FLOOR MAT AND METHOD OF MANUFACTURE
A floor mat having a first layer and a second layer. The second layer has a hinge that at least partially separates the second layer into a body section and a flap section. The hinge allows the flap section to be folded relative to the body section.
1 . A floor mat comprising:
a first layer; and
a second layer disposed proximate the first layer, the first layer having a hinge that at least partially separates the first layer into a body section and a flap section and permits the flap section to be folded relative to the body section.
2 . The floor mat of claim 1 wherein the second layer further comprises a first surface that faces the first layer and a second surface disposed opposite the first surface, wherein the hinge is provided as an indentation that extends from the second surface toward the first surface.
3 . The floor mat of claim 1 wherein the hinge has reduced thickness than surrounding portions of the second layer.
4 . The floor mat of claim 1 wherein the hinge is provided as a separate component that is attached to the second layer.
5 . The floor mat of claim 3 wherein the hinge is provided as a separate component that is at least partially disposed in the second layer.
6 . The floor mat of claim 1 wherein the hinge is made of a first material and the body and flap sections are made of a second material that differs from the first material.
7 . The floor mat of claim 1 wherein the body section further comprises a first retention feature and the flap section further comprises a second retention feature that differs from the first retention feature, the first and second retention features being disposed on the second surface and adapted to engage a vehicle surface to inhibit movement of the floor mat.
8 . The floor mat of claim 7 wherein the first retention feature is a nib that extends from the second surface and the second retention feature is a hook and loop fastener that is at least partially recessed into the second surface.
9 . A floor mat for a motor vehicle, comprising:
a unitary backing layer including:
a first surface,
a second surface disposed opposite the first surface, and
a first hinge provided as an indentation line that extends along the second surface; and
a carpet layer disposed on the first surface;
wherein the first hinge divides the backing layer into a body section and a first flap section and facilitates folding of the first flap section relative to the body section.
10 . The floor mat of claim 9 wherein the body section further comprises a first retention feature and the first flap section further comprises a second retention feature that differs from the first retention feature, the first and second retention features being disposed on the second surface and adapted to engage a vehicle surface to inhibit movement of the floor mat.
11 . The floor mat of claim 9 further comprising a second hinge provided as an indentation line that extends along the second surface, wherein the second hinge divides the body section from a second flap section.
12 . The floor mat of claim 11 wherein the first hinge is spaced apart from the second hinge.
13 . The floor mat of claim 11 further comprising a first flap hinge disposed at an intersection of the first and second flap sections.
14 . The floor mat of claim 13 wherein the first flap hinge is an indentation disposed on the second surface.
15 . The floor mat of claim 10 further comprising a third hinge that extends along the second surface, wherein the third hinge divides the body section from a third flap section.
16 . The floor mat of claim 15 further comprising a second flap hinge disposed at an intersection of the second and third flap sections.
17 . The floor mat of claim 16 wherein the second retention feature is disposed on the third flap section and adapted to engage a vehicle surface to inhibit movement of the floor mat.
18 . A method of making a floor mat, comprising:
providing a carpet layer; and
molding a backing layer on the carpet layer such that the backing layer includes an indentation that defines a hinge.
19 . The method of claim 18 further molding a first retaining feature into a body section of the backing layer and providing a second retaining feature on a flap section of the backing layer, the flap section being at least partially separated from the body section by the hinge.
20 . The method of claim 19 wherein the second retaining feature is provided as a separate component and is molded into the backing layer when the backing layer is molded on the carpet layer.