Vehicle Cabin Floor Mat with Form-Locked Accessory Mount
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Solution Overview
Problem
Existing cabin floor mats in vehicles allow fluid and dirt ingress due to holes, and require modifications to accommodate various cabin configurations, leading to high costs and alignment issues.
Innovation Solution
A multi-layer mat with an accessory mount that uses a formable material layer and an accessory mount with a cross-section design for form-locking, allowing secure anchoring of accessories without holes, and a positioning arrangement for precise alignment in a moulding tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If holes are made in the mat for anchoring accessories, then accessories can be securely anchored to the cabin floor, but fluids and dirt can leak through the holes into the cabin
Solution Approach 1:
The accessory mount is nested within the mat structure, with the formable material layer completely enclosing the anchoring arrangement. The mount creates a three-dimensional anchoring volume within the mat thickness, nesting the fastening function inside the mat body rather than creating through-holes, thus preventing fluid and dirt ingress while maintaining anchoring strength
Solution Approach 2:
The anchoring system transitions from a two-dimensional surface mounting (through-holes) to a three-dimensional volumetric anchoring. The accessory mount extends through the foam material layer, creating anchoring arrangements distributed throughout the mat thickness, utilizing the third dimension (depth) to provide secure fastening without compromising the mat's fluid barrier function
2Adaptability or versatility
If the cabin body is modified to accommodate various cabin configurations, then different operating conditions can be supported, but modification costs increase
Solution Approach 1:
The accessory mount with its positioning arrangement and form-closing connection serves multiple functions: it anchors accessories, defines precise positioning within the mat, and accommodates various cabin configurations without requiring cabin modifications. This universal mounting solution replaces the need for custom cabin modifications for different vehicle types and configurations
Solution Approach 2:
The mat system provides its own anchoring and positioning capabilities through the accessory mount integrated into the mat structure. The formable material layer and form-closing connection enable the mat to self-configure and secure accessories without external cabin modifications, making the system self-sufficient for adapting to different cabin environments
3Ease of operation
If holes or modifications are made in the mat for accessory anchoring, then accessories can be mounted, but alignment errors and positioning inaccuracies occur
Solution Approach 1:
The positioning arrangement is pre-integrated into the accessory mount design before mat manufacturing. The formable material layer is pre-configured with positioning features that guide the accessory mount placement, ensuring accurate alignment and positioning is established before the actual accessory mounting operation occurs
Solution Approach 2:
The mechanical alignment system replaces manual positioning and drilling operations. The form-closing connection between the accessory mount and formable material layer provides automatic self-alignment and secure attachment, eliminating the need for precise manual hole drilling and fastener installation that typically cause alignment errors
Data Source
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Figure 3A~3B
AI summary
A multi-layer mat for covering a cabin floor of a vehicle, comprising a foam material layer, a formable material layer, and an accessory mount with an anchoring arrangement for anchoring a mat accessory to the accessory mount, and a positioning arrangement for positioning the accessory mount in a moulding tool, thereby providing a mould insert for forming the formable material layer to a shape of the accessory mount. The accessory mount is shaped with a cross section that is narrower towards a top surface of the mat and wider towards an interior of the mat, for providing a form-closing connection between the accessory mount and the formable material layer, so that the accessory mount is form-locked by the formable material layer.