructed of a continuous unit that extends across the width of the opening <NUM> and the frame as a single, unitary drum-type roller, rather than separated into individual roller units as shown. In this application, the compliant rollers can be configured to deform as described herein to effectively handle the contours of the three-dimensional mat, yet still grip and grab that mat to advance it along the pathway P1.

The compliant rollers <NUM> and <NUM> as described herein can rotate about the respective bars 43B and 53B as described above. The rollers also can rotate about the respective axes of rotation 40A and 50A respectively. As shown in <FIG>, each of the compliant rollers can include multiple spokes and an outer perimeter. For example, the roller unit <NUM> can include multiple spokes <NUM> that connect an inner portion or hub 43I, which circumferentiates the axis 40A, to an outer perimeter portion 43PP, which extends to an outer perimeter 43P of that roller unit <NUM>. The roller itself can be constructed from a compliant material, such as rubber, nitrile, neoprene, foam, ethyl vinyl acetate, thermoplastic polyurethane, silicone or other materials. The spokes <NUM> can extend from and connect the inner hub 43I with the perimeter portion 43PP around the axis 40A. The hub, spokes and perimeter portion all can be integrally and monolithically formed of the same material that extends homogeneously through these elements. Of course in other applications, these elements can be separately constructed and not integral, but rather glued, fastened, secured or otherwise attached to one another.

The spokes <NUM> can be thin and deformable, which can allow them and their outer perimeter 43P to deflect or deform radially toward the axis of rotation 40A, as shown in <FIG>. There, a portion of the curved transition 102C of the mat <NUM>, which can be semi rigid, can engage the outer perimeter 43P of the roller <NUM>. As a result, that perimeter surface 43P can move radially inward in direction RI generally toward the axis of rotation 40A of the roller. In doing so, the outer perimeter, spokes and/or the roller <NUM> can slightly deform, deflect, move or otherwise become modified and move in that direction RI. It will be appreciated that the other rollers <NUM> and <NUM> of the first roller set <NUM>, as well as the individual roller units of the second roller set <NUM>, also can deform in a similar manner, being constructed similarly to the roller unit <NUM> as described above.

Depending on the particular contours of a particular vehicle mat, the deflection can be greater or less than that shown in <FIG>. For example, where the contour 102C, which as shown can be a curved transition (but can be of any other three-dimensional contour of the mat), contacts the outer perimeter 43P, that outer perimeter can move in direction RI or deform, such that the outer perimeter 43P moves a distance DD toward the axis <NUM>. When the perimeter 43P deforms and moves toward the access 40A, the radius R1 of the roller <NUM> can be reduced to a second, lesser distance or radius R2 as the outer perimeter deforms. The distance DD by which the compliant roller deforms can be at least optionally at least <NUM> (<NUM>/<NUM> inch), at least <NUM> (<NUM>/<NUM> inch), at least <NUM> (<NUM>/<NUM> inch), at least <NUM> (<NUM>/<NUM> inch), at least <NUM> (<NUM> inch), at least <NUM> (<NUM><NUM>/<NUM> inch), or other distances depending on the durometer and compliance of the rollers, and/or the rigidity and/or contours of the vehicle mat.

Of course, after the perimeter no longer contacts the contour 102C, the outer perimeter 43P can automatically deform or extend outward again, away from the axis 40A, so that the radius R1 is reestablished at the location where the outer perimeter 43P was temporarily deformed. This process of deforming the rollers can be repeated multiple times for various contours of the mat, and as described above, also can transfer forces from the compliant rollers to the mat itself, causing the mat to bend, deform, deflect or otherwise become slightly modified when engaging the respective rollers, as well as the brushes or deflectors as described below.

As shown in <FIG>, the first and second compliant rollers <NUM> and <NUM> can exert a force F1 on the mat <NUM>. This force F1 can be a compressive force so that the mat is compressed within an optional opening CO between the two sets of rollers. This compressive force can bend a portion of the mat <NUM>. As shown, the mat <NUM> passing between the rollers <NUM> and <NUM> can be engaged by the force F1. This in turn can change the angle A1 to a different, for example, greater or lesser, angle A2 between the forward wall <NUM> and the floor <NUM> of the mat. Optionally, this can move at least one of the forward wall <NUM> and/or the floor <NUM> toward a common plane CP. If there are any curved transitions, for example, a contour 102C, the compressive force F1 optionally can compress, modify or flatten slightly that curved transition or contour 102C, which in some cases can alter the previous angle A1 to a different angle A2 between the floor and one or more of the walls of the mat.

As mentioned above, the first set of compliant rollers <NUM> can rotate in a first direction R1 and the second set of compliant rollers <NUM> can rotate in a second direction R2, which can be opposite the first direction R1. With these opposite rotational characteristics, the rollers can grip the respective lower surface <NUM> and upper surface 100U of the mat <NUM> and advance it along the pathway P1 away from the opening <NUM> toward the brushes <NUM> and <NUM>. The first brush <NUM> can rotate in a direction R3 which can be different from a fourth direction R4 in which the second brush <NUM> rotates. The first brush <NUM> can have a greater brush diameter DB1 then a brush diameter DB2 of the second brush <NUM> as shown. Of course, in other applications, these diameters can vary depending on the desired scrubbing action on the respective vehicle mat. The first brush <NUM> can rotate in direction R3 at a greater RPM than the second brush <NUM>. For example, the first brush <NUM> can rotate at an RPM that is RPMG, which can be optionally at least <NUM> RPMs, optionally at least <NUM> RPMs, at least <NUM> RPMs, at least <NUM> RPMs, at least <NUM> RPMs, at least <NUM> RPMs greater than the RPM that is the RPML of the second brush <NUM>, shown in <FIG>, as well as the RPMs of the first set of rollers <NUM> and second set of rollers <NUM>.

Again, this difference in RPMs of the first brush <NUM> relative to the RPMs of the compliant rollers <NUM> and <NUM>, which grab and hold the mat, allows the first brush <NUM> to quickly rotate at a fast enough rate to scrub and clean the mat, instead of allowing the first brush to actually advance the mat quickly through or past the brushes <NUM> and <NUM>. The first brush thus scrubs and moves over the surfaces of the mat, rather than pulling it, while the rollers advance the mat toward the brushes as they grab the mat. The first brush <NUM> also can rotate at a greater RPM than the compliant rollers to exert a tension T on a first portion 100P1 of the vehicle mat between the compliant rollers and the first brush. A second portion 100P2 of the vehicle mat beyond the first brush, however, optionally is not under the tension T.

For example, as shown in <FIG>, the mat <NUM> is advanced along the pathway P1. The portion of the mat 100P1 between the rollers <NUM>, <NUM>, and the brushes <NUM>, <NUM> can be under the tension T. The portion 100P2 of the mat that extends beyond the first <NUM> and second <NUM> brushes optionally can be under no tension. In that portion 100P2, there optionally can be no external forces between the brushes <NUM>, <NUM>, and some other component that produces a tension in that portion 100P2. Thus, when moving along the pathway P1, the mat <NUM> can include a first portion 100P1 that is under tension, and a second portion 100P2 that is not under any tension, downstream of the brushes <NUM>, <NUM>. Of course, when that second portion 100P2 encounters another element of the washer <NUM>, it may or may not be placed under tension.

With reference to <FIG> and <FIG>, the first and second brushes <NUM> and <NUM> can be constructed to include multiple bristles. These bristles can be in the form of elongated or rigid fibers, strands, straws, pieces of fabric, pieces of nylon or other materials. The bristles can project outward from the respective axes of rotation 60A and 70A of the respective brushes. The brushes can directly contact one another, or can form a brush opening BO along the pathway P1. The brush opening BO can be optionally less than <NUM> (<NUM> inches), optionally less than <NUM> (one inch), optionally less than <NUM> (<NUM>/<NUM> inch) or other dimensions depending on the scrubbing action of the brushes on the upper and lower surfaces of the mat <NUM>.

Optionally, the bristles of the brushes can engage the respective upper 100U and lower <NUM> surfaces of the mat <NUM>, or other surfaces thereof, and can engage pieces of debris DBR, effectively scrubbing or removing the debris from the mat, transporting it along the bristles away from the mat as shown in <FIG>. This engagement of the mat with the first brush <NUM> and the second brush <NUM> can be simultaneous, so that those brushes can simultaneously engage the vehicle mat from above the vehicle mat and from below the vehicle mat to scrub the debris while moving on the first pathway P1. As used herein, debris can be any dirt, mud, particulate matter, waste, water, liquids or other materials. As also used herein, scrub can refer to any mechanical or cleaning action that removes, loosens or reduces debris from one or more surfaces of the mat <NUM>, whether in contact with the mat or not.

In some cases, the first brush <NUM> and second brush <NUM> of the mat washer <NUM> can engage the mat with a compressive force F2 therebetween. This compressive force or other force depending on the direction of the force F2, can push against the floor and/or the walls of the mat <NUM> to alter, bend or otherwise change the shape and or relationship of the walls and floor relative to one another. For example, as shown in <FIG>, when the force F2 is applied by the brushes on the mat <NUM>, that force F2 can change the original angle A1 between the forward wall <NUM> and the floor <NUM> to a second, greater angle A2 between those elements. Of course, the angle A1 alternatively could become a lesser angle A2, depending on the application and type of force applied. The force F2 between the brushes also can flatten out or modify any curved transition or other contour, for example 102C, between the floor and the walls. Further optionally, the wall <NUM> and floor <NUM> can be compressed toward a common plane so that the first angle A1 changes to the second angle A2 as shown in <FIG>.

Optionally, where the mat washer <NUM> is configured to redirect the mat from the first opening <NUM> to the second opening <NUM>, which is located below the first opening <NUM>, as shown in <FIG> and <FIG>, the mat washer <NUM> can include one or more deflectors <NUM>. As shown in <FIG>, <FIG> and <FIG>, these deflectors optionally can be in the form of additional compliant rollers, similar to the rollers <NUM> and <NUM> described above. These deflectors optionally can be powered by the motor <NUM> to rotate in a direction R5 to further direct the mat <NUM> downward to an additional set of rollers <NUM> and <NUM> along a second pathway P2. This second pathway P2 can extend in a second direction different from, and transverse to, the first pathway P1. Optionally, the deflector <NUM> can engage the mat <NUM> to bend the mat downward in a direction as shown in <FIG>, and advance it toward the additional compliant rollers <NUM> and <NUM> so that those rollers can feed the mat toward the holding pan <NUM>. In some cases, the deflector <NUM> can be optionally replaced with a panel 80P, shown in broken lines in <FIG>, which can be bent or curved toward the rollers <NUM> and <NUM>.

When the mat encounters a deflector, the mat can be deflected downstream of the first and second brushes <NUM> and <NUM> to a second pathway P2 different from the first pathway P1. During this deflecting, the mat optionally can bend, deform otherwise and become modified as shown at B in <FIG>. The mat <NUM> also can be modified so that when the deflector engages the mat, it bends at least one of the floor and the walls of the mat so that the first angle A1 changes to a second angle A2, which again is different from the first angle A1. The second angle can be greater than the first angle. Further, when it bends, the distal portion 100D of the mat can project along the pathway toward an opening between the first and second rollers <NUM> and <NUM>. The rollers ultimately can grab the mat and advance it toward the holding pan <NUM> along the pathway P2. This is shown further in <FIG>. There, the distal end 100D of the mat <NUM> has been advanced by the rollers <NUM> and <NUM> toward the holding pan <NUM>. In some applications, at this point, the directions of rotation of the brushes <NUM> and <NUM> can be reversed. For example, the direction of rotation R3 of the first brush can be altered to an opposite direction R6. This reversing of the direction of the brush optionally can impair or prevent the mat <NUM> from becoming bunched in case the proximal end 100P of the mat stays engaged with the brush <NUM>. Sometimes, if this occurs, the proximal end 100P can be bent toward the floor <NUM> and can bind or bunch the mat in the mat washer <NUM> so that it can become stuck, not advancing any farther through the washer.

<FIG> shows where the mat <NUM> transitions to the holding pan <NUM> and travels along a third pathway P3 that is transverse to the second pathway P2. As shown in <FIG>, the mat <NUM> can travel along the pathway P3 and the holding pan <NUM> toward the second opening <NUM>. From that opening <NUM>, a user can gain access to the mat <NUM> and remove it from the holding pan <NUM> and generally from the mat washer <NUM>. The holding pan <NUM> can be disposed below the first brush <NUM> and the second brush <NUM>, as well as the compliant roller sets <NUM> and <NUM>. It will be noted that when the mat is deposited on the holding pan <NUM>, the mat <NUM> can be supported by the holding pan so that the upper surface 100U of the mat faces upward and the lower surface <NUM> can face downward, which opposite the configuration when the mat <NUM> was first introduced to the mat washer <NUM> through the first opening <NUM> as shown in <FIG>.

The angle between the forward wall <NUM> and the floor <NUM> can optionally return to the angle A1 of the contoured mat before being washed and the mat washer <NUM>. As shown, the holding pan <NUM> can be an open mesh material so that liquids used to clean the mat <NUM> can impinge upon the pan and drip or drain through it. In other cases, the holding pan can be a panel or sheet, which optionally can include one or more drainage holes. In other cases, the pan can be a solid panel with no holes, depending on the application.

The mat washer <NUM> can include one or more sprayers <NUM> and <NUM> as shown in <FIG>. The sprayers <NUM> and <NUM> can distribute spray patterns S1 and S2 of cleaning liquids and/or rinsing liquids onto the mat <NUM> as it is advanced through the mat <NUM> by the washer <NUM>. As an example, the sprayer <NUM> can spray a first spray pattern S1 between the compliant rollers <NUM>, <NUM> and the brushes <NUM>, <NUM>. The first spray pattern can include a cleaning solution, such as soap, cleaner or other chemicals to facilitate removal of debris DBPR from the mat. The second sprayer <NUM> can spray a second spray pattern S2 downstream of the brushes <NUM>, <NUM> and downstream of the rollers <NUM> and <NUM>. This second spray pattern S2 can be initially sprayed on the second portion 100P2 of the mat as shown in <FIG>, and then on the remainder of the mat as shown in <FIG>. This second spray pattern can include a rinse solution, for example, a liquid such as water or some other rinsing liquid, depending on the application. Of course, other sprayers can spray other spray patterns on the mat in various locations within the mat washer. In some cases, the spray patterns S1 and S2 can drain or drip down to the holding pan <NUM> and impinge on the holding pan <NUM> before the vehicle mat <NUM> actually reaches the pan <NUM>. In other applications, the mat <NUM> can shield the holding pan from all or a portion of the spray patterns S1 and S2.

A method of using the mat washer <NUM> of the current embodiment will now be generally described. The method can include providing a vehicle mat including a floor substantially conforming to a floor of a vehicle foot well and a wall integrally formed with the floor of the mat and extending rigidly upward from the floor at a first angle; advancing the vehicle mat with a plurality of compliant rollers that are rotating under power, at least one of the compliant rollers deforming radially toward an axis of rotation when contacting and grabbing the vehicle mat; engaging the vehicle mat with a first brush to scrub debris from the vehicle mat while moving along a first pathway; and bending at least one of the floor and the wall so that the first angle changes to a second angle different from the first angle.

More particularly, as explained above, a user can insert a dirty mat in the mat washer <NUM> by projecting it into the opening <NUM> as shown in <FIG>. The compliant rollers <NUM> and <NUM> as shown in <FIG> can grab the mat and advance it toward the brushes <NUM> and <NUM> as described above. The math <NUM> can travel along the pathway P1 in so doing and can enter the frame <NUM>. The motor <NUM> can power the respective rollers <NUM> and <NUM>, as well as the brushes <NUM> and <NUM>. These items can rotate in the directions as described above. Optionally, the first brush <NUM> can rotate at faster RPMs than the rollers <NUM> and <NUM>. This can exert a tension T in the portion 100P1 of the mat between the brushes and the rollers as described above. This can allow for additional scrubbing of debris from the mat by the brushes <NUM> and <NUM> as explained above.

The mat <NUM> can continue to be advanced along the pathway P1 as shown in <FIG> with a portion 100P1 under tension T, while remaining portion 100P2 is under no tension. The sprayers <NUM>, <NUM> can spray the liquids in these spray patterns S1 and S2 on the mat as described above. The rollers <NUM> and <NUM> optionally can deflect or deform the mat so that it bends as shown in <FIG>. Portions of the roller also can deflect toward the axes of rotation. As described in connection with <FIG>, the mat <NUM> can continue along the pathway P1 until being deflected by deflector <NUM> to transition to a second pathway P2 transverse to the first pathway P1. The mat can bend after contacting the deflector as described above. As shown in <FIG>, the mat can bend to change the first angle A1 to a second greater or generally a different angle A2 as described above.

The mat <NUM> can be advanced by the deflector along the second pathway P2 toward the secondary rollers <NUM> and <NUM> to transition toward the holding pan <NUM>. The rollers <NUM> and <NUM> also optionally can bend the mat and/or change the first angle to a second angle when the mat goes between the rollers. The rollers <NUM> and <NUM> can advance the mat toward the holding pan <NUM> so that the mat then travels along the pathway P3 and along the holding pan toward the opening <NUM>, where it can be accessed by user as described above.

A first alternative embodiment of the mat washer is shown in <FIG> and generally designated <NUM>. This mat washer can be similar in structure, function and operation to the current embodiment of the mat washer <NUM> described above with several exceptions. For example, this mat washer <NUM> can include a first set of compliant rollers <NUM> and a second set of compliant rollers <NUM> that are juxtaposed relative to one another adjacent and opening <NUM> of an enclosure <NUM>. These compliant rollers can be virtually identical to the sets of compliant rollers described above, however, there can be additional individual roller units within each of roller sets, and each of the individual rollers can be placed closer to one another than in the embodiment above. The rollers <NUM> and <NUM> also can be offset relative to a first brush <NUM> and a second brush <NUM>, which can be virtually identical to the embodiment described above.

In this embodiment, the first set of rollers <NUM> can be mounted on respective bar 143B and can rotate about an axis centered in a plane P6 that is set backward or farther away from the opening <NUM> than the bar 153B upon which the second set of rollers <NUM> is are mounted. These rollers <NUM> can rotate about an axis that is in the vertical plane P7, which is closer to the opening than the vertical plane P6. In this configuration, the lower or second set of rollers <NUM> can be the first rollers that engage and contact a respective mat <NUM> that is fed into the mat washer <NUM>. In some cases, when the mat <NUM> is initially placed in the opening, the force of gravity can cause the distal end 100D of the mat to move toward and rest or engage the lower rollers <NUM>. The distal part 100D of the mat <NUM> thus can be grabbed or advanced more easily by the lower set of rollers <NUM> to advance the mat toward the upper set of compliant rollers <NUM> and thereby fully grab the mat with both roller sets. The rollers can rotate similar to the corresponding sets of rollers <NUM> and <NUM>, can be compliant and can deform like those rollers as described above. Accordingly, these rollers sets <NUM> and <NUM>, as well as their individual rollers, bars and drives will not be described again in detail here.

With reference to <FIG>, the mat <NUM> is advanced along a first pathway P1 by the first <NUM> and second <NUM> compliant rollers grabbing the mat and advancing it along that pathway toward the first brush <NUM> and second brush <NUM>. As this occurs, the compliant rollers can modify the contours and angles of the mat, and can deform themselves as they engage the mat <NUM>, as described above. The first brush <NUM> and second brush <NUM> can operate similar to the embodiment above to remove and scrub debris from the upper and lower surfaces of the mat <NUM>. The brushes also can exert forces on the mat to flatten it or otherwise affect the contours and angles of the mat <NUM> as described in the embodiment above.

In this embodiment, as shown in <FIG> and <FIG>, the mat washer <NUM> can include an enclosure <NUM> that can have various panels to provide enhanced concealment and service exposure to the components housed in the enclosure. For example, the enclosure <NUM> can include a lid <NUM>, a front panel 130F and respective side panels <NUM> that each can be easily attached to and removed from the frame of the mat washer. The frame also can be optionally mounted on castors or wheels <NUM> to allow the mat washer to be moved around a facility. The mat washer <NUM> as shown also can include a motor <NUM> that can drive the various rollers and brushes, similar to the embodiment above. A system of pulleys and belts can be organized relative to the motor <NUM> to drive each roller and brush in respective directions to advance the mat through the washer to clean or wash the mat.

Optionally, the mat washer <NUM> can include a frame trough <NUM> that can be disposed below the various rollers and brushes. This trough can collect a cleaner or rinsing solution that is sprayed on the mat from sprayers, which are not shown, but are similar to the sprayers in the embodiment above. The trough can include a drain and hose, also not shown, that can collect and convey cleaner or rinse solution out from the mat washer and to a container or drain for storage or disposal.

With reference to <FIG> and <FIG>, the mat washer <NUM> can include a third set of compliant rollers <NUM> and a fourth set of compliant rollers <NUM> that are disposed adjacent one another and that can rotate in opposite directions R8 and R9. These roller sets <NUM> and <NUM> can be disposed downstream from the first brush <NUM> and the second brush <NUM>. As shown in <FIG>, the third set <NUM> of compliant rollers can be disposed on a bar 183B and can rotate about an axis that lays in a vertical plane P8, and can be disposed downstream of the first brush <NUM> and the second brush <NUM>. This third set of rollers <NUM>, also referred to as downstream upper rollers, can be further disposed in a horizontal plane P11 and rotate about an axis that lays in that plane P11. This plane P11 can be disposed above another horizontal plane P10, in which an axis of rotation of the first rollers <NUM> can rotate.

Optionally, the third set of rollers <NUM> can be slightly higher vertically than the first and second sets of rollers <NUM>, <NUM> which are upstream of the first brush and second brush <NUM>, <NUM>. Thus, as shown in <FIG>, when the distal end 100D of the mat <NUM> projects beyond the first and second brushes, it can engage the upper compliant roller set <NUM> which then, due to its rotational direction R8, guides that distal end 100D into the opening between the compliant rollers <NUM> and <NUM>. This in turn will guide the mat <NUM> between the third set of rollers <NUM> and fourth set of rollers <NUM> along the path P2, which can be generally aligned with or aimed toward the upper portion 127U of the capture tray <NUM>.

As mentioned above, the upper or third set of rollers <NUM> can guide the distal end 100D of the mat 100D between the compliant rollers <NUM> and <NUM> so that these rollers can grip and pull the mat from the brushes <NUM> and <NUM>, deflecting the mat from the first pathway to the second pathway P2, which can be transvers to the first pathway. As this occurs, the mat can bend, and the mat <NUM> can be pressed between the compliant rulers <NUM> and <NUM> and can have certain angles of respective walls relative to the floor and the like adjusted or modified as described above in connection with the first and second rollers <NUM> and <NUM>. Likewise, parts of the rollers <NUM>, <NUM> can deflect or deform, similar to the rollers <NUM>, <NUM> as described above.

The third and fourth sets of compliant rollers can eject the mat <NUM> out of the enclosure <NUM> through a rear opening <NUM> of the enclosure and toward the tray or holding pan <NUM>, which optionally can be curved, can extend from adjacent the rear opening <NUM> to the front second opening <NUM> of the enclosure. The mat can engage the upper surface 127U of the tray and slide down an intermediate curved portion 127I along a third pathway P3 that is transverse to the second pathway P2, toward a lower portion <NUM> of the tray or holding pan <NUM>. Eventually, a user can access the mat <NUM> on the lower portion <NUM> of the tray or holding pan <NUM> through the opening <NUM>. Of course, other set ups for retrieving and supporting the mat can be substituted for those shown.

Although the different elements and assemblies of the embodiments are described herein as having certain functional characteristics, each element and/or its relation to other elements can be depicted or oriented in a variety of different aesthetic configurations, which support the ornamental and aesthetic aspects of the same. Simply because an apparatus, element or assembly of one or more of elements is described herein as having a function does not mean its orientation, layout or configuration is not purely aesthetic and ornamental in nature.

Directional terms, such as "vertical," "horizontal," "top," "bottom," "upper," "lower," "inner," "inwardly," "outer" and "outwardly," are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. The use of directional terms should not be interpreted to limit the invention to any specific orientation(s).

In addition, when a component, part or layer is referred to as being "joined with," "on," "engaged with," "adhered to," "secured to," or "coupled to" another component, part or layer, it may be directly joined with, on, engaged with, adhered to, secured to, or coupled to the other component, part or layer, or any number of intervening components, parts or layers may be present. In contrast, when an element is referred to as being "directly joined with," "directly on," "directly engaged with," "directly adhered to," "directly secured to," or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between components, layers and parts should be interpreted in a like manner, such as "adjacent" versus "directly adjacent" and similar words.

Claim 1:
A method of washing a vehicle mat, the method comprising:
providing a vehicle mat (<NUM>) including a floor substantially conforming to a floor of a vehicle foot well and a wall (<NUM>) integrally formed with the floor of the mat and extending rigidly upward from the floor at a first angle;
advancing the vehicle mat with a plurality of compliant rollers (<NUM>, <NUM>) that are rotating under power, at least one of the compliant rollers deforming radially toward an axis of rotation when contacting and grabbing the vehicle mat;
engaging the vehicle mat with a first brush (<NUM>) to scrub debris from the vehicle mat while moving along a first pathway beyond the plurality of compliant rollers; and
bending at least one of the floor and the wall so that the first angle changes to a second angle different from the first angle.