Patent Application
20110006562
The present invention relates to a floor system for a vehicle, more particularly to a modular floor system for a vehicle.
Most floor assemblies in conventional vehicle assembly operations, particularly in heavy equipment and bus or van applications, include a vehicle structural subfloor of steel or aluminum, a plywood or fiber-composite subfloor, and a top surface material which is usually constructed from vinyl or rubber. The entire subfloor is typically created by cutting standard size plywood or fiber-composite sheet stock material (e.g., 4′×8′ sheets) into multiple, discreet sections based on the profile of the vehicle floor and in order to accommodate various components that must be routed or accessed through the floor. Depending upon the size of the vehicle, this could result in a dozen or more individual pieces that must be placed onto the steel or aluminum vehicle subfloor in a “puzzle-like” manner. After placing the individual subfloor pieces, they are attached to the metallic vehicle subfloor with fasteners which are typically spaced apart by less than one foot in a pattern across the floor of the vehicle. Even closer spacing is used in the areas of the subfloor seams. To apply the top surface material, the floor must be cleaned and prepped for application of the adhesive which bonds the two materials together. The adhesive must be applied in a controlled and even manner and allowed to cure before subsequent processing may take place. All of these steps are typically performed on the main vehicle assembly line.
The process and materials mentioned above contain several potential negative aspects. First, it requires a very labor-intensive operation. This operation involves the steps of placing the multiple subfloor sections into the vehicle, installing dozens of fasteners through the subfloor, and preparing the surface of the subfloor for attaching the top surface. Additionally, this process has further drawbacks, which include an adhesive cure time for the top surface that may be excessive relative to other operations and an increased potential for worker injuries with additional labor around the vehicle (this is particularly true while the line is moving). Additional precautions are necessary for the adhesive fumes (e.g., special ventilation). There is an increased potential for slip hazards and paint contamination from the resulting saw dust, and the use of plywood or fiber-composite flooring materials results in increased likelihood of damage and degradation due to moisture penetration, which in turn leads to an increased likelihood of the flooring material budding.
The present invention relates to a modular floor panel system for use in a vehicle. The modular floor system comprises at least one floor panel. The floor panel is comprised of a top surface material and an interlocking subfloor having one or more interlocking pieces. The top surface material and the interlocking subfloor are affixed to one another.
Another aspect of the invention is a method of making a modular floor panel. The method comprises obtaining a top surface material, obtaining an interlocking subfloor having one or more interlocking pieces, and affixing the top surface material and the interlocking subfloor to one another. The top surface material and the interlocking subfloor are preferably affixed to one another by bonding.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
The present invention will become more fully understood from the detailed description and the accompanying drawings, which are not necessarily to scale, wherein:
The following detailed description of the embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
The present invention is directed to a modular floor system for a vehicle. The modular floor system comprises at least one floor panel. A floor panel is pre-cut or pre-formed to match a particular vehicle floor layout. A single floor panel may be used. Alternatively, multiple floor panels may be used.
The floor panel comprises a top surface material and an interlocking subfloor affixed to the top surface material. The top surface material and the interlocking subfloor may each be formed as a subassembly. The subfloor and top surface subassemblies are prepared before vehicle assembly in a manner that provides the greatest surface area coverage in a size that allows appropriate manipulation during the vehicle assembly operation. The floor panels are also cut or formed to match the floor shape of the vehicle and to accommodate various components that must be routed or accessed through the floor. The subfloor is preferably comprised of a polymeric or elastomeric material that is molded, formed, or manufactured into a structural grid that contains additional features for securing it to the vehicle floor assembly. The top surface material and subfloor are preferably permanently attached or affixed to one another.
Referring now to the figures,
The top surface material 10 is shaped through thermal cutting, water jet cutting, Computer Numeric Controlled (CNC) cutting, or other known shaping or cutting methods. The top surface material 10 is comprised of any floor covering material or a combination of one or more floor covering materials. The choice of a top surface material may depend upon what is typical for a particular industry or use. Examples of materials suitable for use as a top surface material in accordance with the present invention include, but are not limited to, polymeric materials and elastomeric materials. Examples of suitable polymeric materials include, but are not limited to, polyethylene such as High Density Polyethylene (HDPE) and Low Density Polyethylene (LDPE), polypropylene, urethane, vinyl, other thermoplastic resin materials or a combination thereof. Examples of suitable elastomeric materials include, but are not limited to, rubber. The materials may be adjusted by known methods to address specific needs, such as color, hardness, abrasion resistance, or other parameters.
The subfloor 20, shown in
The top surface material 10 and the subfloor 20 may be attached or affixed to each other in a variety of ways. One acceptable method, as illustrated in
An additional method of joining or affixing the subfloor 20 and the top surface material 10 is to mold or manufacture the subfloor 20 and the top surface material 10 at the same time. Therefore, it is acceptable to have the top surface material molded or manufactured into place at the time of the manufacture of the subfloor. Similarly, the top surface material may also be applied to the subfloor in a fluid form and then be cured prior to further processing. Once joined or attached, the top surface material and the subfloor form a floor panel that can be cut and shaped using the techniques described above and installed in vehicles.
When installing the flooring materials to form a vehicle floor, the assembly line workers place the modular floor panels into the vehicle as required for the specific manufacturing operation. As the modular floor system uses the interlock feature shown in
There are fewer assembly and installation steps with the modular floor system of the present invention, which in turn leads to an increase in both safety and efficiency. Further, the pre-assembly of the panels in the manner of the present invention also requires the use of less adhesive at installation. This results in a significant reduction in both the adhesive fumes and the resulting safety issues attendant with the use of adhesives. Additionally, the use of non-plywood flooring materials all but eliminates the likelihood of the floor undergoing buckling following the installation of the floor panels.
An additional advantage of the present invention is a lesser number of panels are required for larger vehicles than in conventional methods. Unlike conventional methods, the present invention requires less floor panels as a result of using the sheet stock material described herein. Further, the ability to use fewer and larger sheets, up to and including a single sheet of flooring material, provides increased efficiency and safety.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements.
This application claims priority from U.S. Provisional Patent Application No. 61/270,428, filed on Jul. 8, 2009. The disclosure of which is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61270428 | Jul 2009 | US |
