Note: Descriptions are shown in the official language in which they were submitted.
CA 02708965 2010-07-07
MODULAR FLOOR SYSTEM FOR VEHICLES
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from United States Provisional
Patent Application No. 61/270,428, filed on July 8, 2009. The disclosure of
which is
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a floor system for a vehicle, more
particularly to a modular floor system for a vehicle.
BACKGROUND OF THE INVENTION
[0003] 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' x 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
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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.
[0004] 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 buckling.
SUMMARY OF THE INVENTION
[0005] 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.
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[0006] 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.
[0007] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present invention will become more fully understood from the
detailed description and the accompanying drawings, which are not necessarily
to scale,
wherein:
[0009] Figure 1 is an exploded view of a modular floor system in accordance
with the present invention in a multi-piece floor panel construction.
[0010] Figure 2 is a perspective view of the top side of a subfloor panel of a
floor panel in accordance with the modular floor system of the present
invention.
[0011] Figure 3 is a perspective view of the underside of a subfloor panel
having a structural grid pattern.
[0012] Figure 4 is a view illustrating an interlocking feature of the subfloor
of
the present invention.
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[0013] Figure 5 is a sectional side view illustrating an adhesive bonded floor
panel construction in accordance with the present invention.
[0014] Figure 6 is a sectional side view illustrating a thermally bonded floor
panel construction in accordance with the present invention.
[0015] Figure 7 is a partial view of a subfloor that has been formed into a
structural grid pattern prior to contact with the top surface material.
[0016] Figure 8 is a partial view illustrating the interlocking mechanism
feature of the subfloor in accordance with the present invention prior to the
subfloor
pieces being interlocked together.
[0017] Figure 9 is a partial view illustrating the interlocking mechanism
feature of the subfloor in accordance with the present invention after the
subfloor pieces
are interlocked together.
[0018] Figure 10 is an exploded view of a modular floor system in accordance
with the present invention, in which the top surface material is comprised of
a single
piece.
[0019] Figure 11 is a perspective view of an installed modular floor system of
the present invention in which the modular floor system also includes a
wheelchair track
system.
DETAILED DESCRIPTION OF THE INVENTION
[0020] 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.
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[0021] 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.
[0022] 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.
[0023] Referring now to the figures, Figure 1 is an exploded view of a
modular floor system 100 in accordance with the present invention in a multi-
piece floor
construction. Figure 1 illustrates a top surface material 10 and a subfloor
20. Also, as
shown in Figure 1, the subfloor 20 optionally comprises a cut out 30. The
subfloor 20
has an interlocking mechanism.
[0024] 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
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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.
[0025] Figure 2 is a perspective view of the top side or surface 210 of a
subfloor panel 200. Figure 3 is a perspective view of the underside or surface
310 of the
subfloor panel 200 of Figure 2.
[0026] The subfloor 20, shown in Fig. 1, is shaped through thermal cutting,
water jet cutting, Computer Numeric Controlled (CNC) cutting, or other known
shaping
or cutting methods. The choice of a material for a subfloor may depend upon
what is
typical for a particular industry or use. Examples of materials suitable for
use as a
subfloor 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
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known methods to address specific needs, such as color, hardness, abrasion
resistance, or
other parameters. The material of the subfloor 20 preferably is a moisture
resistant
material, an anti-fungal material, an anti-microbial material, or a
combination thereof.
Additionally, the top surface material 10 may be comprised of the same
material as the
material of the subfloor 20.
[0027] Figure 3 is a perspective view of the underside 310 of the subfloor
panel 200 of Figure 2 having a structural grid pattern. The subfloor panel 200
is
optionally formed or manufactured entirely or partly into a structural grid
pattern, as
illustrated in Figure 3. The grid pattern provides additional strength for
mounting of
various components, as it aids in the resistance of the compressive forces of
the
components mounted to the floor.
[0028] Figure 4 is a view illustrating an interlocking feature of subfloor 20
of
the present invention. Figure 4 illustrates an interlocking mechanism of the
subfloor 20
in the modular floor system of the present invention by which the subfloor 20
provides
interlocking between adjoining panels. An example of a suitable interlocking
mechanism
is an interlocking tab 410. The interlocking feature of the present invention
is utilized,
for example, either before or during the vehicle assembly process.
[0029] 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 Figure
5, is attachment of the top surface material 520 and the subfloor 540 by using
an adhesive
bonding application. Any adhesive that is typical in the industry may be used.
Figure 5 is
a sectional side view illustrating an adhesive bonded floor panel construction
in
accordance with the present invention. Figure 5 illustrates an adhesive
bonding material
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530 having been applied between top surface material 520 and subfloor 540 to
attach or
affix subfloor 540 to top surface material 520. Figure 6 is a sectional side
view
illustrating a thermally bonded floor panel construction in accordance with
the present
invention. Figure 6 also shows top surface material 620 and subfloor 640
affixed to one
another. The top surface material optionally possesses a modified surface
texture (not
shown). As seen in Figures 5 and 6, the subfloor is optionally formed or
manufactured
with voids or "hollow features", 550 and 650, respectively, as seen from the
sectional
views. Figures 5 and 6 thus further illustrate the cross-section of the panels
shown in
Figures 1 and 3.
[0030] 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
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.
[0031] Figure 7 is a partial view of a subfloor that has been formed into a
structural grid pattern 720 prior to contact with the top surface material.
[0032] Figure 8 is a partial view illustrating the interlocking mechanism
feature of the subfloor 800 in accordance with the present invention prior to
pieces of the
subfloor 800 being interlocked together. Figure 9 is a partial view
illustrating the
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interlocking mechanism feature of the subfloor 800 in accordance with the
present
invention after pieces of the subfloor 800 are interlocked together.
[0033] Figure 10 is an exploded view of a modular floor system 110 in
accordance with the present invention in which the top surface material is
comprised of a
single piece. When combined, the top surface material 120 and the subfloor 140
may
form a single piece as seen in Figure 10 and may be suitable for use as the
flooring for an
entire vehicle or may serve as an individual modular floor panel which is then
used as a
component of a multi-piece floor panel construction as seen in Figure 1.
[0034] Figure 11 is a perspective view of an installed modular floor system
900 of the present invention in which the modular floor system also includes a
wheelchair
track system. As illustrated in Figure 11, the top surface material may
accommodate
various seat or wheelchair track systems through the use of an insert 910
formed to
interlock with the top surface material and mate with the track system.
[0035] 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 Figures 8 and 9, the floor panels do not require as many fasteners to
secure to
the vehicle subfloor as the flooring materials of other known methods.
Additionally,
since the panels already include the top surface material, there is no need
for the installer
to clean the subfloor, apply the adhesive, and allow for a cure time. This
results in
increased efficiency for the installer, as well as improved safety conditions.
[0036] 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
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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.
[0037] 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.
[0038] 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
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be construed to limit the present invention or otherwise to exclude any such
other
embodiments, adaptations, variations, modifications and equivalent
arrangements.
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