COVER WITH PULL-THROUGH PREVENTION ARRANGEMENT

Description

BACKGROUND OF THE INVENTION

The present invention relates to a cover or mat with a pull-through prevention arrangement, and in particular to marine floor mats that include foam layers of various densities and quick connect couplers that cooperate to allow easy detachment of the mat from an associated boat surface while simultaneously preventing pull-through of the fastener through the various layers of the mat arrangement and tearing or damage to the floor mat.

SUMMARY OF THE INVENTION

One embodiment as shown and described herein includes a marine floor mat arrangement that includes a first layer having an exposed upper surface and a bottom surface opposite the upper surface, the first layer comprising a first foam material having a firs density of between about 7.5 lbs/ft³ and about 9.5 lbs/ft³, a second surface layer having an upper surface facing the bottom surface of the first layer and a bottom surface opposite the upper surface of the second layer, the second layer comprising a foam having a second density of between about 8 lbs/ft³ and about 12.9 lbs/ft³, and a plurality of snap couplers. Each snap coupler may include a first portion including a body portion extending entirely through the first layer and the second layer between the exposed upper surface of the first layer and the bottom surface of the second layer and a flanged portion extending outwardly from the body portion where the flanged portion abuts the exposed upper surface of the first layer, and a second portion releasably connected with the first portion of the snap coupler, where the second portion of the snap coupler is attached to the surface of a marine vehicle.

Another embodiment as shown and described herein may further or alternatively include a marine floor mat arrangement that includes a first layer having an exposed first surface and a second surface opposite the first surface, the first layer comprising a first foam material having a first density, a second layer having a first surface facing the second surface of the first layer and a second surface opposite the first surface of the second layer and configured to abut a surface of a marine vehicle, the second layer comprising a foam having a second density that is less than the first density, and a plurality of quick release couplers. Each quick release coupler may include a first portion extending entirely through the first and second layers and including an outwardly extending flanged portion abutting the first surface of the first layer, and a second portion of the quick release coupler configured to releasably couple with the first portion of the quick release coupler, where the second portion of the quick release coupler is configured to attach to the surface of the marine vehicle.

The present inventive marine deck cover with pull-through prevention arrangement provides a durable uncomplicated design that is well adapted to provide protective and non-slip coverings to associated marine vehicle surfaces, while allowing easy removal of the mats and preventing damage caused to the mats by the associated fasteners tearing or ripping through the various surfaces of the mats during removal. The covers or mats are efficient in use, economical to manufacture, are capable of a long operating life, and are particularly well adapted for the proposed use.

These and other advantages of the invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a plurality of floor coverings and marine floor mats each embodying the present invention;

FIG. 2 is a cross-sectional top plan view of the plurality of floor coverings and marine floor mats taken along the line II-II, FIG. 1;

FIG. 3 is a top plan view of a marine floor mat;

FIG. 4 is a cross-sectional side elevation view of the marine floor mat of FIG. 3 taken along the line IV-IV, FIG. 3; and

FIG. 5 is a cross-sectional side elevation view of an alternative embodiment of the marine floor mat.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in FIGS. 1-3. However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

The reference numeral 10 (FIGS. 1 and 2) generally designates a deck cover floor mat while the reference numeral 12 generally designates a swim platform cover or mat each embodying the present invention. In the illustrated example, the deck mat 10 and the swim platform mat 12 are supported by and releasably coupled to a deck surface 14 and a swim deck surface 16 of a boat 18, respectively. As best illustrated in FIG. 2, the mats 10, 12 are sized and configured so as to effectively cover a majority or all of the given area of the deck surface 14 and the swim deck surface 16 thereby providing a cushioned and slip resistant use area.

As the swim platform cover or mat 12 and the deck cover or mats 10 are similar in construction the swim platform mat 12 is described in detail herein as an exemplary embodiment. In the illustrated example, the mat 12 defines a peripheral edge 20 having a non-quadrilateral shape. In the illustrated example, the mat 12 (FIGS. 3 and 4) includes a first or upper layer 22 having a top or outer surface 24 and a bottom or inner surface 26, and a second or lower layer 28 having a top or inner surface 30 and a bottom surface 32 that abuts the swim deck surface 16 of the swim deck 34. The upper layer 22 preferably comprises a foam such as an EVA foam, a PE foam, and an EPDM foam, or a combination thereof. Preferably, the upper layer 22 comprises a density EPA foam with a preferable density of within the range of between 7 lbs/ft³ and about 9.5 lbs/ft³, more preferably within the range of between about 8 lbs/ft³ and about 9.5 lbs/ft³, even more preferably within the range of about 8 lbs/ft³ and about 9 lbs/ft³, and most preferably of about 8.5 lbs/ft³. The upper layer 22 further has a tear strength of within the range of about 35 lbs/inch to about 40 lbs/inch. In the illustrated example, the upper layer 22 has a thickness between the outer surface 24 and the inner surface 26 of within the range of about 2.5 mm to about 3.8 mm, more preferably of between about 2.8 mm and about 3.5 mm, even more preferably of about 2.9 mm to about 3.3 mm, and most preferably of about 3 mm. The lower layer 28 comprises a foam material such as EVA foam, PE foam, EPDM foam or combinations thereof. Preferably, the lower layer 28 comprises a relatively higher density EVA foam having a density of within the range of 8 lbs/ft³ to about 12.9 lbs/ft³, more preferably of within the range of about 9 lbs/ft³ to about 11.9 lbs/ft³, even more preferably of within the range of about 9.5 lbs/ft³ to about 10.5 lbs/ft³, and most preferably of about 10 lbs/ft³. The bottom layer 28 further preferably has a tear strength of within a range of between about 50 lbs/inch and about 60 lbs/inch. In the illustrated example, the lower layer 28 preferably has a thickness of about 4.6 mm to about 5.8 mm, more preferably of between about 4.8 mm to about 5.6 mm, even more preferably of between about 5 mm to about 5.4 mm, and most preferably of about 5 mm. As best illustrated in FIG. 4, the outer surface 24 of the upper layer 22 is provided with a non-slip surface and specifically may be provided with a textured surface so as to enhance or increase the non-slip characteristics of the mat 12.

The upper layer 22 is connected to or coupled with the lower layer 28 via a flame lamination process, preferably a roll lamination process, however, other methods may be used, including general adhesives, contact adhesives, sonic welding, and the like. If adhesives are utilized, it is preferable that water resistant adhesives are used.

As best illustrated in FIGS. 3 and 4, the lower layer 28 is preferably provided as an integral, single piece covering the entire surface area of the swim deck surface 16 intended to be covered, while the upper layer 22 may be provided as an integral, single piece or alternatively as multiple pieces having channels 36 extending between or separating the the multiple pieces. The upper layer 22 and the lower layer 28 may also be provided in different colors from one another. In the example illustrated in FIG. 3, the the channels 36 and relative sizes of the segments or pieces of the lower layer 28 and upper layer 22 allow the differing colors between the layers to be seen through the channels 36 and about the peripheral edge 20.

The mat 12 further includes a plurality of quick release couplers which in the illustrated example includes snap-type couplers 38 having a first snap coupler portion 40 that releasably snappingly engages a second snap coupler portion 42. The first snap portion 40 includes a cylindrical body portion 44 and a head or flanged portion 46 that extends outward from the body portion 44. The body portion 44 extends completely through the thickness of both the upper layer 22 and the lower layer 28 between the outer surface 24 of the upper layer 22 and the bottom surface 32 of the lower layer 28. The body portion 44 may extend through an associated pre-formed aperture 48 or may be punched through the upper layer 22 and the lower layer 28 without preforming the aperture 48. The flanged portion 46 extends outwardly from the body portion and abuts the outer surface 24 of the upper layer 22 and provides an enlarged contact area therebetween. The second snap coupler portion 42 may be attached to the swim deck surface 16 of the swim deck 34 via an adhesive 50, or attached thereto via associated mechanical fasteners that are either integral with or separate from the second snap coupler portion 42 and that positively engage the swim deck surface 16.

As best illustrated in FIGS. 2 and 3, the snap couplers 38 are positioned relative to the overall plan form of the mat 12 so as to provide adequate attachment and connection of the mat 12 to the swim deck 34 so as to prevent inadvertent removal or uncoupling of the mat 12 from the swim deck 34, such as through use, accidental lifting of the mat, relative wind during operation of the marine vehicle, and the like. The snap couplers 38 may be placed about a periphery of the mat 12, or centrally located depending upon the specific requirements of the arrangement. The quick-coupling characteristics as provided by the multiple snap couplers 38 allow the mat 12 to be easily removed from connection with the swim deck 34 to allow for cleaning of the mat 12 or the swim deck surface 16, access to maintenance panels that may be located beneath the mat 12, general maintenance to be conducted, replacement of a worn or damaged mat 12, and the like, without damage to the swim deck 34 and without damage to the mat 12 such that the mat 12 can be easily resecured once the necessary procedure is conducted. The high-density foam of the lower layer 28 resists tearing or a pull through of the snap coupler 38 while the mat 12 is removed from or uncoupled from the swim deck 34 while the relatively lower density foam of the upper layer 22 reduces the overall weight of the mat 12 and provides additional cushioning properties.

The reference numeral 12a (FIG. 5) generally designates another embodiment of the present invention. Since the swim platform cover or mat 12a is similar to the previously described swim platform cover or mat 12, similar parts or elements appearing in FIGS. 2-4 and FIG. 5 respectively are represented by the same, corresponding reference numeral, except for the suffix “a” in the numerals of the latter. In the illustrated example of the alternative embodiment, the most notable difference between the mat 12a and the previously described mat 12 is a multi-layer upper layer arrangement 22a. In the illustrated example, the upper layer arrangement 22a includes a first sublayer 52 that includes the outer surface 24a and a bottom or inner surface 54, and a second sublayer 56 that includes the bottom or inner surface 26a and a top or inner surface 58. The first sublayer 52 and the second sublayer 56 each comprise foams as described above with respect to the upper layer 22, but may comprise different foams from one another. The mat 12a may further include a plurality of channels 36a extending through the first sublayer 52 and the second sublayer 56 of the upper layer 22a, a plurality of channels 60 extending through only the first sublayer 52 of the upper layer 22a, where the first sublayer 52, the second sublayer 56 and the lower layer 28a may be provided in different colors from one another. In addition, the upper layer 22a and/or the lower layer 28a may each comprise two or more sublayers.

In the foregoing description, it will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed herein. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise.