Cover with Pull-Through Prevention Arrangement

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.

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/ftand about 9.5 lbs/ft, 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/ftand about 12.9 lbs/ft, 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.

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. 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() generally designates a deck cover floor mat while the reference numeralgenerally designates a swim platform cover or mat each embodying the present invention. In the illustrated example, the deck matand the swim platform matare supported by and releasably coupled to a deck surfaceand a swim deck surfaceof a boat, respectively. As best illustrated in, the mats,are sized and configured so as to effectively cover a majority or all of the given area of the deck surfaceand the swim deck surfacethereby providing a cushioned and slip resistant use area.

As the swim platform cover or matand the deck cover or matsare similar in construction the swim platform matis described in detail herein as an exemplary embodiment. In the illustrated example, the matdefines a peripheral edgehaving a non-quadrilateral shape. In the illustrated example, the mat() includes a first or upper layerhaving a top or outer surfaceand a bottom or inner surface, and a second or lower layerhaving a top or inner surfaceand a bottom surfacethat abuts the swim deck surfaceof the swim deck. The upper layerpreferably comprises a foam such as an EVA foam, a PE foam, and an EPDM foam, or a combination thereof. Preferably, the upper layercomprises a density EPA foam with a preferable density of within the range of between 7 lbs/ftand about 9.5 lbs/ft, more preferably within the range of between about 8 lbs/ftand about 9.5 lbs/ft, even more preferably within the range of about 8 lbs/ftand about 9 lbs/ft, and most preferably of about 8.5 lbs/ft. The upper layerfurther has a tear strength of within the range of about 35 lbs/inch to about 40 lbs/inch. In the illustrated example, the upper layerhas a thickness between the outer surfaceand the inner surfaceof 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 layercomprises a foam material such as EVA foam, PE foam, EPDM foam or combinations thereof. Preferably, the lower layercomprises a relatively higher density EVA foam having a density of within the range of 8 lbs/ftto about 12.9 lbs/ft, more preferably of within the range of about 9 lbs/ftto about 11.9 lbs/ft, even more preferably of within the range of about 9.5 lbs/ftto about 10.5 lbs/ft, and most preferably of about 10 lbs/ft. The bottom layerfurther 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 layerpreferably 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, the outer surfaceof the upper layeris 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.

The upper layeris connected to or coupled with the lower layervia 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, the lower layeris preferably provided as an integral, single piece covering the entire surface area of the swim deck surfaceintended to be covered, while the upper layermay be provided as an integral, single piece or alternatively as multiple pieces having channelsextending between or separating the the multiple pieces. The upper layerand the lower layermay also be provided in different colors from one another. In the example illustrated in, the the channelsand relative sizes of the segments or pieces of the lower layerand upper layerallow the differing colors between the layers to be seen through the channelsand about the peripheral edge.

The matfurther includes a plurality of quick release couplers which in the illustrated example includes snap-type couplershaving a first snap coupler portionthat releasably snappingly engages a second snap coupler portion. The first snap portionincludes a cylindrical body portionand a head or flanged portionthat extends outward from the body portion. The body portionextends completely through the thickness of both the upper layerand the lower layerbetween the outer surfaceof the upper layerand the bottom surfaceof the lower layer. The body portionmay extend through an associated pre-formed apertureor may be punched through the upper layerand the lower layerwithout preforming the aperture. The flanged portionextends outwardly from the body portion and abuts the outer surfaceof the upper layerand provides an enlarged contact area therebetween. The second snap coupler portionmay be attached to the swim deck surfaceof the swim deckvia an adhesive, or attached thereto via associated mechanical fasteners that are either integral with or separate from the second snap coupler portionand that positively engage the swim deck surface.

As best illustrated in, the snap couplersare positioned relative to the overall plan form of the matso as to provide adequate attachment and connection of the matto the swim deckso as to prevent inadvertent removal or uncoupling of the matfrom the swim deck, such as through use, accidental lifting of the mat, relative wind during operation of the marine vehicle, and the like. The snap couplersmay be placed about a periphery of the mat, or centrally located depending upon the specific requirements of the arrangement. The quick-coupling characteristics as provided by the multiple snap couplersallow the matto be easily removed from connection with the swim deckto allow for cleaning of the mator the swim deck surface, access to maintenance panels that may be located beneath the mat, general maintenance to be conducted, replacement of a worn or damaged mat, and the like, without damage to the swim deckand without damage to the matsuch that the matcan be easily resecured once the necessary procedure is conducted. The high-density foam of the lower layerresists tearing or a pull through of the snap couplerwhile the matis removed from or uncoupled from the swim deckwhile the relatively lower density foam of the upper layerreduces the overall weight of the matand provides additional cushioning properties.

The reference numeral() generally designates another embodiment of the present invention. Since the swim platform cover or matis similar to the previously described swim platform cover or mat, similar parts or elements appearing inandrespectively 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 matand the previously described matis a multi-layer upper layer arrangement. In the illustrated example, the upper layer arrangementincludes a first sublayerthat includes the outer surfaceand a bottom or inner surface, and a second sublayerthat includes the bottom or inner surfaceand a top or inner surface. The first sublayerand the second sublayereach comprise foams as described above with respect to the upper layer, but may comprise different foams from one another. The matmay further include a plurality of channelsextending through the first sublayerand the second sublayerof the upper layer, a plurality of channelsextending through only the first sublayerof the upper layer, where the first sublayer, the second sublayerand the lower layermay be provided in different colors from one another. In addition, the upper layerand/or the lower layermay 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.