U.S. patent application number 15/648706 was filed with the patent office on 2018-03-01 for floor mat with hidden base component.
This patent application is currently assigned to Milliken & Company. The applicant listed for this patent is Milliken & Company. Invention is credited to Michael D. Bishop, Ty G. Dawson, Dale S. Kitchen, Franklin S. Love, Barry R. McClure, Padmakumar Puthillath.
Application Number | 20180056626 15/648706 |
Document ID | / |
Family ID | 61240861 |
Filed Date | 2018-03-01 |
United States Patent
Application |
20180056626 |
Kind Code |
A1 |
Puthillath; Padmakumar ; et
al. |
March 1, 2018 |
Floor Mat with Hidden Base Component
Abstract
This invention relates to a washable multi-component magnetic
floor mat with a hidden base component. The floor mat contains a
textile component and a base component. The textile component and
the base component are attached to one another by magnetic
attraction. The magnetic attraction is provided by incorporation of
magnetic particles in both the textile and base components. The
textile component is designed to be soiled, washed, and re-used,
thereby providing ideal end-use applications in areas such as
building entryways. The present invention eliminates the need to
wash the base component of the floor mat which results in
environmental, cost and labor conservation. Alignment and
deployment of the textile component with the base component in an
efficient manner is also described herein.
Inventors: |
Puthillath; Padmakumar;
(Greer, SC) ; Love; Franklin S.; (Columbus,
NC) ; Kitchen; Dale S.; (Boiling Springs, SC)
; Dawson; Ty G.; (Spartanburg, SC) ; McClure;
Barry R.; (Campobello, SC) ; Bishop; Michael D.;
(Chesnee, SC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Milliken & Company |
Spartanburg |
SC |
US |
|
|
Assignee: |
Milliken & Company
Spartanburg
SC
|
Family ID: |
61240861 |
Appl. No.: |
15/648706 |
Filed: |
July 13, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62378739 |
Aug 24, 2016 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 5/02 20130101; B32B
2307/208 20130101; B32B 2305/28 20130101; D06N 2211/066 20130101;
B32B 2264/102 20130101; D06N 2209/045 20130101; D06N 2213/068
20130101; B32B 7/06 20130101; B60N 3/046 20130101; D05C 17/02
20130101; D06N 2213/066 20130101; B32B 7/12 20130101; A47G 27/02
20130101; H01F 7/00 20130101; H01F 7/126 20130101; A47G 27/04
20130101; B32B 2264/105 20130101; D06N 2205/20 20130101; B32B
2471/04 20130101; A47L 23/266 20130101; D06N 7/0094 20130101; E04F
15/02144 20130101; A47G 27/0293 20130101 |
International
Class: |
B32B 7/06 20060101
B32B007/06; B32B 5/02 20060101 B32B005/02; B32B 7/12 20060101
B32B007/12 |
Claims
1. A multi-component floor mat comprising: (a) A textile component
comprising (i) a first layer of tufted pile carpet formed by
tufting face yarns through a primary backing layer and (ii) a
second layer of vulcanized rubber material that contains magnetic
particles; (b) A base component comprised of (i) vulcanized rubber
that contains magnetic particles or (ii) vulcanized rubber having a
magnetic coating applied thereto; wherein the textile component and
the base component are releasably attachable to one another via
magnetic attraction; and wherein the textile component is at least
5% larger in length and width than the base component.
2. The multi-component floor mat of claim 1, wherein the textile
component is at least 10% larger in length and width than the base
component.
3. The multi-component floor mat of claim 1, wherein the textile
component is magnetically receptive.
4. The multi-component floor mat of claim 1, wherein the base
component is permanently magnetized.
5. The multi-component floor mat of claim 1, wherein the textile
component of the floor mat can withstand at least one wash cycle in
a commercial or residential washing machine whereby the textile
component is suitable for re-use after exposure to the at least one
wash cycle.
6. The multi-component floor mat of claim 1, wherein the face yarns
are selected from the group consisting of synthetic fiber, natural
fiber, man-made fiber using natural constituents, inorganic fiber,
glass fiber, and mixtures thereof
7. The multi-component floor mat of claim 1, wherein the face yarns
are selected from nylon 6; nylon 6,6; polyester; polypropylene; or
combinations thereof.
8. The multi-component floor mat of claim 1, wherein the face yarns
comprise cut pile, loop pile, or combinations thereof.
9. The multi-component floor mat of claim 1, wherein the face yarns
are dyed, undyed, printed, or combinations thereof.
10. The multi-component floor mat of claim 1, wherein the primary
backing layer is selected from the group consisting of woven
material, nonwoven material, knitted material, and combinations
thereof.
11. The multi-component floor mat of claim 1, wherein the primary
backing layer is selected from the group consisting of synthetic
fiber, natural fiber, man-made fiber using natural constituents,
inorganic fiber, glass fiber, and mixtures thereof.
12. The multi-component floor mat of claim 1, wherein the
vulcanized rubber is selected from the group consisting of nitrile
rubber, polyvinyl chloride rubber, ethylene propylene diene monomer
(EPDM) rubber, vinyl rubber, thermoplastic elastomer, and mixtures
thereof.
13. The multi-component floor mat of claim 1, wherein the magnetic
particles are in the size range of from 1 micron to 10 microns.
14. The multi-component floor mat of claim 1, wherein the magnetic
particles are magnetizable magnetic particles selected from the
group consisting of Fe.sub.3O.sub.4, SrFe.sub.3O.sub.4, NdFeB,
AlNiCo, CoSm and other rare earth metal based alloys, and mixtures
thereof.
15. The multi-component floor mat of claim 1, wherein the magnetic
particles are magnetically receptive particles selected from the
group consisting of Fe.sub.2O.sub.3, Fe.sub.3O.sub.4, steel, iron
particles, and mixtures thereof.
16. The multi-component floor mat of claim 1, wherein the magnetic
coating further includes a binder material.
17. The multi-component floor mat of claim 16, wherein the binder
material is selected from a thermoplastic elastomer material, a
thermoplastic vulcanite material, and mixtures thereof.
18. The multi-component floor mat of claim 17, wherein the binder
material is selected from the group consisting of
urethane-containing materials, acrylate-containing materials,
silicone-containing materials, and mixtures thereof.
19. The multi-component floor mat of claim 1, wherein the base
component further includes an adhesive composition.
20. The multi-component floor mat of claim 19, wherein the adhesive
composition is selected from the group consisting of pressure
sensitive adhesive materials, an adhesive material comprising a
rosin ester, and an elastomeric material comprising natural rubber,
nitrile rubber or silicone rubber with a tackifier.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent
Application No. 62/378739, entitled "Floor Mat with Hidden Base
Component" which was filed on Aug. 24, 2016, and which is entirely
incorporated by reference herein.
TECHNICAL FIELD
[0002] This invention relates to a washable multi-component
magnetic floor mat with a hidden base component. The floor mat
contains a textile component and a base component. The textile
component and the base component are attached to one another by
magnetic attraction. The magnetic attraction is provided by
incorporation of magnetic particles in both the textile and base
components. The textile component is designed to be soiled, washed,
and re-used, thereby providing ideal end-use applications in areas
such as building entryways. The present invention eliminates the
need to wash the base component of the floor mat which results in
environmental, cost and labor conservation. Alignment and
deployment of the textile component with the base component in an
efficient manner is also described herein.
BACKGROUND
[0003] High traffic areas, such as entrances to buildings,
restrooms, break areas, etc., typically have the highest
floorcovering soiling issue. Currently, washable one-piece mats
having a pile surface are found in these locations. The washable
multi-component magnetic floor mat of the present invention is
designed to replace these one-piece floor mats. The use of washable
multi-component floor mats in high traffic, highly soiled areas is
pragmatic because the soiled textile component may be easily
removed, laundered, and re-installed. The need to launder the base
portion of the floor mat is eliminated. The reduction in weight and
bulk from one-piece mats to the textile component of the
multi-component mat provides significant savings in water and
energy for the laundering facilities and in labor for the service
people that transport and install the floor mats.
[0004] Furthermore, because the attachment and/or alignment
mechanisms can utilize a high amount of force to hold the top and
bottom components of the floor mat together, the initial alignment
and deployment of the top textile component onto the base component
can present challenges. This problem is exaggerated by the large
surface area of the two components that are in contact with one
another. In this regard, even if the adherence force per unit area
is low, the large surface area means that the total resistance to
sliding and movement can be very high making realignment of the
components very difficult. If not corrected, mis-alignment of the
textile component with the base component may create trip hazards
within the floor mat and may be aesthetically not pleasing.
[0005] The present invention overcomes these challenges via the use
of alignment and deployment techniques that rely upon temporary
reduction in surface area of the textile and/or base component
and/or temporary reduction in adherence force between the textile
and base components. Thus, the washable multi-component magnetic
floor mats of the present invention are an improvement over
one-piece floor mats of the prior art.
BRIEF SUMMARY
[0006] In one aspect, the invention relates to a multi-component
floor mat comprising: (a) a textile component comprising (i) a
first layer of tufted pile carpet formed by tufting face yarns
through a primary backing layer and (ii) a second layer of
vulcanized rubber material that contains magnetic particles; (b) a
base component comprised of (i) vulcanized rubber that contains
magnetic particles or (ii) vulcanized rubber having a magnetic
coating applied thereto; wherein the textile component and the base
component are releasably attachable to one another via magnetic
attraction; and wherein the textile component is at least 5% larger
in length and width than the base component.
[0007] In another aspect, the invention relates to a process for
cleaning a multi-component floor mat, said process comprising the
steps of: (a) providing the multi-component floor mat as described
herein; (b) removing the textile component from the base component;
(c) laundering the textile component in an industrial, commercial,
or residential washing machine; and (d) re-installing the textile
component on the base component.
[0008] In another aspect, the invention relates to a process for
making a multi-component floor mat, said process comprising the
steps of: (a) tufting face yarns into a primary backing material to
form a tufted pile carpet; (b) optionally, printing the tufted pile
carpet; (c) providing a layer of unvulcanized rubber that contains
magnetic particles; (d) adhering the tufted pile carpet to the
layer of magnetic particle-containing unvulcanized rubber via a
rubber vulcanization process to form a washable textile component
having a vulcanized rubber backing; (e) cutting the textile
component into a shape and size wherein the textile component is at
least 5% larger in length and width than the base component; (f)
providing a base component comprised of (i) vulcanized rubber and
magnetic particles or (ii) vulcanized rubber and a magnetic
coating; and (g) attaching the textile component to the base
component via magnetic attraction.
[0009] In a further aspect, the invention relates to a method for
installation of a floor mat comprising the following steps: (a)
providing a base component, wherein the base component contains at
least one alignment mechanism; (b) providing a textile component,
wherein the textile component is comprised of tufted pile carpet
and contains at least one alignment mechanism that works in
corresponding relationship with the at least one alignment
mechanism of step "a," wherein the base component and the textile
component are releasably attachable to one another via the at least
one alignment mechanism, and wherein the textile component is at
least 5% larger in length and width than the base component; (c)
aligning the textile component with the base component, wherein the
step of aligning is accomplished via the use of the alignment
mechanisms; and (d) deploying the textile component onto the base
component.
[0010] In another aspect, the invention relates to a
multi-component floor mat comprising: (a) a textile component
comprising (i) a first layer of tufted pile carpet formed by
tufting face yarns through a primary backing layer and (ii) a
second layer of vulcanized rubber material that contains magnetic
particles; (b) a base component comprised of (i) vulcanized rubber
that contains magnetic particles or (ii) vulcanized rubber having a
magnetic coating applied thereto; wherein the textile component and
the base component are releasably attachable to one another via
magnetic attraction, and wherein the textile component is at least
5% larger in length and width than the base component; and (c) at
least one alignment or deployment mechanism.
[0011] In a further aspect, the invention relates to a
multi-component floor mat comprising: (a) a textile component
comprising (i) a first layer of tufted pile carpet formed by
tufting face yarns through a primary backing layer and (ii) a
second layer of vulcanized rubber material that contains magnetic
particles; and (b) a base component comprised of (i) materials
selected from the group consisting of concrete,
cellulose-containing materials, metal, thermoplastic materials,
thermoset materials, and combinations thereof, and (ii) magnetic
particles or a magnetic coating applied to the base component;
wherein the textile component and the base component are releasably
attachable to one another via magnetic attraction, and wherein the
textile component is at least 5% larger in length and width than
the base component.
[0012] In a further aspect, the invention relates to a
multi-component floor mat comprising: (a) a textile component
comprising (i) a first layer of tufted pile carpet formed by
tufting face fibers through a primary backing layer and (ii) at
least one surface attachment means; and (b) a base component,
wherein the base component contains at least one surface attachment
means; and wherein the textile component and the base component are
releasably attachable to one another via the at least one surface
attachment means; wherein the textile component and the base
component further contain at least one edge attachment means; and
wherein the textile component is at least 5% larger in length and
width than the base component.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1A is an expanded side view of the textile component of
the multi-component floor mat.
[0014] FIG. 1B is an expanded side view of another embodiment of
the textile component of the multi-component floor mat.
[0015] FIG. 1C is a top perspective view of one embodiment of the
back surface of the textile component of the floor mat.
[0016] FIG. 1D is an expanded angle view of one embodiment of the
multi-component floor mat showing the textile component of FIG. 1C
partially pulled back from the base component.
[0017] FIG. 2 is a top perspective view of another embodiment of
the multi-component floor mat with the textile component partially
pulled back from the base component.
[0018] FIG. 3A is a top perspective view of the back surface of the
textile component of the multi-component floor mat illustrating a
recessed border area along the edge of the textile component.
[0019] FIG. 3B is a top perspective view of an multi-component
floor mat illustrating the textile component of FIG. 3A partially
pulled back and in combination with the base component.
[0020] FIG. 4A is a top perspective view of another embodiment of
the back surface of the textile portion of the multi-component
floor mat illustrating rounded corners.
[0021] FIG. 4B is a top perspective view of a multi-component floor
mat illustrating the textile component of FIG. 4A partially pulled
back and in combination with the base component.
[0022] FIG. 5A is a top perspective view of the back surface of a
multi-component floor mat illustrating the textile component having
a raised, 3-dimensional chevron rubber shaped protrusion on its
back surface and the base component having a corresponding chevron
shaped receiving area at one end of the base component.
[0023] FIG. 5B illustrates the back surface of the multi-component
floor mat and alignment of the textile component with the base
component.
[0024] FIG. 6A is a top perspective view of the back surface of a
multi-component floor mat illustrating the textile component having
a raised, 3-dimensional half circle rubber-shaped protrusion on its
back surface and the base component having a corresponding half
circle shaped receiving area at one end of the base component.
[0025] FIG. 6B illustrates the back surface of the multi-component
floor mat and alignment of the textile component with the base
component.
[0026] FIG. 7 is a schematic diagram of one embodiment of the
manufacturing process of the multi-component floor mat.
[0027] FIG. 8 is a schematic diagram illustrating the magnetic
alignment properties of the magnetic particles of the present
invention.
[0028] FIG. 9A is a schematic diagram illustrating a step in the
installation of a multi-component floor mat of the present
invention.
[0029] FIG. 9B is a schematic diagram illustrating a step in the
installation of a multi-component floor mat of the present
invention.
[0030] FIG. 9C is a schematic diagram illustrating a step in the
installation of a multi-component floor mat of the present
invention.
[0031] FIG. 9D is a schematic diagram illustrating a step in the
installation of a multi-component floor mat of the present
invention.
[0032] FIG. 9E is a schematic diagram illustrating a step in the
installation of a multi-component floor mat of the present
invention.
[0033] FIG. 9F is a schematic diagram illustrating a step in the
installation of a multi-component floor mat of the present
invention.
[0034] FIG. 10A is an expanded side view of an adhesive-containing
base component of the multi-component floor mat.
[0035] FIG. 10B is an expanded side view of another embodiment of
an adhesive-containing base component of the multi-component floor
mat.
DETAILED DESCRIPTION
[0036] The present invention described herein is a washable,
multi-component magnetic floor mat. The mat is comprised of a
textile component and a base component. The textile component and
the base component are attached to one another via magnet
attraction.
[0037] In the present invention, the base component of the floor
mat is wholly covered with a textile component. Typically, the
textile component will be lighter in weight than the base
component. Inversely, the base component will weigh more than the
textile component.
[0038] As shown in FIG. 1A, textile component 100 may be comprised
of tufted pile carpet 125. Tufted pile carpet 125 is comprised of
primary backing layer 117 and face yarns 115. The primary backing
layer 117 is typically included in the tufted pile carpet to give
stability to the face yarns. The materials comprising face yarns
115 and primary backing layer 117 may independently be selected
from synthetic fiber, natural fiber, man-made fiber using natural
constituents, inorganic fiber, glass fiber, and a blend of any of
the foregoing. By way of example only, synthetic fibers may include
polyester, acrylic, polyamide, polyolefin, polyaramid,
polyurethane, or blends thereof. More specifically, polyester may
include polyethylene terephthalate, polytrimethylene terephthalate,
polybutylene terephthalate, polylactic acid, or combinations
thereof. Polyamide may include nylon 6, nylon 6,6, or combinations
thereof. Polyolefin may include polypropylene, polyethylene, or
combinations thereof. Polyaramid may include
poly-p-phenyleneteraphthalamide (i.e., Kevlar.RTM.),
poly-m-phenyleneteraphthalamide (i.e., Nomex.RTM.), or combinations
thereof. Exemplary natural fibers include wool, cotton, linen,
ramie, jute, flax, silk, hemp, or blends thereof. Exemplary
man-made materials using natural constituents include regenerated
cellulose (i.e., rayon), lyocell, or blends thereof.
[0039] The material comprising face yarns 115 and primary backing
layer 117 may be formed from staple fiber, filament fiber, slit
film fiber, or combinations thereof. The fiber may be exposed to
one or more texturing processes. The fiber may then be spun or
otherwise combined into yarns, for example, by ring spinning,
open-end spinning, air jet spinning, vortex spinning, or
combinations thereof. Accordingly, the material comprising face
yarns 115 will generally be comprised of interlaced fibers,
interlaced yarns, loops, or combinations thereof.
[0040] The material comprising face yarns 115 and primary backing
layer 117 may be comprised of fibers or yarns of any size,
including microdenier fibers or yarns (fibers or yarns having less
than one denier per filament). The fibers or yarns may have deniers
that range from less than about 0.1 denier per filament to about
2000 denier per filament or, more preferably, from less than about
1 denier per filament to about 500 denier per filament.
[0041] Furthermore, the material comprising face yarns 115 and
primary backing layer 117 may be partially or wholly comprised of
multi-component or bi-component fibers or yarns in various
configurations such as, for example, islands-in-the-sea, core and
sheath, side-by-side, or pie configurations. Depending on the
configuration of the bi-component or multi-component fibers or
yarns, the fibers or yarns may be splittable along their length by
chemical or mechanical action.
[0042] Additionally, face yarns 115 and primary backing layer 117
may include additives coextruded therein, may be precoated with any
number of different materials, including those listed in greater
detail below, and/or may be dyed or colored to provide other
aesthetic features for the end user with any type of colorant, such
as, for example, poly(oxyalkylenated) colorants, as well as
pigments, dyes, tints, and the like. Other additives may also be
present on and/or within the target fiber or yarn, including
antistatic agents, brightening compounds, nucleating agents,
antioxidants, UV stabilizers, fillers, permanent press finishes,
softeners, lubricants, curing accelerators, and the like.
[0043] The face yarns 115 may be dyed or undyed. If the face yarns
115 are dyed, they may be solution dyed. The weight of the face
yarn, pile height, and density will vary depending on the desired
aesthetics and performance requirements of the end-use for the
floor mat. In FIG. 1A, face yarns 115 are illustrated in a loop
pile construction. Looking to FIG. 1B, textile component 100 is
shown with face yarns 115 in a cut pile construction. Of course, it
is to be understood that face yarn constructions including
combinations of loop pile and cut pile may likewise be used.
[0044] The primary backing layer 117 can be any suitable primary
backing material. The primary backing layer 117 may be comprised of
a woven, nonwoven or knitted material, or combinations thereof. The
general purpose of primary backing layer 117 is to support the
tufts of face yarns 115. In one aspect, primary backing layer 117
is a nonwoven polyester spunbond material. One commercially
available example of the polyester spunbond material is
Lutradur.RTM. from Freudenberg Nonwovens of Weinheim, Germany. In
another aspect, flat woven polyester tapes, such as Isis.TM. from
Propex of Chattanooga, Tenn., may be utilized. Also, Colback.RTM.
nonwoven backing material may also be suitable for use. If needed,
a primary backing layer made of a woven tape with either staple
fibers or nonwoven fabrics affixed can be used. Also, stitch bonded
and knitted polyester fabrics may be used.
[0045] The tufted pile carpet 125 that includes face yarns tufted
into a primary backing layer may be heat stabilized to prevent
dimensional changes from occurring in the finished mat. The heat
stabilizing or heat setting process typically involves applying
heat to the material that is above the glass transition
temperature, but below the melting temperature of the components.
The heat allows the polymer components to release internal tensions
and allows improvement in the internal structural order of the
polymer chains. The heat stabilizing process can be carried out
under tension or in a relaxed state. The tufted pile carpet is
sometimes also stabilized to allow for the yarn and primary backing
to shrink prior to the mat manufacturing process.
[0046] In one aspect of the present invention, the tufted pile
carpet is comprised of yarn tufted into fabric, which is then
injection or fluid dyed, and then bonded with a rubber layer or
washable latex backing. The carpet yarn may be selected from nylon
6; nylon 6,6; polyester; and polypropylene fiber. The yarn is
tufted into a woven or nonwoven substrate. The yarn can be of any
pile height and weight necessary to support printing. The tufted
pile carpet may be printed using any print process. In one aspect,
injection dyeing may be utilized to print the tufted pile
carpet.
[0047] Printing inks will contain at least one dye. Dyes may be
selected from acid dyes, direct dyes, reactive dyes, cationic dyes,
disperse dyes, and mixtures thereof. Acid dyes include azo,
anthraquinone, triphenyl methane and xanthine types. Direct dyes
include azo, stilbene, thiazole, dioxsazine and phthalocyanine
types. Reactive dyes include azo, anthraquinone and phthalocyanine
types. Cationic dyes include thiazole, methane, cyanine, quinolone,
xanthene, azine, and triaryl methine. Disperse dyes include azo,
anthraquinone, nitrodiphenylamine, naphthal imide, naphthoquinone
imide and methane, triarylmethine and quinoline types.
[0048] As is known in the textile printing art, specific dye
selection depends upon the type of fiber and/or fibers comprising
the washable textile component that is being printed. For example,
in general, a disperse dye may be used to print polyester fibers.
Alternatively, for materials made from cationic dyeable polyester
fiber, cationic dyes may be used.
[0049] The printing process of the present invention uses a jet
dyeing machine, or a digital printing machine, to place printing
ink on the surface of the mat in predetermined locations. One
suitable and commercially available digital printing machine is the
Millitron.RTM. digital printing machine, available from Milliken
& Company of Spartanburg, S.C. The Millitron.RTM. machine uses
an array of jets with continuous streams of dye liquor that can be
deflected by a controlled air jet. The array of jets, or gun bars,
is typically stationary. Another suitable and commercially
available digital printing machine is the Chromojet.RTM. carpet
printing machine, available from Zimmer Machinery Corporation of
Spartanburg, S.C. In one aspect, a tufted carpet made according to
the processes disclosed in U.S. Pat. No. 7,678,159 and U.S. Pat.
No. 7,846,214, both to Weiner, may be printed with a jet dyeing
apparatus as described and exemplified herein.
[0050] Viscosity modifiers may be included in the printing ink
compositions. Suitable viscosity modifiers that may be utilized
include known natural water-soluble polymers such as
polysaccharides, such as starch substances derived from corn and
wheat, gum arabic, locust bean gum, tragacanth gum, guar gum, guar
flour, polygalactomannan gum, xanthan, alginates, and a tamarind
seed; protein substances such as gelatin and casein; tannin
substances; and lignin substances. Examples of the water-soluble
polymer further include synthetic polymers such as known polyvinyl
alcohol compounds and polyethylene oxide compounds. Mixtures of the
aforementioned viscosity modifiers may also be used. The polymer
viscosity is measured at elevated temperatures when the polymer is
in the molten state. For example, viscosity may be measured in
units of centipoise at elevated temperatures, using a Brookfield
Thermosel unit from Brookfield Engineering Laboratories of
Middleboro, Mass. Alternatively, polymer viscosity may be measured
by using a parallel plate rheometer, such as made by Haake from
Rheology Services of Victoria Australia.
[0051] After printing, the tufted pile carpet may be vulcanized
with a rubber backing. The thickness of the rubber will be such
that the height of the finished textile component will be
substantially the same height as the surrounding base component
when the base component is provided in a tray configuration. Once
vulcanized, the textile component may be pre-shrunk by washing it
prior to installing it on the base component.
[0052] The textile component 100 further comprises a magnetic
coating layer 110. The magnetic coating layer 110 is present on the
surface of the textile component 100 that is opposite face yarns
115. The magnetic coating layer is at least one surface attachment
means. Application of magnetic coating layer 110 to the tufted pile
carpet 125 will be described in greater detail below. The resulting
textile component 100 is wash durable and exhibits sufficient tuft
lock for normal end-use applications. In one alternative embodiment
of the invention, the textile component may be a disposable textile
component that is removed and disposed of or recycled and then
replaced with a new textile component for attachment to the base
component.
[0053] After the textile component has been made, it will be custom
cut to fit onto the base component. The textile component may be
cut using a computer controlled cutting device, such as a Gerber
machine. It may also be cut using a mechanical dye cutter, hot
knife, straight blade, rotary blade, water jet, laser, and the
like, and combinations thereof. In one aspect of the invention, the
textile component will have substantially the same dimensions as
the base component (e.g. the same length and width). In another
aspect, the textile component will be larger in size than the base
component. For example, the textile component will have a larger
length and/or width than that base component. In one aspect, the
textile component may be at least 5% wider than the base component,
or at least 10% wider than the base component, or at least 20%
wider than the base component, or at least 30% wider than the base
component. In addition, or alternatively, the textile component may
be at least 5% longer than the base component, or at least 10%
longer than the base component, or at least 20% longer than the
base component, or at least 30% longer than the base component. Any
combination of widths and lengths disclosed herein may be suitable
for use as dimensions of the multi-component floor mat of the
present invention.
[0054] FIG. 1C illustrates one embodiment of the textile component
of the multi-component floor mat of the present invention. The back
surface 101 of textile component 100 is shown with elongated oval
protrusions 103. Elongated oval protrusions 103 are spaced along
the inner edge of textile component 100. The elongated oval
protrusions are raised from the planar surface of textile component
100 and are 3-dimensional in space. Elongated oval protrusions 103
may be spaced in a uniform or non-uniform configuration from one
another. In one aspect, elongated oval protrusions 103 are
comprised of rubber and are attached to textile component 100
through a rubber vulcanization process using heat and pressure.
[0055] FIG. 1D illustrates multi-component floor mat 1 comprised of
textile component 100 and base component 150. Elongated oval
protrusions 103 of textile component 100 are aligned with elongated
oval receiving areas 105 of base component 150. When textile
component 100 is aligned with base component 150, elongated oval
protrusions 103 fit into the open space provided by elongated oval
receiving areas 105.
[0056] While not specifically illustrated in FIGS. 1C and 1D, the
floor mat of the present invention may further include at least one
edge attachment means. The at least one edge attachment means may
be included in the construction of the floor mat to aid in securing
and aligning the textile component of the mat to the base component
of the mat. Thus, the textile component and the base component may
both further include at least one edge attachment means. Edge
attachment and/or alignment means include hook and loop fastening
systems (such as Velcro.RTM. fasteners), mushroom-type hook
fastening systems (such as Dual Lock.TM. fasteners from 3M), and
the like, and combinations thereof. For example, the loop portion
of a hook and loop fastening system may be attached to the textile
component. The corresponding hook portion of the hook and loop
fastening system may be attached to the base component. The
alternative arrangement of loop and hook portions is also
contemplated to be within the scope of this invention wherein the
loop portion is attached to the base component and the hook portion
is attached to the textile component. In addition, the edge
attachment means (e.g. hook and loop fastening system) may be used
alone, without an alignment mechanism, to attach the textile
component to the base component. The edge attachment means may be
present on one edge, on two edges, on three edges, or on all four
edges of the textile and/or base component.
[0057] FIG. 2 illustrates another embodiment of the multi-component
floor mat of the present invention. Floor mat 2 is comprised of
textile component 200 and base component 250. Round protrusions 203
of textile component 200 are aligned with round receiving areas 205
of base component 250. When textile component 200 is aligned with
base component 250, round protrusions 203 fit into the open space
provided by round receiving areas 205. Any of the protrusions
described herein for securing the textile component to the base
component are also known as surface attachment means, along with
magnetic coatings, and any combinations thereof.
[0058] The base component of the floor mat may be flat and have no
recessed area (i.e. the base component is trayless). A flat base
component is manufactured from a sheet of material, such as a
rubber material, that has been cut in the desired shape and
vulcanized. The base component may be formed in a single molding
process as a unitary article. Examples of suitable materials for
forming the base component are elastomers, such as natural and
synthetic rubber materials, thermoplastic and thermoset resins and
metal. The rubber material may be selected from the group
consisting of nitrile rubber, including dense nitrile rubber, foam
nitrile rubber, and mixtures thereof; polyvinyl chloride rubber;
ethylene propylene diene monomer (EPDM) rubber; vinyl rubber;
thermoplastic elastomer; and mixtures thereof. In one aspect, the
base component is typically comprised of at least one rubber
material. The rubber material may contain from 0% to 40% of a
recycled rubber material.
[0059] FIG. 3A illustrates another embodiment of the textile
component of the floor mat of the present invention. In FIG. 3A,
textile component 300 is shown with back surface 301 facing the
viewer. Textile component 300 is shown with corners that are
approximately 90 degrees in shape, i.e. two sides come together and
form approximately a 90 angle. On back surface 301, there is a
border 370. Border 370 is attached to back surface 301. Border 370
is a raised, 3-dimensional area which is present in continuous
arrangement along all inner edges of textile component 300. In one
aspect, border 370 is comprised of rubber and is attached to back
surface 301 via a rubber vulcanization process that includes heat
and pressure. While border 370 is shown in a continuous
configuration around all four inner edges of textile component 300,
it is contemplated that the border may be present on only one inner
edge of the textile component, on only two inner edges of the
textile component, or on only three inner edges of the textile
component.
[0060] As seen in FIG. 3B, floor mat 3 is present in an arrangement
wherein textile component 300 overlaps base component 350. Base
component 350 is also shown with corners formed from two sides
coming together at approximately a 90 degree angle. The length and
width of textile component 300 are larger in size than the length
and width of base component 350. A corner of textile component 300
is turned back to further illustrate how the two components fit
together within border 370.
[0061] FIG. 4A illustrates another embodiment of the textile
component of the floor mat of the present invention. In FIG. 4A,
textile component 400 is shown with back surface 401 facing the
viewer. Textile component 400 is also shown with rounded corners.
On back surface 401, there is a border 470. Border 470 is attached
to back surface 401. Border 470 is a raised, 3-dimensional area
which is present in continuous arrangement along all edges of
textile component 400. In one aspect, border 470 is comprised of
rubber and is attached to back surface 401 via a rubber
vulcanization process that includes heat and pressure. While border
470 is shown in a continuous configuration around all four edges of
textile component 400, it is contemplated that the border may be
present on only one edge of the textile component, on only two
edges of the textile component, or on only three edges of the
textile component.
[0062] As seen in FIG. 4B, floor mat 4 is present in an arrangement
wherein textile component 400 overlaps base component 450. Base
component 450 is also shown with rounded corners. The length and
width of textile component 400 are larger in size than the length
and width of base component 450. Base component 450 is not visually
observable in its end-use application as a floor mat because it is
completely covered by textile component 400. A corner of textile
component 400 is turned back to further illustrate how the two
components fit together within border 470.
[0063] FIG. 5A illustrates another embodiment of the
multi-component floor mat of the present invention. Floor mat 5 is
comprised of textile component 500 and base component 550. Textile
component 500 is shown with back surface 501 facing the viewer.
Textile component 500 contains an alignment mechanism 503. In this
instance, alignment mechanism 503 is a V-shaped, 3-dimensional area
located at one end of floor mat 5. In one aspect, alignment
mechanism 503 is comprised of rubber and is attached to back
surface 501 via a rubber vulcanization process that includes heat
and pressure. Base component 550 contains a cut-out area 505 that
corresponds in size and shape to alignment mechanism 503 of textile
component 550.
[0064] As seen in FIG. 5B, the cut out area 505 of base component
550 fits snugly against alignment mechanism 503 of textile
component 500. Floor mat 5 is present in an arrangement wherein
textile component 500 is larger in size than base component 550.
Note that in order to illustrate how base component 550 and textile
component 500 are aligned together, floor mat 5 is shown flipped
over, with the face yarns toward the floor and the back surface
facing the viewer. Base component 550 is not visually observable in
its end-use application as a floor mat because it is completely
covered by textile component 500.
[0065] FIG. 6A illustrates another embodiment of the
multi-component floor mat of the present invention. Floor mat 6 is
comprised of textile component 600 and base component 650. Textile
component 600 is shown with back surface 601 facing the viewer.
Textile component 600 contains an alignment mechanism 603. In this
instance, alignment mechanism 603 is a half circle-shaped,
3-dimensional area located at one end of floor mat 6. In one
aspect, alignment mechanism 603 is comprised of rubber and is
attached to back surface 601 via a rubber vulcanization process
that includes heat and pressure. Base component 650 contains a
cut-out area 605 that corresponds in size and shape to alignment
mechanism 603 of textile component 650.
[0066] As seen in FIG. 6B, the cut out area 605 of base component
650 fits snugly against alignment mechanism 603 of textile
component 600. Floor mat 6 is present in an arrangement wherein
textile component 600 is larger in size than base component 650.
Note that in order to illustrate how base component 650 and textile
component 600 are aligned together, floor mat 6 is shown flipped
over, with the face yarns toward the floor and the back surface
facing the viewer. Base component 650 is not visually observable in
its end-use application as a floor mat because it is completely
covered by textile component 600.
[0067] In summary, the textile component and base component that
form the floor mat of the present invention may include a
discontinuous alignment mechanism that attaches the textile
component to the base component, such as that which is shown in
FIGS. 1C and 1D. The alignment mechanism acts to secure the textile
component to the base component. The alignment mechanism may be
present on the textile and base components at a location that
comprises the inner edge of each component. This inner edge area
may begin at about 0.5 inches, or at about 1.0 inches, or at about
1.5 inches, or at about 2.0 inches or greater from the cut edge (or
molded edge) of the component and measuring towards the center of
the component. The discontinuous alignment mechanism present in an
area along this inner edge portion of the textile and base
components as described above is illustrated in FIGS. 1C, 1D and 5A
to 6B. A continuous alignment mechanism may be present on the
textile component of the floor mat of the present invention. The
continuous alignment mechanism present in an area along this inner
edge portion of the textile component as described above is
illustrated in FIGS. 3A and 3B.
[0068] Alternatively, the alignment mechanism may be present at the
very edge of the textile component of the multi-component floor
mat. FIGS. 4A and 4B illustrate a continuous alignment mechanism
present on the textile component of the floor mat. The alignment
mechanism is located at the cut edge (or molded edge) of the
textile component such that it forms a rim around the cut edge (or
molded edge) of the textile component. The alignment mechanism is
present along the perimeter of the textile component. In this
instance, the multi-component floor mat is comprised of a textile
component with a continuous alignment mechanism and an undersized
base component (i.e. a base component that is smaller in size than
the textile component). One advantage of this arrangement is that
the presence of the alignment mechanism at the cut edge (or molded
edge) of the textile component provides increased thickness at the
edge which in turn provides increased tear resistance to the
textile component. The tear resistance feature provides further
wash durability to the textile component.
[0069] It is also contemplated to be within the scope of the
present invention that any combination of elements illustrated in
the Figures and/or described herein may be used to form the floor
mat of the present invention. For example, the features illustrated
in FIGS. 3A and 5A may be combined together in a floor mat. Or, the
features illustrated in FIGS. 3A and 6A may be combined together in
a floor mat. In another aspect of the invention, the textile
component of FIG. 1C may be combined with the base component of
FIG. 3B.
[0070] The continuous perimeter border may be applied to the
textile component according to the following procedure. Rubber
strips are placed overlapping the edges of a metal plate. The metal
plate is to be placed on top of a sheet rubber and covered on all 4
sides by strip rubber. As the metal plate applies force to the
rubber, it will bond the sheet rubber to the strips. This process
may be completed, for example, at a temperature of 370.degree. F.
and a pressure of 36 psi. However, depending upon the rubber
materials selected, the temperature may be in the range from
200.degree. F. to 500.degree. F. and the pressure may be in the
range from 10 psi to 50 psi. Using the recommend settings, the
rubber may be completely cured in 8 minutes. After the rubber
strips are bound to the rubber sheet, the metal plate is removed
leaving a void (i.e. a recessed area in the textile component) in
which to place the base component. The textile component has the
ability to be deployed/installed and removed/uninstalled from the
base component multiple times. The continuous perimeter border can
have a smooth or a cleated surface or any other pattern (e.g.
Megahold) to assist in holding the edges of the textile component
to the floor. Note that in one aspect of this invention, at least a
portion of the back surface of the textile component makes direct
physical contact with the floor.
[0071] The textile component and the base component may be of the
same size (e.g. same length and width) or the textile component may
be larger in size than the base component (e.g. larger length
and/or width). In instances when the textile component is larger in
size than the base component, the textile component may further
include a visible rubber border along the edges (or along the
perimeter) of textile component. The presence of the border allows
the floor mat to resemble a traditional one-piece floor mat having
a rubber border along its edges.
[0072] In another configuration, the base component may have a
gradually varying cross-section providing a thickness gradient from
its center to the edges. Further, if the region bounded by the
border in the textile component is referred to as a cell, a single
textile component may have multiple cells that match up with
complimentary features on the base component. The base component
itself may be multi-segment.
[0073] The textile component and the base component are attached to
one another by magnetic attraction. Magnetic attraction is achieved
via application of a magnetic coating to the textile component
and/or base component or via incorporation of magnetic particles in
a rubber-containing layer prior to vulcanization. Alternatively,
magnetic attraction can be achieved using both methods such that a
magnetic coating is applied to the textile component and magnetic
particles are included in the vulcanized rubber of the base
component. The inverse arrangement is also contemplated.
[0074] The magnetic coating may be applied to the textile component
and/or the base component by several different manufacturing
techniques. Exemplary coating techniques include, without
limitation, knife coating, pad coating, paint coating, spray
application, roll-on-roll methods, troweling methods, extrusion
coating, foam coating, pattern coating, print coating, lamination,
and mixtures thereof.
[0075] FIG. 7 illustrates one embodiment of the manufacturing
process of the textile component of the present invention. The
uncoated tufted pile carpet 725 is fed to laminating belt 710. The
belt moves through the coating zone to lamination zone of the
lamination press. A magnetic coating 720 is fed transversely to
laminating belt 710. As magnetic coating 720 is fed to laminating
belt 710, it passes under coating knife 730. The coating knife 730
is adjusted so that the desired coating thickness is achieved. For
example, a magnetic coating thickness of 25 mil may be desirable.
After magnetic coating 720 passes under coating knife 730, it comes
into contact with tufted pile carpet 725. The magnetic coating 720
and tufted pile carpet 725 then move transversely to laminating
press 740. Laminating press 740 is located above laminating belt
710. The laminating press 740 is lowered onto laminating belt 710,
pressing tufted pile carpet 725 and magnetic coating 720 together.
The laminating press 740 is heated and therefore provides both heat
and pressure to the lamination process. Providing heat at this
point of the lamination process further serves to cure any
materials (e.g. binder materials) that may be contained within the
magnetic coating. After a pre-determined amount of time, laminating
press 740 is lifted from laminating belt 710. The magnetic coating
720 is now laminated to tufted pile carpet 725 to form textile
component 750. In one aspect, the laminating press may be operated
at a temperature in the range from 200.degree. F. to 500.degree. F.
and at a pressure in the range from 10 psi to 50 psi, or even at
300.degree. F. and a pressure of 36 psi.
[0076] In instances wherein magnetic attraction is achieved by
incorporating magnetic particles in a rubber-containing layer, the
following procedure may be utilized: (a) an unvulcanized
rubber-containing material is provided (such as nitrile, SBR, or
EPDM rubber), (b) magnetic particles are added to the unvulcanized
rubber, (c) the particles are mixed with the rubber, and (d) the
mixture of step "c" is formed into a sheet and attached to the
bottom of the textile component and/or represents the base
component. Mixing in step "c" may be achieved via a rubber mixing
mill.
[0077] FIG. 8 is provided in order to illustrate some of the terms
used herein with respect to various types of magnets and
magnetization properties. In this application, magnetizable is
defined to mean the particles present in the coating or vulcanized
rubber layer are permanently magnetized or can be magnetized
permanently using external magnets or electromagnets. Once the
particles are magnetized, they will keep their magnetic response
permanently. The magnetizable behavior for generating permanent
magnetism falls broadly under ferromagnets and ferrimagnets. Barium
ferrites, strontium ferrites, neodymium and other rare earth metal
based alloys are non-limiting examples of materials that can be
applied in the magnetic coatings and/or vulcanized rubber
layer.
[0078] As used herein, magnetically receptive is defined to mean
the particles present in the coating and/or vulcanized rubber layer
are only magnetically responsive in the presence of external
magnets. The component that contains the magnetic particles is
exposed to a magnetic field which aligns the dipoles of magnetic
particles. Once the magnetic field is removed from the vicinity,
the particles will become non-magnetic and the dipoles are no
longer aligned. The magnetically receptive behavior or responsive
magnetic behavior falls broadly under paramagnets or
superparamagnets (particle size less than 50 nm).
[0079] This feature of materials being reversibly magnetic is shown
in FIG. 8 whereby the dipoles of the superparamagnetic or
paramagnetic materials are not aligned, but upon exposure to a
magnet, the dipoles line up and point in the same direction thereby
allowing the materials to exhibit magnetic properties. Non-limiting
examples of materials exhibiting these features include iron oxide,
steel, iron, nickel, aluminum, or alloys of any of the
foregoing.
[0080] Further examples of magnetizable magnetic particles include
BaFe.sub.3O.sub.4, SrFe.sub.3O.sub.4, NdFeB, AlNiCo, CoSm and other
rare earth metal based alloys, and mixtures thereof. Examples of
magnetically receptive particles include Fe.sub.2O.sub.3,
Fe.sub.3O.sub.4, steel, iron particles, and mixtures thereof. The
magnetically receptive particles may be paramagnetic or
superparamagnetic. The magnet particles are typically characterized
as being non-degradable.
[0081] In one aspect of the invention, particle size of the
magnetically receptive particles is in the range from 1 micron to
10 microns. Particle size of the magnetically receptive particles
may be in the range from 10 nm to 50 nm for superparamagnetic
materials. Particle size of the magnetically receptive particles is
typically greater than 100 nm for paramagnetic and/or ferromagnetic
materials.
[0082] Magnetic attraction is typically exhibited at any loading of
the above magnetic materials. However, the magnetic attraction
increases as the loading of magnetic material increases. In one
aspect of the invention, the magnetic field strength of the textile
component to the base component is greater than 50 gauss, more
preferably greater than 100 gauss, more preferably greater than 150
gauss, or even more preferably greater than 200 gauss.
[0083] In one aspect, the magnetic material is present in the
coating composition in the range from 25% to 95% by weight of the
coating composition. In another aspect, magnetic particle loading
may be present in the magnetic coating applied to the textile
component in the range from 10% to 70% by weight of the textile
component. The magnetic particle loading may be present in the
magnetic coating applied to the base component in the range from
10% to 90% by weight of the base component.
[0084] The magnetically receptive particles may be present in the
vulcanized rubber layer of the textile component in a substantially
uniform distribution. In another aspect of the present invention,
it is contemplated that the magnetically receptive particles are
present in the rubber layer of the textile component in a
substantially non-uniform distribution. One example of a
non-uniform distribution includes a functionally graded particle
distribution wherein the concentration of particles is reduced at
the surface of the textile component intended for attachment to the
base component. Alternatively, another example of a non-uniform
distribution includes a functionally graded particle distribution
wherein the concentration of particles is increased at the surface
of the textile component intended for attachment to the base
component.
[0085] The magnetic attraction between the textile component and
the base component may be altered by manipulation of the surface
area of one or both of the textile and/or base components. The
surfaces of one or both of the components may be textured in such a
way that surface area of the component is increased. Such
manipulation may allow for customization of magnetic attraction
that is not directly affected by the amount of magnetic particles
present in the floor mat.
[0086] For instance, a substantially smooth (less surface area)
bottom surface of the textile component will generally result in
greater magnetic attraction to the top surface of the base
component. In contrast, a less smooth (more surface area) bottom
surface of the textile component (e.g. one having ripples or any
other textured surface) will generally result in less magnetic
attraction to the top surface of the base component. Of course, a
reverse arrangement is also contemplated wherein the base component
contains a textured surface. Furthermore, both component surfaces
may be textured in such a way that magnetic attraction is
manipulated to suit the end-use application of the inventive floor
mat.
[0087] As discussed previously, the magnetic particles may be
incorporated into the floor mat of the present invention either by
applying a magnetic coating to surface of the textile component or
by including the particles in the rubber material of the textile
material and/or the base component prior to vulcanization. When
incorporation is via a magnetic coating, a binder material is
generally included. Thus, the magnetic coating is typically
comprised of at least one type of magnetic particles and at least
one binder material.
[0088] The binder material is typically selected from a
thermoplastic elastomer material and/or a thermoplastic vulcanite
material. Examples include urethane-containing materials,
acrylate-containing materials, silicone-containing materials, and
mixtures thereof. Barium ferrites, strontium ferrites, neodymium
and other rare earth metal based alloys can be mixed with the
appropriate binder to be coated on the textile and/or base
component.
[0089] In one aspect, the binder material will exhibit at least one
of the following properties: (a) a glass transition (T.sub.g)
temperature of less than 10.degree. C.; (b) a Shore A hardness in
the range from 30 to 90; and (c) a softening temperature of greater
than 70.degree. C.
[0090] In one aspect, an acrylate and/or urethane-containing binder
system is combined with Fe.sub.3O.sub.4 to form the magnetic
coating of the present invention. The ratio of Fe.sub.3O.sub.4:
acrylate and/or urethane binder is in the range from 40-70%:60:30%
by weight. The thickness of the magnetic coating may be in the
range from 10 mil to 40 mil. Such a magnetic coating exhibits
flexibility without any cracking issues.
[0091] Following application or inclusion of the magnetic particles
into the textile and/or base component, the particles need to be
magnetized. Magnetization can occur either during the curing
process or after the curing process. Curing is typically needed for
the binder material that is selected and/or for the rubber material
that may be selected.
[0092] During the curing process, the magnetizable particles are
mixed with the appropriate binder and applied via a coating
technique on the substrate to be magnetized. Once the coating is
complete, the particles are magnetized in the presence of external
magnets during the curing process. The component that contains the
magnetic particles is exposed to a magnetic field which aligns the
dipoles of magnetic particles, locking them in place until the
binder is cured. The magnetic field is preferably installed in-line
as part of the manufacturing process. However, the magnetic field
may exist as a separate entity from the rest of the manufacturing
equipment.
[0093] Alternatively, the magnetic particles may be magnetized
after the curing process. In this instance, the magnetizable
particles are added to the binder material and applied to the
textile and/or base component in the form of a film or coating. The
film or coating is then cured. The cured substrate is then exposed
to at least one permanent magnet. Exposure to the permanent magnet
may be done via direct contact with the coated substrate or via
indirect contact with the coated substrate. Direct contact with the
permanent magnet may occur, for example, by rolling the permanent
magnet over the coated substrate. The magnet may be rolled over the
coated substrate a single time or it may be rolled multiple times
(e.g. 10 times). The permanent magnet may be provided in-line with
the manufacturing process, or it may exist separately from the
manufacturing equipment. Indirect contact may include a situation
wherein the coated substrate is brought close to the permanent
magnet, but does not contact or touch the magnet.
[0094] Depending upon the pole size, strength and domains on the
permanent magnet (or electromagnet), it can magnetize the
magnetizable coating to a value between 10 and 5000 gauss or a
value close to the maximum gauss value of the magnetizing medium.
Once the coating is magnetized, it will typically remain
permanently magnetized.
[0095] It is further contemplated to be within the scope of the
present invention that the base component of the multi-component
floor mat is comprised of any substance that includes a magnetic
material. The base component does not have to be comprised of
vulcanized rubber. Instead, the base component may be comprised of
concrete, cellulose-containing materials (e.g. wood), metal,
thermoplastic materials, thermoset materials, and the like, and
combinations thereof. In one instance, the base component may be
the floor itself where the textile component is to be installed.
Herein, the floor would include at least one magnetic material that
is used to adhere the textile component to the floor. The textile
component can then be laid directly on the floor which has at least
one magnetic material applied thereto. Suitable magnetic materials
include any of those described previously herein. In one aspect,
the magnetic materials may be incorporated into a paint composition
and applied to the floor. Or, an electromagnetic force may be
applied to the area where the textile component is to be installed.
Any of these magnetic features will provide the necessary adherence
of the textile component to the floor without the need for a
vulcanized rubber base component.
[0096] In another aspect of the invention, the base component may
be secured to a flooring surface with an adhesive composition.
FIGS. 10A and 10B illustrate two different embodiments of
adhesive-containing base component 1500. As shown in FIG. 10A, base
component 150 contains magnetic particles 111 and adhesive layer
153. In another embodiment, FIG. 10B illustrates base component 150
with magnetic particles 111 contained in magnetic coating layer 160
on one of its surfaces and adhesive composition 153 on its opposite
surface (on the floor-facing surface). The flooring surface may be
a hard surface (such as concrete, wood, vinyl, tile, and the like),
or it may be a carpeted surface (such as tile carpet, broadloom
carpet, and the like having a cut and/or loop pile). The adhesive
composition may be a pressure sensitive adhesive material
(including one that allows for repositioning of the base
component), an adhesive material comprised of a rosin ester with an
elastomer of water based or solvent based acrylic polymers, or an
elastomeric material comprised of natural rubber or nitrile rubber
or silicone rubber with a suitable tackifier. The adhesive
composition may be used as the sole material securing the base
component to the flooring surface, or it may be used in combination
with additional mechanical or chemical means for securing the base
component to the flooring surface.
[0097] Floor mats of the present invention may be of any geometric
shape or size as desired for its end-use application. The
longitudinal edges of the floor mats may be of the same length and
width, thus forming a square shape. Or, the longitudinal edges of
the floor mats may have different dimensions such that the width
and the length are not the same. Alternatively, the floor mats may
be circular, hexagonal, and the like. As one non-limiting example,
floor mats of the present invention may be manufactured into any of
the current industry standards sizes that include 2 feet by 4 feet,
3 feet by 4 feet, 3 feet by 5 feet, 4 feet by 6 feet, 3 feet by 10
feet, and the like.
[0098] The washable floor mat of the present invention may be
exposed to post treatment steps. For example, chemical treatments
such as stain release, stain block, antimicrobial resistance,
bleach resistance, and the like, may be added to the washable mat.
Mechanical post treatments may include cutting, shearing, and/or
napping the surface of the washable multi-component floor mat.
[0099] The performance requirements for commercial matting include
a mixture of well documented standards and industry known tests.
Tuft Bind of Pile Yarn Floor Coverings (ASTM D1335) is one such
performance test referenced by several organizations (e.g. General
Services Administration). Achieving tuft bind values greater than 4
pounds is desirable, and greater than 5 pounds even more
desirable.
[0100] Resistance to Delamination of the Secondary Backing of Pile
Yarn Floor Covering (ASTM D3936) is another standard test.
Achieving Resistance to Delamination values greater than 2 pounds
is desirable, and greater than 2.5 pounds even more desirable.
[0101] Pilling and fuzzing resistance for loop pile (ITTS112) is a
performance test known to the industry and those practiced in the
art. The pilling and fuzzing resistance test is typically a
predictor of how quickly the carpet will pill, fuzz and prematurely
age over time. The test uses a small roller covered with the hook
part of a hook and loop fastener. The hook material is Hook 88 from
Velcro of Manchester, N.H. and the roller weight is 2 pounds. The
hook-covered wheel is rolled back and forth on the tufted carpet
face with no additional pressure. The carpet is graded against a
scale of 1 to 5. A rating of 5 represents no change or new carpet
appearance. A rating of less than 3 typically represents
unacceptable wear performance.
[0102] An additional performance/wear test includes the Hexapod
drum tester (ASTM D-5252 or ISO/TR 10361 Hexapod Tumbler). This
test is meant to simulate repeated foot traffic over time. It has
been correlated that a 12,000 cycle count is equivalent to ten
years of normal use. The test is rated on a gray scale of 1 to 5,
with a rating after 12,000 cycles of 2.5=moderate, 3.0=heavy, and
3.5=severe. Yet another performance/wear test includes the Radiant
Panel Test. Some commercial tiles struggle to achieve a Class I
rating, as measured by ASTM E 648-06 (average critical radiant
flux>0.45=class I highest rating).
[0103] The textile component of the floor mat may be washed or
laundered in an industrial, commercial or residential washing
machine. Achieving 200 commercial washes on the textile component
with no structural failure is preferred.
[0104] FIGS. 9A-9F illustrate the installation method for the
multi-component floor mat of the present invention. FIG. 9A shows a
person ("installer") 901 preparing to install a multi-component
floor mat according to the present invention. The installer 901 is
shown standing on base component 950 and holding textile component
910. The arrow indicates the direction of force being applied to
textile component 910 by installer 901 in order to prepare the
components of the floor mat for installation. FIG. 9B is another
view of the installation process showing textile component 910
moved closer to alignment with base component 950. FIG. 9C is
another view of the installation process showing textile component
910 moved even closer to alignment with base component 950. The
installer 901 is holding textile component 910 so that the pile
carpet is facing away from base component 950 and the edge
attachment means is facing toward base component 950. The installer
901 has aligned one edge of textile component 910 with base
component 950. FIG. 9D shows installer 901 lowering textile
component 910 onto base component 950. The arrow again indicates
the direction of force applied to textile component 910 by
installer 901. FIG. 9E shows textile component 910 almost
completely lowered onto base component 950 by installer 901. The
arrow again indicates the direction of force applied to textile
component 910 by installer 901. FIG. 9F shows multi-component floor
mat 900 after installation by installer 901. The textile component
910 is properly aligned onto and deployed with base component 950.
The installer 901 was able to easily install multi-component floor
mat 900 while remaining in the standing position (i.e. feet on the
floor; not on his/her hands and/or knees) and without having to
adjust and/or re-align textile component 910 with base component
950.
[0105] As shown in FIGS. 9A-9F, the person installing the
multi-component floor mat simply moves the textile component over
the top of the base component, aligning it with left and right
alignment marks to achieve horizontal alignment. The textile
component is then automatically locked down on the alignment end in
near perfect angular and vertical alignment with the base
component. Once the alignment end is locked down to the base
component, the installer can then assert tension to the textile
component by pulling it onto the base component and dropping the
textile component onto the near end of the base component using a
second set of alignment marks. The result is that the textile
component is in near perfect in vertical, horizontal and angular
alignment with the base component. The installation of the
multi-component floor mat is achieved quickly and by an installer
that can remain in the standing position (e.g. feet flat on the
floor).
[0106] As further illustrated by FIGS. 9A-9F, the installation of
the floor mat may include movement of the textile component to the
base component by dragging the textile component to the base
component. The textile component may be dragged to the base
component until the edge attachment means of the textile component
(e.g. the loop portion of the edge attachment means) comes into
physical contact with the edge attachment means of the base
component (e.g. the hook portion of the edge attachment means). In
one aspect, the dragging movement may continue until the edge
attachment means of the textile component (e.g. the loop portion of
the edge attachment means) comes into lateral side-by-side contact
with the edge attachment means of the base component (e.g. the hook
portion of the edge attachment means).
[0107] The following additional alignment and deployment techniques
may be used for installing the multi-component floor mat:
[0108] In the first case, it has been found that if the top half is
rolled up in a fairly tight roll--face in--and then placed down on
the base, that the total attraction force is so reduced that an
installer can slide the roll enough to be able to get a good
alignment with the base using the exposed end of the roll as a
guide to align to the base. This method is mainly envisioned for
small two part mats. Alignment marks can be put on the base to
assist the top alignment.
[0109] The second method is to use the first method but coupled
with a removable temporary "mask" that reduces the attractive
force. This can be accomplished by using film or paper that is
placed down on the base between the rolled up top and the base only
in the area where the rolled up top will touch. Now that the total
area is greatly reduced by the roll AND the force per unit area is
reduced by the mask, then the ease of moving the roll around to
achieve alignment is now even greater. Once alignment is achieved,
the film or paper is slid out.
[0110] A third method, that is a refinement of the removable mask
method, is to use a mask that is permanently installed and that
selectively masks only the most critical area--i.e. the area
directly below the roll, and leaves the area near the mat edge
alone. For example, if using a magnetic base and iron containing
top, one can use a thin magnetically receptive material known as
"FlexIron". This material has the ability to significantly reduce
the magnetic force while at the same time strongly sticks to the
magnetic base and thus will not move; the result is a permanently
installed "mask". This mask is sized and positioned so as to only
mask the magnetic force directly below the roll, but leaves the
edges alone so as to keep the force high where the edges must
resist kicking up. One still manually aligns the roll and its edge
to the base, but now the alignment is relatively easy and can be
done quickly. Additionally, the base component can be selectively
magnetized so that a masking section is not magnetized. The
perimeter around the masking section, as well as the perimeter that
attracts the edge of the top piece, can be selectively
magnetized.
[0111] A fourth method can be used in concert with any of the above
methods or alone. This method relies on an alignment pins or
grommets that can capture two or more of the carpet corners. The
pins are located in either the base or top and associated with the
pins are complementary holes in the top or base. Once inserted, the
pins capture the other half of the carpet requiring such that the
two halves cannot be separated without substantial force. Once
captured, the top mat can be picked up and gently laid down in
alignment with the base. If a mat top should become disturbed or
misaligned in the field, it is relatively easy to realign by simply
picking the top up and laying it back down. If used in concert with
1-3 above, alignment now becomes not only easy, but quick and
precise. Furthermore if care is taken to ensure that the masked
area is always below the alignment pins and is sufficient size so
that if the top is picked up that where it drapes is masked, then
alignment/deployment is always easy.
[0112] A fifth method is a refinement of number 4 whereby the
attachment pins are hidden and not visible from the face of the mat
top. Methods to accomplish this are tightly fitting grommets or
strong magnets molded into or glued to the back of the top mat, or
grommets with strong magnets--all associated with complimentary
holes with or without magnets in the base. This method can also be
used in association with any of the 1-3 methods.
[0113] Another variation includes a line or pattern of magnetic
pairs on one end of the textile component that "snap" the textile
component and base component together. These pairs can be spaced
such that a single alignment is highly favorable over any other
attraction. The magnet pairs may be arranged with opposing poles
and the different pairs in the line or pattern have alternating
spacing to prevent misalignment.
[0114] Thus, the multi-component floor mat of the present invention
provides many advantages over the prior art. The textile component
is easily deployed/installed with the base component by dragging
the textile component over the base component until the alignment
mechanisms are contacted and secured in place. Also, the textile
component is easily picked up/uninstalled from the base component
by a field service person (e.g. installer) by lifting up the edge
or corner of the textile component and removing it from the base
component. The textile component of the multi-component floor mat
can be made with a rubber edge around its perimeter so that it is
similar in appearance to a traditional one-piece mat. The rubber
edge perimeter also can be used to prevent metal pieces from being
attracted to the sides of the base and/or textile components which
contain a magnetic coating.
EXAMPLES
[0115] The invention may be further understood by reference to the
following examples which are not to be construed as limiting the
scope of the present invention.
[0116] Several Variables Were Tested:
Test Procedures
[0117] Commercial Wash Procedure: [0118] 1. 140 degree Fahrenheit
wash for 10 minutes. [0119] 2. 3 rinses, 140 degrees, 3 minutes
each. [0120] 3. 2 rinses, 90 degrees, 3 minutes each. [0121] 4. 2
minutes low extraction. [0122] 5. 10 minutes high extraction.
[0123] Some samples were evaluated on a "pass" or "fail" basis. A
"pass" rating indicates that the textile component did not fall
apart, but rather maintained its structural integrity and was
suitable for use in its intended purpose. A "fail" rating indicates
that one or more layers of the textile component came apart, that
the textile did not maintain its structural integrity, and/or the
textile was not suitable for use in its intended purpose.
[0124] Torture Wash: [0125] 1. 190 degree Fahrenheit wash for 30
minutes. [0126] 2. 2 rinses, 90 degrees, 3 minutes each. [0127] 3.
2 minutes low extraction. [0128] 4. 10 minutes high extraction.
[0129] A Torture Wash is intended to be equivalent to 10 commercial
washes.
[0130] Lateral Movement Test:
[0131] The amount of movement in a floor mat is measured using the
lateral movement test. First a location on the floor is marked
usually using a piece of tape. Next a floor mat is placed at that
mark. For a lateral movement walk test, the person conducting the
test walks over the test piece 150 times. Each pass must be in the
same direction to ensure accurate measurement movement. Once this
is done 150 times in the same direction, the person conducting the
test must measure how far the test piece is from the original
location. This should be done on both of the front corners. Once a
walk test is completed, a second Lateral Movement Cart Test is run.
This test involves the same process, but requires a cart holding a
100 lb. load to roll over the test piece 50 times. The distance is
then measured and recorded.
[0132] Thickness Determination:
[0133] The thickness of each sample was measured using a Starrett
pocket dial gauge. The specific model was the Starrett No. 1010.
The pocket dial that was used came with an inspection certificate
(Form 804) to ensure accuracy.
[0134] Tuft Lock Test:
[0135] The tuft lock test was conducted by cutting out a sample of
finished textile component approximately 6''.times.10''. Once the
sample was cut out, it was placed in a TensiTech tensile testing
machine. A tensile testing program was then run allowing the
machine to grasp on to a single tuft in the carpet. Once the
machine locked on to a single tuft, it recorded how much force was
required to pull the tuft out of the rubber backed textile
component. This data was then recorded and run 4 more times for a
total of 5 pulls. Then, once all tests were complete the data was
evaluated making sure all pulls recorded a value higher than 4.0
lbf.
[0136] Body Tear Test:
[0137] The body tear test was conducted by cutting out a sample of
finished textile component approximately 4''.times.7'' with a 2''
slit at one end of it. Once the sample was cut out, it was placed
in a TensiTech tensile testing machine with one side of the slit in
the top clamp, and the other side of the slit in the bottom clamp.
A tensile testing program was then run pulling the top clamp
upwards. The force required to pull the top clamp up was recorded
as the sample ripped in half. This data was then recorded and run 2
more times for a total of 3 pulls. Then, once all tests were
complete the data was evaluated making sure all pulls recorded a
value higher than 13.0 lbf.
[0138] The magnetic hold strength test was conducted by cutting out
a 8''.times.8'' sample of finished textile component with smooth
magnetically responsive backing. Once the sample was cut out, it
was clamped in the top clamp of the Instron tensile testing machine
such that the full width of the mat was in the 9 inch wide top
clamp to a length of at least 1'' inch. A 6''.times.2'' magnetic
strip with a magnetic strength of 200 gauss was mounted on a stiff
metal plate measuring 10''.times.8'' with the long side oriented in
the vertical direction. The metal plate was mounted in an immobile
fixture on the base of the machine and aligned parallel to the
textile component in such a manner that the magnetic strip was in
intimate contact with the magnetically responsive backing of the
finished textile component. A testing program was then run pulling
the top clamp upwards. The force required to pull the top clamp up
was recorded as the sample traversed across the length of the
magnetic strip. This data was then recorded and run 2 more times
for a total of 3 pulls. Then once all tests were complete the data
was evaluated at 0.1'' traverse to assess the magnetic hold
strength in lbf/inch.
Example 1
[0139] In this example, the textile component of the floor mat was
approximately 3' wide by 5' long and the base component was roughly
4'' shorter in both the width and the length, giving a 2'' overlap
of the textile component on each side and hiding the base
component. The underside of the textile component and the top of
the base component were smooth with no protrusions, and the textile
component was deployed in a sweeping motion keeping the contact
area of the textile component to the base component small until the
textile component was mostly over the top of the base component.
The textile component was then dropped down on the base component.
Because the textile component was substantially oversized compared
to the base component, the alignment of the textile component was
not critical and the result was that the base component was hidden
underneath the textile component. The presence of the base
component kept the textile component from undesirable movement
during use.
Example 2
[0140] In this example, the floor mat of Example 1 was altered so
that there was a hook strip of Velcro on the short edge of the base
component and a matching strip of loop Velcro on the underside of
the textile component. These two strips were positioned so that
they were in alignment when the textile component was in alignment
with the base component. As the textile component was dragged onto
the base component, as in Example 1 above, the two strips of Velcro
made physical contact and locked into/onto one another, thus
stopping the movement of the textile component and ensuring the
forward to back alignment of the components was correct.
Example 3
[0141] In this example, the Velcro of Example 2 was replaced with a
rubber ridge approximately 1/8'' high extending along the short
edge of the textile component and molded into the underside of the
textile component; it was positioned in the same place as the
Velcro in Example 2. The Velcro on the base component of Example 2
was eliminated, and the rubber ridge of the textile component
engaged the edge of the base component so as to provide the same
alignment capability of Example 2.
Example 4
[0142] This example was the same as Example 2, except that the
Velcro strips were replaced with a mushroom type engaging fastener
such as 3M Dual Lock.
[0143] Evaluation of Backing Material
[0144] Example A--Mat with Nitrile Rubber Backing
[0145] A mat was prepared as follows:
[0146] A tufted face assembly was prepared comprising a nylon 6,6
yarn tufted into a pre-shrunk Lutrador 52 nonwoven primary backing.
The nylon 6,6 yarn was 1/8.sup.th inch gauge and was tufted at 8.70
stiches per inch. Tufts were sheared to a pile height of
18/64.sup.th inch, resulting in a fabric weight of 20.0 oz/sq.
yard. The tufted roll measured 145 inches from outside tuft row to
outside tuft row.
[0147] The tufted roll was then printed using a Millitron.RTM.
digital printing machine. The tufted face assembly was run down the
Millitron.RTM. digital printing machine at a speed of 25
feet/minute. A combination of 12 gun bars was utilized to
distribute dye to the tufted face assembly with the dye flow set to
36. The tufted face assembly was then exposed to a first steam step
in a steamer at 209.degree. F., and then again in a post
steam/stain blocker step at 150.degree. F. The printed tufted face
assembly was then dried at 240.degree. F.
[0148] The printed tufted face assembly was then slit into 3.2'
wide rolls. These rolls were placed on top of 0.130'' (thickness)
nitrile rubber. The uncured nitrile rubber was then sent into a
press with the printed tufted face assembly on top. The press
heated up to 365.degree. F. from the bottom as soon as the printed
assembly entered the press area. The press then applied pressure at
35 psi to the top of the printed tufted face assembly to push it
into the rubber. The printed tufted face assembly was then held in
the press for 8 minutes before it was removed. After it was
removed, it was preshrunk in a drier at 290.degree. F. to form a
washable carpet in roll form. The washable carpet in roll form was
then cut into the desired shape and/or size.
[0149] In another example, a mat was made with a 0.030'' thick
magnetically responsive filler loaded nitrile rubber backing. The
mat had solution dyed yarn (SDN) yarn tufted in a polyester
non-woven primary backing layer. It was bonded to the backing at
370.degree. F. under 35 psi pressure and cured for 4 minutes. No
further preshrinking was done. However, the backing layer was then
exposed to a needling process to make it porous.
[0150] Evaluation of Backing Style
[0151] Smooth Nitrile Backed Mat
[0152] A smooth rubber backing has no protrusions on the rubber
surface of the mat (e.g. the surface of the mat that comes in
contact with the magnetic base). In other words, the smooth backing
is free from protrusions. Protrusions are typically added to the
magnetic base to aid in preventing unintended lateral movement of
the mat.
[0153] The construction of the washable mat was identical to the
mat produced in Example A. When the nitrile rubber was placed on
the press, it was put on a Teflon coated belt that had no
indentions in it. The top of the belt was smooth which allowed the
bottom of the rubber to have a smooth surface as well.
[0154] Gripper (Standard Cleat) Nitrile Backing for Magnetic Base
Component
[0155] The nitrile rubber for the base was constructed by layering
of the magnetic rubber and the rubber without any magnetic fillers
with the latter one forming the gripper base. A gripper rubber
backing was characterized by having (1) a grid pattern on the
rubber surface that was free from protrusions and (2) protrusions
on the interior spaces between the protrusion free areas. The
protrusions were present in a square pattern. Thus, the gripper
backing contained a repeating pattern of small protrusions in areas
that were 7/8.sup.ths inch by 1 inch square. The protrusions were
approximately 1/16.sup.th inch high. The protrusions covered
approximately 70 percent of the surface of the rubber backing.
[0156] The construction of the washable mat was the same as the mat
produced in Example A. When the nitrile rubber was placed on the
press, it was put on a Teflon coated belt that had 1/16.sup.th inch
indention in it in small square patterns. When the press reached
365.degree. F., it caused the rubber to become very soft. Once the
pressure of 35 psi was applied to the top of the washable mat
assembly, it pushed the soft rubber into the indentions forming the
"gripper" pattern.
[0157] Megahold Nitrile Backing for Magnetic Base Component
[0158] The nitrile rubber for the base was constructed by layering
of the magnetic rubber and the rubber without any magnetic fillers
with the latter one forming the megahold base. A megahold rubber
backing was characterized by having fewer and larger indentations
on the rubber surface, when compared to the gripper backing. The
indentations were present in groups of four that and were spaced in
a square pattern. Thus, the megahold pattern contained a repeating
pattern of four large indentations in areas that were 3.625 inches
by 3.875 inches square. The indentations were approximately 1/8
inch deep. The indentations covered approximately 40 percent of the
surface of the rubber backing.
[0159] The construction of the washable mat was the same as the mat
produced in Example A. Before the rubber was placed on to the
Teflon belt, the operator placed a metal plate on the belt. The
metal plate contained circles on the top surface. The circles
included a hole drilled in the center to allow rubber to form on
the inside. The nitrile rubber was then placed on top of the metal
plate, with the fabric/carpet on top. When the press reached
365.degree. F., it caused the rubber to become very soft. Once the
pressure of 35 psi was applied to the top of the washable mat
assembly, it pushed the soft rubber around and into the metal plate
forming the "Megahold" backing.
[0160] Evaluation of Magnetic Coating Thickness on Textile
Component
[0161] The magnetic backcoating layer thickness was varied. Samples
were prepared with 20 mils, 25 mils and 30 mils of magnetic
backcoating. The backcoatings were applied to Forever.RTM. mats
from Milliken & Company of Spartanburg, S.C. These mats were
then subject to the standard wash and body tear test and a magnetic
shear hold test.
[0162] To perform the magnetic shear hold test a test set-up was
created where the bottom grip of an Instron was replaced by a
vertical aluminum plate with a permanent magnet sheet attached. The
permanent magnetic sheet was similar in construction and in
magnetic strength (measured in Gauss) to the magnetic base
component that the magnetic backcoated textile component was
installed on. The magnetic backcoated textile component was gripped
on the top jaw of the test frame such that the magnetic backcoating
was attached to the permanent magnet sheet. The assembly was
adjusted to ensure that the backcoated textile component moved
parallel to the face of the magnetic sheet on the aluminum plate
when the top jaw was moved at a rate of 12 inches/minute. The force
on the load cell after a 1'' traverse was recorded as the magnetic
shear force.
[0163] The results from testing the backcoated textile at 1.times.,
10.times. and 20.times. torture washes is presented in Table 1
below.
TABLE-US-00001 TABLE 1 Evaluation of Magnetic Coating Thickness on
Textile Component After Washing Control Coating Thickness Coating
Thickness Coating Thickness mat - 53 mil 30 mil 25 mil 20 mil Mat
Units 1X 1X 10X 20X 1X 10X 20X 1X 10X 20X Trouser lb 32.6 23.2 23.9
23.9 20.7 24.2 23.7 20.9 23.5 21.9 tear force Tuft Lock lb 4.9 4.9
5.0 4.2 5.2 4.9 4.8 4.5 4.2 3.6 force Magnetic gf -- 450.5 350.0
539.0 359.0 160.0 184.0 370.5 94.0 103.5 Hold (Shear)
[0164] All references, including publications, patent applications,
and patents, cited herein are hereby incorporated by reference to
the same extent as if each reference were individually and
specifically indicated to be incorporated by reference and were set
forth in its entirety herein.
[0165] The use of the terms "a" and "an" and "the" and similar
referents in the context of describing the subject matter of this
application (especially in the context of the following claims) are
to be construed to cover both the singular and the plural, unless
otherwise indicated herein or clearly contradicted by context. The
terms "comprising," "having," "including," and "containing" are to
be construed as open-ended terms (i.e., meaning "including, but not
limited to,") unless otherwise noted. Recitation of ranges of
values herein are merely intended to serve as a shorthand method of
referring individually to each separate value falling within the
range, unless otherwise indicated herein, and each separate value
is incorporated into the specification as if it were individually
recited herein. All methods described herein can be performed in
any suitable order unless otherwise indicated herein or otherwise
clearly contradicted by context. The use of any and all examples,
or exemplary language (e.g., "such as") provided herein, is
intended merely to better illuminate the subject matter of the
application and does not pose a limitation on the scope of the
subject matter unless otherwise claimed. No language in the
specification should be construed as indicating any non-claimed
element as essential to the practice of the subject matter
described herein.
[0166] Preferred embodiments of the subject matter of this
application are described herein, including the best mode known to
the inventors for carrying out the claimed subject matter.
Variations of those preferred embodiments may become apparent to
those of ordinary skill in the art upon reading the foregoing
description. The inventors expect skilled artisans to employ such
variations as appropriate, and the inventors intend for the subject
matter described herein to be practiced otherwise than as
specifically described herein. Accordingly, this disclosure
includes all modifications and equivalents of the subject matter
recited in the claims appended hereto as permitted by applicable
law. Moreover, any combination of the above-described elements in
all possible variations thereof is encompassed by the present
disclosure unless otherwise indicated herein or otherwise clearly
contradicted by context.
* * * * *