Integral Floor Mat Grommet for Simpler Vehicle Post Retention
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Solution Overview
Problem
Conventional vehicle floor mat grommet technologies are complex and costly to produce, requiring multiple pieces and coordinating separate designs between grommet and mat manufacturers to meet vehicle manufacturer guidelines, necessitating a simpler and more adaptable solution.
Innovation Solution
An integral grommet is integrated into the vehicle floor mat, featuring a grommet body with a post-engagement throughbore and a radially extending flange with slots, made of a plastic material with a higher melting point than the mat material for insert molding compatibility, and a vertically offset region for secure engagement with vehicle posts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional multi-piece grommet technology is used, then the grommet can be assembled on the mat, but the assembly becomes complicated and production costs increase
Solution Approach 1:
The patent merges the grommet and mat into a single integral component formed by injection molding. The grommet is created as an integrated part of the mat body, eliminating the need for separate grommet pieces and their assembly. This combining approach directly reduces device complexity while maintaining the functional reliability of the grommet assembly.
2Reliability
If multiple separate grommet pieces are used, then the grommet can engage the post, but the number of parts increases and coordination between manufacturers becomes necessary
Solution Approach 1:
The grommet is merged with the mat into a single molded component, eliminating the need for coordination between separate grommet and mat manufacturers. The integral design allows one manufacturer to produce both components simultaneously through injection molding, greatly simplifying the manufacturing process and eliminating supply chain coordination requirements while maintaining post engagement reliability.
Solution Approach 2:
The integral grommet design creates a universal solution that can accommodate various post types and configurations. By forming the grommet as part of the mat structure, the design becomes adaptable to different vehicle manufacturers' post specifications without requiring custom grommet tooling for each customer, enhancing manufacturing ease and versatility.
3Ease of manufacture
If the grommet is made of the same material as the mat, then the materials are compatible, but the grommet cannot withstand the insert molding process temperatures
Solution Approach 1:
The patent applies local quality by using a different material for the grommet than for the mat. The grommet is formed from a high-temperature resistant plastic that can withstand insert molding process temperatures, while the mat uses a different material optimized for foot comfort and durability. This localized material differentiation allows the grommet to survive the molding process while maintaining chemical compatibility for bonding with the mat material.
Solution Approach 2:
The patent employs composite materials by combining two different plastics - a high-temperature resistant plastic for the grommet and a thermoplastic elastomer or similar material for the mat. This composite approach allows each material to be optimized for its specific function while maintaining compatibility for bonding during the injection molding process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The integral grommet configuration simplifies assembly, reduces production costs, and allows for adaptability to various post attachment technologies, enhancing bonding and fastening within the mat while maintaining structural integrity during the molding process.
Implementation Method 1
The grommet is made of a plastic material having a melting point greater than that of the surrounding mat so that it can withstand the insert molding process
Implementation Method 2
the grommet is made of a plastic that is chemically compatible with the mat material so that they will bond together during the molding process
Data Source
AI summary
A retainer for a floor mat positioned on a vehicle floor, where the floor mat includes at least one grommet. The retainer includes a body having a top edge and a bottom edge, a flange extending radially outwardly from the top edge of the body and a protruding member extending radially outwardly from an inner surface of the body, where the protruding member is between the top edge and the bottom edge of the body, and the body is removably attached to the at least one grommet by engaging the protruding member with the grommet.