[0001] The present disclosure generally relates to a floor structure of motor
vehicles. In particular, the present disclosure described herein relates to a floor
5 carpet structure with a deep draw near a seating area of the motor vehicles.
BACKGROUND
[0002] Motor vehicles usually have a frame structure in the region of the rear
floor which is used for mounting or joining other necessary vehicle components
such as a spare tire, fuel tank, etc., to it and provides stiffness and rigidity to the
10 vehicle. The rear floor includes a horizontal area for mounting of cushion seats
and vertical area for providing the required seating height.
[0003] Nowadays, the rear seat height is increasing to enhance the comfort to
passengers of the vehicle. Due to increased rear seat height, floor carpet soft trim
is designed with deep draw forming. However, forming deep draw leads to weak
15 surface and defects such as thinning and wrinkle formation are observed, which
provide feel of inferior quality of carpet in the vehicle and noise is also generated
inside vehicle cabin due to gap formed between the floor carpet and vertical
surface of vehicle rear floor.
[0004] To address these issues related to the deep draw forming, the thickness
20 of the floor carpet is increased or high cost material is used in order to improve
strength of the floor carpet.
[0005] Also, in some cases, silencer pads are glued behind the floor carpet to
eliminate the hollowness in the vertical areas between carpet area and a body
panel of the vehicle.
3
[0006] However, the existing solutions either increases overall cost, additional
manpower, or production time of the vehicle.
[0007] Therefore, there is a need to strength improvisation in the floor carpet
while addressing the deficiencies of the prior arts.
5 OBJECTS OF THE DISCLOSURE
[0008] Some of the objects of the present disclosure, which at least one
embodiment herein satisfy, are listed hereinbelow.
[0009] It is a general or primary object of the present disclosure to strength
improvisation in the floor carpet.
10 [0010] It is another object of the present disclosure to provide a floor carpet
structure near a seat mounting area.
[0011] These and other objects and advantages will become more apparent
when reference is made to the following description and accompanying drawings.
SUMMARY
15 [0012] This summary is provided to introduce concepts related to a floor
carpet structure with a deep draw near a seating area. The concepts are further
described below in the detailed description. This summary is not intended to
identify key features or essential features of the claimed subject matter, nor is it
intended to be used to limit the scope of the claimed subject matter.
20 [0013] The present disclosure relates to a floor carpet structure for a vertical
area of a rear seating area. The floor carpet structure includes multiple angular
beads formed in a vertical wall surface of the floor carpet structure. The angular
beads are parallel to each other. Each angular bead is divided into a first segment
and a second segment. The first segment and the second segment are formed with
25 different draft angles. The second segment is parallel to non-beaded profile of the
4
vertical wall surface of the floor carpet structure, and the first segment is at angle
with the non-beaded profile of the vertical wall surface of the floor carpet
structure.
[0014] In an aspect, the first segment has a lower draft angle than that of the
5 second segment.
[0015] In an aspect, the first segment has a length equal to or less than onethird length of the angular bead.
[0016] In an aspect, the second segment has a length equal to or more than
two-third length of the angular bead.
10 [0017] To further understand the characteristics and technical contents of the
present subject matter, a description relating thereto will be made with reference
to the accompanying drawings. However, the drawings are illustrative only but
not used to limit the scope of the present subject matter.
[0018] Various objects, features, aspects, and advantages of the inventive
15 subject matter will become more apparent from the following detailed description
of preferred embodiments, along with the accompanying drawing figures in which
like numerals represent like components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] It is to be noted, however, that the appended drawings illustrate only
20 typical embodiments of the present subject matter and are therefore not to be
considered for limiting of its scope, for the invention may admit to other equally
effective embodiments. The detailed description is described with reference to the
accompanying figures. The illustrated embodiments of the subject matter will be
best understood by reference to the drawings, wherein like parts are designated by
25 like numerals throughout. The following description is intended only by way of
example, and simply illustrates certain selected embodiments of devices, systems,
5
and methods that are consistent with the subject matter as claimed herein,
wherein:
[0020] FIG. 1 illustrates a floor carpet structure as per the state of the art;
[0021] FIG. 2 illustrates a perspective view of a floor carpet structure during
5 assembly on a rear floor body panel in accordance with an embodiment of the
present disclosure;
[0022] FIG. 3A illustrates a cross-section of the floor carpet structure with the
body panel at a bead location in accordance with an embodiment of the present
disclosure; and
10 [0023] FIG. 3B illustrates a sectional detailed view of the cross-section
shown in FIG. 3A in accordance with an embodiment of the present disclosure.
[0024] The figures depict embodiments of the present subject matter for the
purposes of illustration only. A person skilled in the art will easily recognize from
the following description that alternative embodiments of the structures and
15 methods illustrated herein may be employed without departing from the principles
of the disclosure described herein.
DETAILED DESCRIPTION
[0025] The detailed description of various exemplary embodiments of the
disclosure is described herein with reference to the accompanying drawings. It
20 should be noted that the embodiments are described herein in such details as to
communicate the disclosure. However, the amount of details provided herein is
not intended to limit the anticipated variations of embodiments; on the contrary,
the intention is to cover all modifications, equivalents, and alternatives falling
within the spirit and scope of the present disclosure as defined by the appended
25 claims.
6
[0026] It is also to be understood that various arrangements may be devised
that, although not explicitly described or shown herein, embody the principles of
the present disclosure. Moreover, all statements herein reciting principles, aspects,
and embodiments of the present disclosure, as well as specific examples, are
5 intended to encompass equivalents thereof.
[0027] The terminology used herein is to describe particular embodiments
only and is not intended to be limiting of example embodiments. As used herein,
the singular forms “a”, “an” and “the” are intended to include the plural forms as
well, unless the context indicates otherwise. It will be further understood that the
10 terms “comprises”, “comprising”, “includes” and/or “including,” when used
herein, specify the presence of stated features, integers, steps, operations,
elements and/or components, but do not preclude the presence or addition of one
or more other features, integers, steps, operations, elements, components and/or
groups thereof.
15 [0028] It should also be noted that in some alternative implementations, the
functions/acts noted may occur out of the order noted in the figures. For example,
two figures shown in succession may be executed concurrently or may sometimes
be executed in the reverse order, depending upon the functionality/acts involved.
[0029] Unless otherwise defined, all terms (including technical and scientific
20 terms) used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which example embodiments belong. It will be further
understood that terms, e.g., those defined in commonly used dictionaries, should
be interpreted as having a meaning that is consistent with their meaning in the
context of the relevant art and will not be interpreted in an idealized or overly
25 formal sense unless expressly so defined herein.
[0030] In the following detailed description of the embodiments of the
disclosure, reference is made to the accompanying drawings that form a part
hereof, and in which are shown by way of illustration specific embodiments in
7
which the disclosure may be practiced. These embodiments are described in
sufficient detail to enable those skilled in the art to practice the disclosure, and it
is to be understood that other embodiments may be utilized and that changes may
be made without departing from the scope of the present disclosure. The
5 following description is, therefore, not to be taken in a limiting sense.
[0031] Hereinafter, a description of an embodiment with several components
in communication with each other does not imply that all such components are
required. On the contrary, a variety of optional components are described to
illustrate the wide variety of possible embodiments of the present disclosure.
10 [0032] As mentioned above, due to increased rear seat height, floor carpet soft
trim 102 is designed with deep draw forming 104 in a forming direction 106, as
shown in FIG. 1. However, the deep draw forming 104 leads to weak surface and
defects such as thinning and wrinkle formation are observed, which provide feel
of inferior quality of carpet in the vehicle and noise is also generated inside
15 vehicle cabin due to gap formed between the floor carpet and vertical surface of
vehicle rear floor.
[0033] To address this issue, the present disclosure provides a floor carpet
structure having multiple vertical angular beads on vertical wall surface facing a
vertical area of a rear seating area. FIG. 2 illustrates the floor carpet structure 200
20 in accordance with an embodiment of the present disclosure. The floor carpet
structure 200 includes multiple angular beads 204 on vertical wall surface of the
floor carpet structure 200. The floor carpet structure 200 is assembled on a rear
floor body panel 206 in accordance with an embodiment of the present disclosure.
[0034] FIG. 3A illustrates a cross-section of the floor carpet structure 200
25 assembled with the body panel 206 at a bead location in accordance with an
embodiment of the present disclosure. As can be seen from FIG. 3A, the angular
beads are parallel to each other. Further, FIG. 3B illustrates a sectional detailed
8
view of the cross-section shown in FIG. 3A in accordance with an embodiment of
the present disclosure.
[0035] As can be seen from FIG. 3B, each angular bead 204 is divided into a
first segment 302 and a second segment 304. The first segment 302 and the
5 second segment 304 are formed with different draft angles Y and X respectively
with respect to a tooling direction Z. In an aspect, the draft angle Y of the first
segment is less than the draft angle X of the second segment.
[0036] In an aspect, the first segment has a length equal to or less than onethird length of the angular bead.
10 [0037] In an aspect, the second segment has a length equal to or more than
two-third length of the angular bead.
[0038] Further, the second segment is parallel to non-beaded profile of the
vertical wall surface of the floor carpet structure, and the first segment is at angle
with the non-beaded profile of the vertical wall surface of the floor carpet
15 structure.
[0039] Further, due to the presence of angular beads, the gap between the
vertical wall surface of the floor carpet and the body panel is reduced, thus
reducing the noise generated.
[0040] Yet further, although the subject matter herein is described with
20 respect to a floor carpet structure’s deep draw near a seating area of motor
vehicles, those skilled in the art would appreciate that the present subject matter is
equally applicable to deep draw of the floor carpet structure in other areas of the
vehicle without deviating from the scope of the present disclosure.
TECHNICAL ADVANTAGES
9
[0041] The present disclosure provides a floor carpet structure with multiple
angular beads which improve strength of floor carpet.
[0042] The present disclosure provides a floor carpet structure with angular
beads which eliminate wrinkle formation.
5 [0043] The present disclosure provides a floor carpet structure withangular
beads which eliminate quality issue like flapping noise.
Equivalents
[0044] While the foregoing describes various embodiments of the present
disclosure, other and further embodiments of the present disclosure may be
10 devised without departing from the basic scope thereof. The scope of the
invention is determined by the claims that follow. The present disclosure is not
limited to the described embodiments, versions or examples, which are included
to enable a person having ordinary skill in the art to make and use the present
disclosure when combined with information and knowledge available to the
15 person having ordinary skill in the art.

WE CLAIM:

1. A floor carpet structure (200) comprising:
multiple angular beads (204) formed in a vertical wall surface of the
floor carpet structure (200),
5 wherein each angular bead (204) is being divided into a first segment
(302) and a second segment (304).
2. The floor carpet structure (200) as claimed in claim 1, wherein the first
segment (302) and the second segment (304) are formed with different draft
angles (Y, X) respectively.
10 3. The floor carpet structure (200) as claimed in claim 1, wherein the second
segment (304) is parallel to non-beaded profile of the vertical wall surface of
the floor carpet structure (200) and the first segment (302) is at an angle with
the non-beaded profile of the vertical wall surface of the floor carpet structure
(200).
15 4. The floor carpet structure (200) as claimed in claim 2, wherein the first
segment (302) has a lower draft angle than that of the second segment (304).
5. The floor carpet structure (200) as claimed in claim 1, wherein the first
segment (302) has a length equal to or less than one-third length of the angular
bead (204).
20 6. The floor carpet structure (200) as claimed in claim 1, wherein the second
segment (304) has a length equal to or more than two-third length of an
angular bead (204).
7. The floor carpet structure (200) as claimed in claim 1, wherein the angular
beads (204) are parallel to each other.