Vehicle Floor Covering Interlock Mechanism
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Solution Overview
Problem
Existing floor covering systems for mobile vehicles require multiple parts and fasteners, increasing installation time and cost, while also presenting a cold feel due to thermal conductivity and an unsightly joint when using extruded metal strips for joining separate coverings.
Innovation Solution
A floor covering system where separate coverings interlock without a separate joining strip or metal fasteners, using formations in one margin that fit into receptacles in another, fabricated from RIM-molded synthetic material with a resilient foam layer for support, creating a flush and aesthetically pleasing joint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an extruded metal strip and separate fasteners are used to join floor coverings, then the joint appearance is acceptable and margins are secured, but the number of parts increases, installation time increases, and manufacturing cost increases
Solution Approach 1:
The patent combines the joining strip and fasteners into a single integrated component. The connection element includes both the joining strip portion that covers the joint between floor coverings and the fastener portion that secures it to the floor, eliminating the need for separate parts and simplifying installation while maintaining joint stability
Solution Approach 2:
The connection element serves multiple functions simultaneously: it acts as a joining strip to cover the joint, provides fastening capability through integrated fasteners, and offers thermal insulation. This multi-functional design reduces the number of separate components needed while achieving all required functions
2Reliability
If an extruded metal strip and separate fasteners are used to join floor coverings, then the joint is secured and appearance is acceptable, but installation time increases
Solution Approach 1:
The connection element combines the joining strip and fasteners into a single integrated component. The joining strip portion covers the joint between floor coverings while the integrated fastener portion secures it to the floor in one piece, reducing assembly steps and installation time while maintaining joint stability
Solution Approach 2:
The connection element is pre-fabricated with fasteners already attached to the joining strip. This preliminary assembly of components allows for quicker installation on-site as the entire connection system can be installed as a single unit rather than assembling multiple separate parts during installation
3Strength
If thermal conductivity of fasteners and extrusion is used, then structural support is provided, but the extrusion feels cold in winter even when the occupant compartment is warm
Solution Approach 1:
The patent changes the material parameter from high thermal conductivity (metal) to low thermal conductivity (thermoplastic elastomer or similar polymer material). This material substitution maintains the structural support function while significantly reducing thermal conductivity, preventing the cold feel in winter while keeping the occupant compartment warm
4Adaptability or versatility
If separate floor coverings are used instead of a single large covering, then functional and appearance considerations are met, but joints create gaps and margins may curl
Solution Approach 1:
The connection element is designed to completely cover the joint area between separate floor coverings, extracting the joint from visibility. By providing a joining strip portion that spans the entire joint width and secures it with fasteners, the solution eliminates the appearance of gaps and prevents margin curling while allowing the use of multiple separate coverings for functional adaptability
Data Source
AI summary
A mobile vehicle has an interior occupant compartment, commonly called a cab when the vehicle is a truck, that has a floor (60) covered by respective floor coverings (12, 14) that have top surfaces opposite the floor. The coverings connect to each other along a joint (16) cooperatively defined by respective over- and under-lapping margins (42, 44) of the respective coverings. One of the margins (44) has two open receptacles (50, 52), and the other (42) has formations (46, 48) each fitted respectively in a respective open receptacle so as to locate the respective top surfaces of the coverings substantially flush with each other and in substantial mutual abutment along the joint. An expanse 42A, 44A that forms at least a portion of the respective top surface is disposed beyond and integrally formed with the respective margin. A foam pad (62, 64) underlies each expanse.