AUTOMOTIVE TRUNK LINER Background of the Invention This invention is an improvement over the automobile trunk liner as disclosed in recently granted U.S. Patent No. 4,673,207, commonly owned by the assignee of this invention. While the one piece trunk liner of this patent is a vast improvement over the multi-piece trunk liners of the prior art, it has been learned that for certain styles of automobiles, it is desirable for the spare tire well to be lined with the same material as that forming the body of the trunk liner.

With the foregoing in mind, it is the primary purpose of this invention to form an automobile trunk liner of integral molded construction wherein there is first drawn portion as represented by side walls extending upwardly from a center floor cover panel, and a second drawn portion as represented by a recessed spare tire well extending downwardly from a medial portion of a center floor cover panel. It is a further object of this invention to provide a molded one-piece trunk liner with an integrally formed recessed spare tire well therein and wherein accommodation is made in the liner for receptio of a separately formed cover and lid for the spare tire well.

Summary of the Invention These and other objects and advantages of the present invention are accomplished by a trunk liner for an automobile trunk compartment wherein the trunk liner comprises an integrally molded relatively stiff fibrous

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body having a center floor cover panel, and a pluralit of panels integrally connected to the center floor cov panel and extending upwardly along the sides of the center panel. A recessed spare tire well liner is integral with and extends downwardly from a medial portion of the center panel.

In the preferred embodiment a thermoplastic coating on the backside of the fibrous body imparts hardness to the backside and an overall stiffness and shape retention to the fibrous body. A spare tire cov overlies the recessed spare tire well liner and has ed portions overlying an adjacent portion of the center floor cover panel. A rigid lid is carried by the spar tire cover on the backside thereof and is adapted to overlie and rest upon adjacent edge portions of the center floor cover panel and cover the spare tire well liner. To present an aesthetically pleasing appearanc to the spare tire cover thereto, the spare tire cover has edge portions overlying and covering the periphery of the rigid lid.

Brief Description of the Drawing's Some of the objects and advantages of the present invention having been stated, others will appe as the description proceeds, when considered in conjunction with the accompanying drawings in which — Figure 1 is a top perspective view of the trun liner substantially as the same appears when taken out of the mold.

Figure 2 is another top perspective view simil to Figure 1 but looking from the opposite side of Figu 1.

Figure 3 is an exploded perspective view of th completed trunk liner after the same has been suitably trimmed following molding ^' and after the insulator pads have been applied at predetermined areas along the bac

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of the various panels and wherein the spare tire cover having a rigid lid connected thereto has been placed i overlying relationship to the recessed spare tire well. Figure 4 is a perspective view of a stack of finished trunk liners shown nestingly arranged for facilitating shipment and handling thereof.

Figure 5 is another top perspective view of th trunk liner wherein the spare tire cover is positioned for overlying engagement with the recessed spare tire well.

Figure 6 is an enlarged transverse sectional view of the spare tire cover taken substantially along Line 6-6 of Figure 5.

Figure 7 is a cutaway top perspective view take along Line 7-7 of Figure 5 showing the trunk liner having the spare tire cover overlying the recessed spar tire well.

Figure 8 is a top plan view showing the trunk liner installed within the trunk compartment of an automobile.

Figure 9 is a sectional view of the trunk compartment taken along Line 9-9 of Figure 8.

Figure 10 is a sectional view of the trunk compartment taken along Line 10-10 of Figure 8. Figure 11 is a top perspective view showing the trunk liner installed within the trunk compartment of a automobile wherein the recessed spare tire well is uncovered.

Detailed Description of the Drawings Referring now specifically to the drawings, there is illustrated a preferred embodiment of the invention wherein reference numeral 10 designates the trunk liner as the same substantially appears when removed from a mold. This form of the trunk liner is best illustrated in Figures 1 and 2 of the drawings. O

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the other hand, reference numeral 10' designates the completed trunk liner after the same has been suitably trimmed following the molding thereof and after the sam has had other components added thereto on the-backside, such as insulator pads and a rigid lid underlying a spare tire cover and acting as a cover for covering a spare tire well. This completed form of the trunk line is best illustrated in Figures 3 to 5 and 7 to 11.

For purposes of simplicity, the various element or features of the completed trunk liner will bear the same reference numerals as the molded but unfinished trunk liner, but with the prime notation added thereto.

As best shown in Figures 1 and 2, the trunk liner 10 shown as removed from a typical pressure molding operation utilizing mating male and female molding components, comprises a center floor cover pan 20 and a plurality of panels extending along the sides of said center floor panel and integrally connected thereto. These panels include a rear end panel 30 having lower end portions connecting rearmost portions of said center floor panel 20 and divergingly extendin upwardly and outwardly therefrom. Right and left rear wheel housing cover panels 40a and 40b, respectively a connected to opposite sides of said center floor cover panel 20 and divergingly extend upwardly and outwardly therefrom. Right and left inner panels 50a and 50b - respectively are also connected to opposite sides of said center floor cover panel 20 and are divergingly "arranged to extend upwardly and outwardly therefrom. These right and left inner panels 50a and 50b are positioned rearwardly of the right and left rear wheel housing cover panels 40a, 40b and are respectively connected to rearmost portions of the right and left rear wheel housing cover panels 40a, 40b, respectively.

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The molded trunk liner 10 is formed of any suitable fibrous material that may readily be subjecte to molding. While many textile fibers may be used, polyester staple fibers that have been needle punched preneedled to form a non-woven fabric have been found be quite suitable as well as economical to use. In th preferred embodiment shown herein, a moldable coating is applied to the backside of the non-woven fabric and dried prior to being molded. This coating serves to impart shape retention and stiffness to the overall molded body upon the molding operation being completed. A relatively lightweight coating of thermoplastic material of a wide variety may be used. However, coatings of polyethylene or moldable latex have each been proven to be suitable, with latex offering the better shape retention. Conventional coating equipmen is readily used with either type of coating. The uppe surface of the trunk liner is desirably formed of soft fibrous material, preferably in the form of pile fiber The back of the body of the trunk liner is relatively hard and rigid to provide the molded memory and shape retention for the trunk liner. Alternatively, instead of a coating, the desired moldability, stiffness and shape retention properties can be imparted to the trunk liner by other means such as by the composition of the fibrous material itself, as an example, through the use of a web containing heat activatable potentially adhesive fibers. One such product is disclosed in commonly owned U.S. Patent No. 4,568,581. Integral with and extending downwardly from a medial portion of the center floor cover panel 20 is a recessed spare tire well liner indicated by reference numeral 60. The recessed spare tire well liner 60 is formed during the molding operation by clamping the trunk liner with a varying pressure ring clamp and deep

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drawing the tire well using male and female mating mold images. The pressure of the ring clamp is varied to allow controlled sliding of the trunk liner fabric into the cavity during- rawing so as to prevent tearing or wrinkling of the fabric.

Molded integral into the center floor cover panel 20 is an upstanding shoulder 70 which extends around a substantial portion of the spare tire well liner 60 and in spaced relation thereto. Extending between the upstanding shoulder 70 and the spare tire well liner 60 is a relatively narrow ledge portion 71. As will be seen later, as the description proceeds, the upstanding shoulder 70 and the relatively narrow ledge portion 71 retain a spare tire cover to provide a lid for the spare tire well liner 60.

Referring now particularly to Figure 3, reference numeral 10' designates the finished or completed trunk liner after the same has been suitably trimmed following the molding thereof and after insulator pads have been added to predetermined areas o the backside thereof, as well as after a cover 61' has been provided for covering the spare tire well liner 60 of the automobile trunk liner 10'. Comparing Figure 3 (wherein the prime notation has been added to molded liner elements) with Figures 1 and 2, it will be noted that gusset portions G in Figures 1 and 2, have been removed as by cutting along the dotted lines as indicated. The removal of these gusset portions G ^" permits the rear end panel 30' to be moved substantiall to the perpendicular position as when installed, as bes seen in Figure 5. Similarly, as also shown in Figure 5 the removal of the gussets G permit the right and left rear wheel housing cover panels 40a', 40b' and right an left inner panels 50a' and 50b', to also be moved to th substantially vertical position. Also, since right and

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left inner panels 50a' and 50b' are integrally connect to the right and left rear wheel housing cover panels 40a', 40b', these inner panels 50a', 50b' may also be moved to the substantially vertical position upon the removal or trimming of the gussets G from the molded liner 10. Once the gussets G are trimmed, the relatively thin shell-like construction and the outwardly diverging relation of the plurality of panel extending along the sides of the center floor cover panel 20' impart nestability to the trunk liner 10' to permit a plurality of the trunk liners 10' to be compactly nested with each other to form a nested stac of trunk liners 10' to thereby facilitate handling and shipping of trunk liners 10' (Figure 4) . As earlier noted, all the plurality of panels extending along the sides of the center floor cover panel 20' are arranged to extend upwardly and outwardl therefrom so as to be in outwardly diverging relation thereto. The overall molded body also is stiff and ha an imparted shape retention. As can best be seen in

Figure 10, which shows a sectional view of the trunk liner 10' installed within the trunk compartment C of automobile, the stiffness of the molded fibrous body a the outwardly diverging relationship of the plurality panels causes the panels to resiliently engage the inn wall surfaces of the trunk compartment C to facilitate maintaining the trunk liner 10' in engagement with the walls of the trunk compartment C.

Referring now to the spare tire cover 61', as best shown in the perspective view of Figure 5 and the sectional view of Figure 6, the spare tire cover 61' is provided with a rigid lid 62' on the backside of the cover 61' thereof and which is suitably secured to the cover 61' as by a suitable adhesive such as a heat activatable hot melt adhesive. The rigid lid 62' can b

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formed of any suitable rigid material such as panel board, compressed board or the like, which will provide structural integrity. To maintain an aesthetically pleasing appearance, the spare tire cover 61' has its edge portions overlying and covering the periphery of the rigid lid 62' (Figure 6).

In use, the spare tire cover 61' overlies and rests upon adjacent edge portions of the center floor cover panel 20' so as to cover the recessed spare tire well liner 60'. As best seen in Figure 7, the spare tire cover 61' is dimensioned to overlie and rest on th relatively narrow ledge portion 71' extending between the upstanding shoulder 70' and the recessed spare tire well liner 60'. When in place, the spare tire cover 61 and the center floor cover panel 20' are essentially coplanar giving an aesthetically pleasing look thereto.

Referring again more particularly to the exploded view of Figure 3, it will be seen wherein a plurality of fibrous insulator pads 80' of various thicknesses are secured to the backside of predetermine areas of the plurality of panels extending upwardly and outwardly from the center floor cover panel 20'. Such pads 80' provide an additional amount of acoustical and thermal insulation which would not ordinarily be provided by the trunk liner 10'. Depending on the acoustical and thermal insulation desired, the insulato pads 80' can vary in thickness as the insulation requirements mandate. It will be noted that three rectangular shaped insulator pads 80' are shown secured to the backside of the rear end panel 30' and that relatively large quadrant shaped insulator pads 80' are secured to the backside of the right and left rear whee housing cover panels 40a', 40b'. It will be noted that these latter insulator pads have notches 80a' cut inwardly from the periphery thereof so that the pads ma

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readily be accommodated to the arcuate inner surfaces the wheel housing cover panels 40a',40b'. These insulator pads 80' may be secured to the molded trunk liner 10' by any suitable adhesive, which may also be the hot melt type of adhesive.

Referring to Figures 3 to 5 and 8 to 9, it wil be noted that the rear end panel 30' has a forwardly bulging portion 30a' in the upper central portion thereof, and that a slot S is provided therethrough. This bulging portion 30a' accommodates therebehind the latching mechanism for the automobile trunk lid with t slot S serving to permit protrusion therethrough of a loop portion of a lock. To aid in prelocating and securing the truck liner 10' within the trunk compartment C, the holes 30b' are punched in the rear end panel 30' on the bulging portion 30a'. Appropriat fasteners are provided therethrough.

Once the trunk liner is installed, an undersiz spare tire as is commonly used in the industry may be positioned within the recessed spare tire well liner

60'. The spare tire well liner 60' is covered with th spare tire cover 61' and rigid lid 62'. In those instances when a full size spare tire is stored, the spare tire cover 61' is not used since a full size tir positioned within the recessed spare tire well liner 6 extends upwardly beyond the well.