U.S. patent application number 14/960037 was filed with the patent office on 2017-06-08 for floor mats with microfiber backing material.
This patent application is currently assigned to VIAM Manufacturing, Inc.. The applicant listed for this patent is Kevin Hurt. Invention is credited to Kevin Hurt.
Application Number | 20170156532 14/960037 |
Document ID | / |
Family ID | 58799412 |
Filed Date | 2017-06-08 |
United States Patent
Application |
20170156532 |
Kind Code |
A1 |
Hurt; Kevin |
June 8, 2017 |
Floor Mats With Microfiber Backing Material
Abstract
An improved floor mat designed to maintain its location in
relation to the carpet upon which it is placed. The floor mat
comprises a layer of carpet, a layer of support material attached
to a layer of carpet, and a layer of loop-pile microfiber material
attached to the layer of support material opposite the layer of
carpet. The layer of loop-pile microfiber material can include a
plurality of split microfibers. The split microfibers can include a
generally acute triangular shape wherein a portion of the generally
acute triangular shape includes at least one generally arcuate
side.
Inventors: |
Hurt; Kevin; (Manchester,
TN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hurt; Kevin |
Manchester |
TN |
US |
|
|
Assignee: |
VIAM Manufacturing, Inc.
Manchester
TN
|
Family ID: |
58799412 |
Appl. No.: |
14/960037 |
Filed: |
December 4, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47G 27/02 20130101 |
International
Class: |
A47G 27/02 20060101
A47G027/02 |
Claims
1. A floor mat comprising: a layer of carpet; a layer of support
material attached to the layer of carpet; and a layer of loop pile
microfiber material attached to the layer of support material
opposite the layer of carpet, the layer of loop pile microfiber
material including a plurality of split microfibers.
2. The floor mat of claim 1, wherein the split microfibers include
generally an acute triangular shape.
3. The floor mat of claim 2, wherein a portion of the generally
acute triangular shapes include at least one generally arcuate
side.
4. The floor mat of claim 1, wherein the layer of loop pile
microfiber material includes: an area; a plurality of piles with
each pile formed by at least one microfiber and including a height;
and a pile density measured in the number of piles per square
centimeter of the area of the layer of loop pile microfiber
material,
5. The floor mat of claim 4, wherein the height of each pile ranges
from approximately 1.0 millimeters to approximately 12.0
millimeters.
6. The floor mat of claim 4, wherein the height of each pile ranges
from approximately 1.5 millimeters to approximately 4.0
millimeters.
7. The floor mat of claim 4, wherein the height of each pile ranges
from approximately 2.0 millimeters to approximately 3.0
millimeters.
8. The floor mat of claim 4, wherein the pile density ranges from
approximately 5 piles per cm.sup.2 to approximately 500 piles per
cm.sup.2.
9. The floor mat of claim 8, wherein the pile density ranges from
approximately +/-10% piles per cm.sup.2
10. The floor mat of claim 4, wherein the pile density ranges from
approximately +/-10% piles per cm.sup.2.
11. The floor mat of claim 1, wherein the layer of loop pile
microfiber material includes: a plurality of piles and each of the
plurality of piles includes one of the split microfibers; each
split microfiber comprises segments as part of the split; and
wherein the number of filaments per pile ranges from approximately
10 to approximately 10,000 and the number of segments as part of
the split ranges from 1 to 64.
12. The floor mat of claim 11, wherein the number of filaments per
pile ranges from approximately 500 to approximately 750.
13. The floor mat of claim 1, wherein the layer of support material
is composed of polyethylene terephthalate, polypropylene, or
polyamide.
14. A floor mat comprising: support material having a first side
and a second side; carpet attached to the first side of the support
material; loop pile constructed microfiber material attached to the
second side, the loop pile microfiber material including a
plurality of piles with each pile including a height and a split
microfiber having segments exposed and extending along the
split.
15. The floor mat of claim 14, wherein the segments include a
generally triangular shape with a portion of the generally
triangular shapes including at least one generally arcuate
side.
16. The floor mat of claim 14, wherein: the loop pile microfiber
material includes an area and a pile density measured in the number
of piles per square centimeter of the area of the loop pile
microfiber material; the height of each pile ranges from
approximately 1 millimeter to approximately 12 millimeters and the
pile density ranges from approximately 5 piles per cm.sup.2 to
approximately 500 piles per cm.sup.2; and the number of filaments
per pile ranges from approximately 10 to approximately 10,000 and
the number of segments as part of the split ranges from 1 to
64.
17. The floor mat of claim 14, wherein the layer of support
material is composed of polyethylene terephthalate, polypropylene,
or polyamide.
18. A floor mat comprising: a layer of carpet having a front side
and a backside; a layer of loop pile microfiber material
operatively attached to the backside of the carpet, the microfiber
material includes a plurality of piles and each of the plurality of
piles includes at least one filament having at least one split
microfiber with each split microfiber comprising segments as part
of the split, wherein the number of filaments per pile ranges from
approximately 10 to approximately 10,000 and the number of segments
as part of each split ranges from 1 to 64.
19. The floor mat of claim 18, wherein the split microfibers
include a plurality of generally protruding edges extending from
the split microfiber surface.
20. The floor mat of claim 18, wherein the layer of loop pile
microfiber material includes: an area:, a plurality of piles with
each pile including a height, wherein the height of each pile
ranges from approximately 1 millimeter to 12 millimeters; and a
pile density measured in the number of piles per square centimeter
of area of the layer of loop pile microfiber material, wherein the
pile density ranges from approximately 5 piles per cm.sup.2 to 500
piles per cm.sup.2.
Description
BACKGROUND
[0001] Technical Field
[0002] The present disclosure relates generally to floor mats and
more particularly, without limitation, to floor mats having a
microfiber backing designed to having a friction interface with the
surface one which the floor mat is placed, such as carpet, to
retain the floor mat in its desired position.
[0003] Background Art
[0004] Referring generally now to FIGS. 1A-1C, an example of
loop-pile construction as known in the textile and carpet art is
shown. This type of product manufacturing basically includes a
needle (1) partially pushing a length of material (2), such as a
strand, yarn, cord, etc., through a primary layer (2), or backing
layer. A looper (4) then grabs the material (2) to form the loop as
the needle retracts. Another part of the material is then pushed
through the backing layer at a second location. This type of carpet
manufacturing of can be referred to as tuft manufacturing, e.g.
tufted carpet. This type of carpeting generally begins with the
loop-pile formation and then the tops of the loops are cut leaving
freestanding pieces as shown in the illustration. This is called
cut-pile because the loop-pile formation is cut. Another type of
textile/carpet manufacturing is referred to as woven. Woven is
where interlaced pieces of the material are formed together in an
alternating over-under pattern. This creates a generally
"interlocked" product. If during the manufacture of the woven
product the interlacing pieces of the material are not drawn taunt,
"loop type" pieces can form in the woven product. These loose
pieces can resemble the loop pile construction just described.
[0005] Floor mats, as known in the art, are typically used to
either 1) protect an underlying surface, such as a floor, 2) change
the engagement surface of the underlying surface for a user of that
surface (e.g. change the coefficient of friction as the user
walks), or 3) change the aesthetic look to the surface. Floor mats
can be composed of many different materials but are generally
composed of a type of plastic or a fabric. The fabric can be
generally referred to as carpet. These floor mats have many uses in
many locations, including residential, commercial, industrial, and
in vehicles.
[0006] One area in particular is the use of floor mats in vehicles
to protect and decorate the vehicle interior. Specifically the
floor mats are used on the floor of the vehicle, or floor board.
The floor board itself is usually covered by carpet used to protect
the underlying materials of the floor board and give an
aesthetically pleasing look to the passengers and/or driver of the
vehicle. This carpet is normally permanently attached to the floor
board and is typically comprised of tufted cut-pile carpet or
non-woven carpet/fabric. It can be expensive to replace the carpet
that is fixed to the floor board. As such, floor mats are often
placed in locations of this carpeting that received the most wear
and tear, or use, during operation of the vehicle.
[0007] Floor mats generally are known in the art and conventionally
comprised of elastomeric materials that have enough flexibility to
generally conform to the shape and contours of the vehicle floors.
These floor mats can also include carpet attached to the
elastomeric material that can provide an aesthetically pleasing
look to the users of the vehicle and/or match the carpet attached
to the floor board. The elastomeric material and conventional
carpet used in floor mats typically do not sufficiently interact
with the carpet on the floor boards to maintain the position of the
floor mat when subject to slight forces during use.
[0008] Movement of floor mats on carpet can damage the carpet and
potentially be unsafe. For example, a person can slip on a floor
mat when walking along a carpeted surface if the floor mat shifts.
Additionally, a floor mat in a vehicle can move during ingress and
egress of a person into the vehicle. This can cause a safety hazard
and potentially interfere with operation of the vehicle if the
floor mat is in the driver's area. This movement also can increase
the wear and tear on the carpet it is trying to protect by
additional stress to the underlying carpet as the floor mat
moves.
[0009] Numerous prior attempts have been made to address the
problem of movement of floor mats relative to underlying floor
board carpeting. For example, U.S. Pat. Nos. 4,425,690, 6,381,806,
and 7,329,451 are examples of prior art attempts. These patents
include various mechanical fasteners designed to secure or maintain
the locale of the floor mat relative to the floor. These concepts
have various drawbacks based upon their design and
configurations.
[0010] What is needed then is an improved floor mat that maintains
its position relative to the carpet upon which it is placed. This
needed floor mat is lacking in the art.
BRIEF SUMMARY
[0011] The present disclosure provides an improved floor mat
designed to maintain its location in relation to the carpet upon
which it is placed.
[0012] In some embodiments, the present disclosure provides a floor
mat comprising a layer of carpet, a layer of primary support
material attached to a layer of carpet with an adhesive, and a
layer of loop-pile microfiber material attached to the layer of
support material opposite the layer of carpet with adhesive. The
layer of loop-pile microfiber material can include a plurality of
split microfibers. In an embodiment, the split microfibers can
include a generally acute triangular shape wherein a portion of the
generally acute triangular shape includes at least one generally
arcuate side.
[0013] In an embodiment, the layer of loop-pile microfiber material
can include an area, a plurality of piles with each pile formed by
at least one strand of microfibers, and each pile can include a
height. The loop-pile microfiber material can have a pile height as
desired by a user of the floor mat. The pile height can generally
fall somewhere in the range from approximately 0.1 millimeters to
15 millimeters as desired. Within this range, the actual variance
of the pile height for a given layer of loop-pile microfiber
material is preferably smaller. For example, in an embodiment, the
height of each pile can range from approximately 1 millimeter to 10
millimeters. In an embodiment, the height of each pile can range
from approximately 5.0 millimeters to 10.0 millimeters. In another
embodiment, the height of each pile can range from approximately
1.0 millimeter to 3.0 millimeters. In another embodiment, the
height of each pile can range from approximately 1.5 millimeters to
4.0 millimeters. In another embodiment, the height of each pile can
range from approximately 2.0 millimeters to 3.0 millimeters.
[0014] In an embodiment, the layer of loop-pile microfiber material
can include a pile density with the pile density measured by the
number of piles per square centimeter of the area of the layer of
the loop-pile microfiber material. The loop-pile microfiber
material can have a pile density as desired by a designer of the
floor mat. The pile density can generally fall somewhere in the
range from approximately 5 piles per centimeter squared to 500
piles per centimeter squared as desired. Within this range, the
actual variance of the pile density for a given layer of loop-pile
microfiber material is relatively small. For example, in an
embodiment, the pile density can be any general density as selected
and desired from the range and vary approximately +/-10% piles per
centimeter squared for that selected density.
[0015] In a preferred embodiment, the layer of loop-pile microfiber
material includes a plurality of piles and each of the plurality of
piles includes strands of microfiber filaments which are split into
smaller segments. Each strand of microfiber can comprise filaments
wherein the number of filaments per strand, ranges from
approximately 500 to 750. In another embodiment, the number of
filaments per strand can range from approximately 10 to 10,000.
Each of the filaments can be split into segments ranging from 1 to
64.
[0016] In an embodiment, the primary layer of support material is
composed of materials such as polyethylene terephthalate,
polypropylene, and polyamide. In another embodiment, the primary
layer of support material is coated with latex or other types of
adhesive. In another embodiment, a secondary layer of support
material such as non-woven, foam, plastic, rubber, etc. is
laminated to the primary layer and bonded with adhesive to provide
body, support, rigidity, retention and a host of other
properties.
[0017] In another embodiment, the present disclosure provides a
floor mat comprising a support material having a first side and a
second side, carpet attached to the first side of the support
material, and loop-pile constructed microfiber material attached to
the second side. The loop-pile microfiber material includes a
plurality of piles with each pile including a height and microfiber
strands having split filaments exposed and extending from the
strands. In this embodiment, the split filaments can include edges
that extend from the strand. These edges can comprise a generally
triangular shape, such as an acute triangular shape, with a portion
of the generally triangular shape including at least one generally
arcuate side.
[0018] The floor mat can further consist of the loop-pile
microfiber material having an area and a pile density measured in
the number of piles per square centimeter of the area of the
loop-pile microfiber material. In this embodiment, the height of
each pile can range from approximately 1 millimeter to 3
millimeters, the pile density can range from approximately 10 piles
per centimeter squared to 400 piles per centimeter squared, and a
number of filaments per microfiber strand can range from
approximately 100 to 10,000.
[0019] In another embodiment, the present disclosure provides a
floor mat having a layer of carpet having a front side and a back
side with a layer of loop-pile microfiber material operatively
attached to the back side of the carpet. The microfiber material
can include a plurality of piles and each of the plurality of piles
can include microfiber strands. Each strand of microfiber can
include filaments with the number of filaments per pile as part of
the split ranging from approximately 100 to 10,000. Each microfiber
filament can be split into multiple fibers. In this embodiment, a
layer of support material can further be included and positioned
between the layer of carpet and the layer of loop-pile microfiber
material.
[0020] Numerous other objects, features and advantages of the
present disclosure will be readily apparent to those skilled in the
art upon a reading of the following description when taken in
conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1A is an example of loop-pile carpeting
construction.
[0022] FIG. 1B is an example of loop-pile carpeting.
[0023] FIG. 1C is an example of cut-pile carpeting.
[0024] FIG. 2 is an image showing of an embodiment of a floor mat
made in accordance with the current disclosure laid against
carpeting.
[0025] FIG. 3A is a perspective view of the carpet side of an
embodiment of a floor mat made in accordance with the current
disclosure.
[0026] FIG. 3B is a perspective view of the microfiber side of an
embodiment of a floor mat made in accordance with the current
disclosure.
[0027] FIG. 4 is view of the microfiber side of a floor mat made in
accordance with the current disclosure.
[0028] FIG. 5 is view of the carpet side of a floor mat made in
accordance with the current disclosure.
[0029] FIG. 6 is an end view of the floor mat made of FIGS.
2-5.
[0030] FIG. 7 is a microscopic picture of a floor mat made in
accordance with the current disclosure.
[0031] FIG. 8 is a cross sectional view of the image shown in FIG.
7 before dyes are added to the microfiber material.
[0032] FIG. 9 is an image from an electron microscope of a floor
mat made in accordance with the current disclosure shown at a
magnification level of 200.times..
[0033] FIG. 10 is a cross sectional view of the image shown in FIG.
9 taken at 1000.times. magnification by an electron microscope.
[0034] FIG. 11 is a cross sectional view showing an example of the
pile density of a floor mat made in accordance with the current
disclosure.
[0035] FIG. 12 is a cross sectional view of 1 microfiber after it
has been split showing the filaments extending therefrom.
[0036] FIG. 13 is a cross sectional view of the comparison between
split and unsplit filaments taken with an electron microscope.
[0037] FIG. 14 is an example of the testing of the retention
characteristics of a floor mat made in accordance with the current
disclosure.
[0038] FIG. 15 is a cross sectional view of the comparison of floor
mats made in accordance with the current disclosure. One is
constructed with the support material and one without.
DETAILED DESCRIPTION
[0039] Referring generally now to FIGS. 1-14, one embodiment of the
present disclosure provides a floor mat generally designated by the
numeral 10. It is understood that, for the sake of clarity, not all
reference numbers are included in each drawing. In addition,
positional terms such as a "upper," "lower," "side," "top,"
"bottom," "vertical," "horizontal," etc. refer to the apparatus
when in the orientation shown in the drawing. The skilled artisan
will recognize that objects in accordance with the present
disclosure can assume different orientations when in use.
[0040] Referring generally now to FIG. 1B, an example of loop-pile
carpet as known in the art is shown. This carpeting basically
includes a sub-straight to which a length of material is connected
to at either end forming a loop. Cut-pile carpeting is shown in
FIG. 1C. This type of carpeting generally begins with the loop-pile
carpeting formation and then the tops of the loops are then cut
leaving freestanding pieces as shown in illustration. This is
called cut-pile because the loop-pile is cut.
[0041] The floor mat 10 is used in conjunction with carpet 12 on a
floor, or other surface such as a floor board of a vehicle. The
floor mat 10 is designed to maintain its positioning on the carpet
12 and have a high resistance to displacement, which can also be
described as a retention, of the floor mat 10 in relation to the
location it is placed on the carpet 12. The carpet 12 can be any
type of carpet known in the art including loop-pile, cut-pile,
other styles and variations thereof. The floor mat 10 works in
conjunction with the various types of carpet 12 to facilitate
retaining its position with respect to that carpet 12.
[0042] In a preferred embodiment, the floor mat 10 comprises a
layer of carpet 14, a layer of support material 16 attached to the
layer of carpet 14, and a layer of loop-pile microfiber material 18
attached to the layer of support material 16 opposite the layer of
carpet 14.
[0043] The layer of carpet 14, which can be described as carpet 14,
can include any type of carpet known in the art including
loop-pile, cut-pile, other forms of carpet, and variations thereof.
This carpet 14 provides a surface for a user of the floor mat 10
and can be colored or decorated to be aesthetically pleasing as
desired.
[0044] The layer of support material 16, which can be described as
support material 16, can be attached to the carpet 14 to provide
enough stability and rigidity in the overall floor mat 10 as
desired. The support material 16 can be comprised of those
materials known in the art to provide rigidity including various
types of plastic, including polyethylene terephthalate (PET),
polypropylene (PP), polyamide, and other types of polymers in woven
or non-woven fabric styles often coated with various forms of latex
adhesive. For example, the support material 16 can be a PET
non-woven fabric material used to provide the level of rigidity
needed to be able to position the floor mat as desired on a floor,
including the floor of a vehicle. The various desired types of
plastic, including the PET, can also provide a level of flexibility
such that the floor mat 10 can contour to the surface it is placed.
For example, the floor mat 10 used with these types of support
material 16 can contour to the floor board of a vehicle yet have
enough rigidity to be positioned and placed as needed by a user of
the floor mats 10.
[0045] The layer of loop-pile microfiber material 18, which can
also be described as microfiber material 18, can include a
plurality of split microfibers 20 that are designed to engage the
carpet 12 to maintain the positioning of the floor mat 10. In a
preferred embodiment, the split microfibers 20 include a generally
triangular shape, such as an acute triangular shape, as best seen
in FIG. 10. In this embodiment, the triangular shape can include at
least one generally arcuate side that generally conforms to the
overall outer diameter dimension of the split microfiber 20.
[0046] In this embodiment, the split microfiber 20, including the
edges of the shapes that the split microfiber 20 takes, such as the
triangular shape, can act as a gripping mechanism to the carpet 12.
Specifically, they can act as a gripping mechanism to entangle the
fibers of the carpet 12, such as tuft cut-pile carpet fibers.
Generally, the fibers of the carpet 12 typically protrude and can
engage and be intertwined in between the microfiber material 18,
and more specifically, the split microfibers 20. This entanglement
of the carpet fibers and the split microfibers 20 yields a strong
frictional resistance that counteracts a force designed to remove
or slide the floor mat 10 across the carpet 12.
[0047] The split microfibers 20 have an advantage over microfiber
materials made from extracted microfiber construction. For example,
the split microfiber construction includes the various edges that
act as the gripping mechanisms. Conversely, extracted type
microfibers have smooth, round, and/or oval cross sections similar
to natural fibers that lack this gripping feature. As such, the
extracted type microfibers do not have the frictional interaction
and the resistance to movement that the split microfibers 20
exhibit. As such, the smooth extracted type microfibers will not
have the resistance to movement of the floor mat 10 in relation to
the carpet 12 when used as part of a floor mat.
[0048] Further, the loop-pile construction provides an additional
advantage of the microfiber material 18 in this disclosure. For
example, the generally uneven loop-pile construction that includes
various porous openings and gaps within adjacent portions of the
microfiber material 18 creates a surface condition that promotes
entanglement of the fibers of the carpet 12 to the split
microfibers 20 of the microfiber material 18. The fiber of the
carpet 12 easily protrudes into the surface of the loop-pile
construction of the microfiber material 18, such as in between the
various split microfibers 20, to promote an engagement and
frictional resistance to movement between the split microfibers 20
and the carpet 12. The surface condition created by the loop-pile
height of the microfiber material 18 when combined with the surface
edges of the split microfibers 20 creates a superior side-to-side
frictional resistance in relation to the fibers of the carpet 12 to
prevent and/or substantially resist the sliding motion between the
carpet 12 and the microfiber material 18 of the floor mat 10.
[0049] The inventor discovered that the loop-pile woven
construction of the microfiber material 18 with the split
microfibers 20 is superior to other types of microfiber material
and normal fiber material. Twill, satin, and plain woven styles of
microfiber material and various non-woven microfiber materials,
such as microfiber material bonded together by mechanical, thermal,
or chemical means, result in a relatively smooth, dense, flat
surface when constructed as a sheet of material. That smooth, flat
surface can generally prevent the fibers of the carpet 12 from
embedding into the surface. As such, these woven or non-woven
microfibers limit the entanglement level, and friction, between
those microfiber materials and the carpet 12. Alternately stated, a
friction grip between the mating surfaces of the woven or non-woven
microfibers is not as substantial as the frictional grip of the
loop-pile microfiber material 18 with split microfibers 20.
Additionally, traditional natural fibers, such as, but not limited
to, cotton, does not have the engagement surfaces present in the
loop-pile microfiber material 18 with the split microfibers 20. As
such, the natural fiber materials as used in a floor mat do not
have the same frictional gripping ability in relation to the carpet
12.
[0050] Further, the level of sliding or tension can specifically
relate to the edges and number of engagement surfaces present in
the split microfibers 20 of the microfiber material 18 as
constructed with the porous loop-pile construction of the current
floor mat 10. Those combined features can enable a maximum level of
entanglement between the microfiber material 18 and the fibers of
the carpet 12 to provide an improved and high level of frictional
resistance to movement between the floor mat 10 and the carpet
12.
[0051] In construction of a floor mat 10 in accordance with the
current disclosure, the microfiber material 18 can include an area
and a plurality of piles 22 with each pile 22 formed by at least 1
strand of microfiber. The piles 22 can include a height and a pile
density measured in the number of piles per square centimeter of
the area of the microfiber 18. In an embodiment, the height of each
pile 22 ranges from approximately 1.0 millimeters to approximately
5.0 millimeters, more preferably from approximately 1.5 millimeter
to approximately 4.0 millimeters, and most preferably from
approximately 2.0 millimeters to approximately 3.0 millimeters. The
pile density can be a specific density for a given microfiber
material and that particular material can have a density ranging
from 5 piles per centimeter squared to approximately 25 piles per
centimeter squared. However, the pile density is usually a specific
density within that range, as desired, and can vary approximately
+/-10% for that specific selected and desired pile density for the
given microfiber material.
[0052] Further, a microfiber of the microfiber material 18 can be
measure and defined in terms of its linear mass density measured in
a denier. A microfiber can have a denier of less than 1 of a given
material relative to the density of that material. Examples of
microfibers can include: 1 D of PP gives an average diameter of
12.46 micrometers; 1 D of PET gives an average diameter of 10.12
micrometers; 1 D of Nylon gives an average diameter of 11.13
micrometers; and 1 D of high density polyethylene (HDPE) gives an
average diameter of 12.19 micrometers. These values can obviously
vary in accordance with manufacturing tolerances and design
preferences and can have the diameters, depending on the exact
material selected, ranging from approximately 1 micrometer to
approximately 14 micrometers, from approximately 4 micrometer to
approximately 13 micrometers, and from approximately 11 micrometers
to 13 micrometers. Further, these diameters that equate to 1 denier
size, while the actual fibers could be less than 1 denier by
definition. The diameter of the microfiber can be circular in
nature or oval in nature and the general length of the diameter
measured accordingly.
[0053] The split microfibers 20 of the microfiber material 18 can
further comprise filaments 24 as part of the split. This is best
seen in FIG. 12. The number of filaments per microfiber as part of
the split can range from approximately 100 to approximately 10,000,
and more preferably range from approximately 300 to approximately
5,000.
[0054] In another preferred embodiment, a floor mat 10 made in
accordance with the current disclosure can be described as having a
support material 16 having a first side 15 and a second side 17
with the carpet 14 attached the first side 15 of the support
material 16. Microfiber material 18, constructed in a loop and pile
manner, can be attached to the second side 17. The microfiber
material 18 can include any characteristics as described
herein.
[0055] In another preferred embodiment, a floor mat can be
constructed without the support material 16. In this embodiment the
floor mat 11 includes a layer of carpet 14 having a front side 26
and a back side 28 and a layer of microfiber material 18 is
attached the back side 28 of the carpet 14. The microfiber material
18 in this embodiment can include any characteristics of the
microfiber material 18 as described herein.
[0056] In testing, the inventors discovered that the retention
comparison of the currently disclosed floor mat with the loop-pile
microfiber material 18 having a split microfibers 20 had an
increased resistance to movement, which can also be described as a
retention factor, when compared to other materials. For example,
the current microfiber material 18 with the split microfiber 20 was
tested in a retention comparison where a maximum load was
discovered. This maximum load was the point at the point of which
the microfiber material 18 began to skid when placed on carpet 12.
This level for the microfiber material 18 having a split
microfibers 20 was approximately 1.24 (Kgf). Normal cotton fibers
had a maximum load of 0.025 Kgf. Woven microfiber had a maximum
load of 0.09 Kgf. Non-woven microfiber had a maximum load of 0.15
Kgf. The sample areas tested were approximately 400 centimeters
squared and there was a tensile speed of 100 millimeters per
minute. This data shows that the microfiber material 18 in a loop
and pile construction with a split microfiber 20 has an increased
retention characteristic when compared to other microfibers and
normal fibers known in the industry.
[0057] Thus, it is seen that the apparatus and methods disclosed
herein achieve the ends and advantages previously mentioned.
Numerous changes in the arrangement and construction of the parts
and steps will be readily apparent to those skilled in the art, and
are encompassed within the scope and spirit of the present
disclosure.
* * * * *