U.S. patent application number 16/278961 was filed with the patent office on 2019-06-13 for flooring system.
The applicant listed for this patent is Milliken & Company. Invention is credited to Brent A. Beukema, Ty G. Dawson, Dale S. Kitchen, Franklin S. Love, III, Padmakumar Puthillath, Venkatkrishna Raghavendran, Brandon T. Roberts, Gordon J. Stannis.
Application Number | 20190174942 16/278961 |
Document ID | / |
Family ID | 57200154 |
Filed Date | 2019-06-13 |
View All Diagrams
United States Patent
Application |
20190174942 |
Kind Code |
A1 |
Dawson; Ty G. ; et
al. |
June 13, 2019 |
Flooring System
Abstract
This invention relates to a flooring system comprised of a
plurality of washable, multi-component floor mats. The floor mats
contain a textile component and a base component. The textile
component and the base component are attached to one another by a
variety of mechanisms, including 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.
Inventors: |
Dawson; Ty G.; (Spartanburg,
SC) ; Love, III; Franklin S.; (Columbus, NC) ;
Raghavendran; Venkatkrishna; (Houston, TX) ; Roberts;
Brandon T.; (Greer, SC) ; Puthillath; Padmakumar;
(Greer, SC) ; Kitchen; Dale S.; (Boiling Springs,
SC) ; Stannis; Gordon J.; (Saugatuck, MI) ;
Beukema; Brent A.; (Grand Rapids, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Milliken & Company |
Spartanburg |
SC |
US |
|
|
Family ID: |
57200154 |
Appl. No.: |
16/278961 |
Filed: |
February 19, 2019 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
15293327 |
Oct 14, 2016 |
|
|
|
16278961 |
|
|
|
|
62241217 |
Oct 14, 2015 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47G 2200/10 20130101;
D06N 7/0068 20130101; A47G 27/0418 20130101; A47G 27/0481 20130101;
A47L 23/266 20130101; A47G 27/0293 20130101; D06N 7/0089 20130101;
A47G 2200/106 20130101; D06N 7/0071 20130101; D06N 2213/068
20130101 |
International
Class: |
A47G 27/02 20060101
A47G027/02; A47G 27/04 20060101 A47G027/04; D06N 7/00 20060101
D06N007/00; A47L 23/26 20060101 A47L023/26 |
Claims
1. A flooring system comprised of at least two multi-component
floor mats, wherein the multi-component floor mat is comprised of
(a) a textile component comprising (i) a first layer of tufted pile
carpet formed by tufting face yarns through a primary backing
layer, (ii) a second layer comprised of at least one polymer
selected from the group consisting of thermoplastic and thermoset
elastomers, and (iii) at least one attachment means; and (b) a base
component comprised of (i) materials selected from the group
consisting of: at least one polymer selected from the group
consisting of thermoplastic elastomers and thermoset elastomers, a
metal material, a cellulose-containing material, and combinations
thereof and (ii) at least one attachment means that works in
corresponding relationship to the attachment means of the textile
component; wherein the textile component and the base component are
releasably attachable to one another via the at least one
attachment means; and wherein the at least two multi-component
floor mats are releasably attachable to one another via at least
one attachment means.
2. The flooring system of claim 1, wherein the flooring system is
comprised of a number of interconnected multi-component floor mats
in the range from at least two to less than twenty.
3. The flooring system of claim 2, wherein the flooring system is
comprised of a number of interconnected multi-component floor mats
in the range from two to ten, or in the range from two to eight, or
in the range from two to six, or in the range from two to four.
4. The flooring system of claim 1, wherein the at least one
attachment means is selected from mechanical attachment, cohesive
attraction, and combinations thereof.
5. The flooring system of claim 1, wherein the base component
further includes sensing mechanisms selected from the group
consisting of electronic sensors, mechanical sensors, and
combinations thereof.
6. A flooring system comprised of at least two multi-component
floor mats, wherein the multi-component floor mat is comprised of
(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 comprised of at least one polymer selected
from the group consisting of thermoplastic and thermoset elastomers
and magnetic particles; and (b) a base component comprised of a
material selected from the group consisting of: at least one
polymer selected from the group consisting of thermoplastic
elastomers and thermoset elastomers, a metal material, a
cellulose-containing material, and combinations thereof, wherein
the material contains magnetic particles or has a magnetic coating
applied thereto; wherein the textile component and the base
component are releasably attachable to one another via at least one
attachment means; and wherein the at least two multi-component
floor mats are releasably attached to one another via at least one
attachment means.
7. The flooring system of claim 6, 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.
8. The flooring system of claim 6, 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.
9. The flooring system of claim 6, wherein the face yarns are
selected from nylon 6; nylon 6,6; polyester; polypropylene; or
combinations thereof.
10. The flooring system of claim 6, wherein the face yarns comprise
cut pile, loop pile, or combinations thereof.
11. The flooring system of claim 6, wherein the face yarns are
dyed, undyed, printed, or combinations thereof.
12. The flooring system of claim 6, wherein the primary backing
layer is selected from the group consisting of woven material,
nonwoven material, knitted material, and combinations thereof.
13. The flooring system of claim 6, 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.
14. The flooring system of claim 6, wherein the at least one
polymer is vulcanized rubber.
15. The flooring system of claim 6, wherein the at least one
polymer contains 0% to 40% recycled rubber material.
16. The flooring system of claim 6, wherein the at least one
attachment means is selected from mechanical attachment, cohesive
attraction, and combinations thereof.
17. The flooring system of claim 6, wherein the base component
further includes sensing mechanisms selected from the group
consisting of electronic sensors, mechanical sensors and
combinations thereof.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application
Ser. No. 15/293,327, entitled "Flooring System," which was filed on
Oct. 14, 2016, which claims priority to U.S. Provisional Patent
Application No. 62/241,217, entitled "Flooring System," which was
filed on Oct. 14, 2015, both of which are entirely incorporated by
reference herein.
TECHNICAL FIELD
[0002] This invention relates to a flooring system comprised of a
plurality of washable, multi-component floor mats. The floor mats
contain a textile component and a base component. The textile
component and the base component are attached to one another by a
variety of mechanisms, including 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.
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 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 flooring system
comprised of at least two multi-component floor mats, wherein the
multi-component floor mat is comprised of (a) a textile component
comprising (i) a first layer of tufted pile carpet formed by
tufting face yarns through a primary backing layer, (ii) a second
layer comprised of at least one polymer selected from the group
consisting of thermoplastic and thermoset elastomers, and (iii) at
least one attachment means; and (b) a base component comprised of
(i) materials selected from the group consisting of: at least one
polymer selected from the group consisting of thermoplastic
elastomers and thermoset elastomers, a metal material, a
cellulose-containing material, and combinations thereof and (ii) at
least one attachment means that works in corresponding relationship
to the attachment means of the textile component; wherein the
textile component and the base component are releasably attachable
to one another via the at least one attachment means; and wherein
the at least two multi-component floor mats are releasably
attachable to one another via at least one attachment means.
[0007] In another aspect, the invention relates to a flooring
system comprised of at least two multi-component floor mats,
wherein the multi-component floor mat is comprised of (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 comprised of at least one polymer selected from the
group consisting of thermoplastic and thermoset elastomers and
magnetic particles; and (b) a base component comprised of a
material selected from the group consisting of: at least one
polymer selected from the group consisting of thermoplastic
elastomers and thermoset elastomers, a metal material, a
cellulose-containing material, and combinations thereof, wherein
the material contains magnetic particles or has a magnetic coating
applied thereto; wherein the textile component and the base
component are releasably attachable to one another via at least one
attachment means; and wherein the at least two multi-component
floor mats are releasably attached to one another via at least one
attachment means.
[0008] In a further aspect, the invention relates to a flooring
system comprised of at least two multi-component floor mats wherein
the multi-component floor mat is comprised of: (a) a textile
component comprising (i) tufted pile carpet wherein face yarns are
tufted through a primary backing layer and (ii) a magnetic coating
wherein the magnetic coating is comprised of magnetic particles and
a binder material; and (b) a base component comprised of a material
selected from the group consisting of: at least one polymer
selected from the group consisting of thermoplastic elastomers and
thermoset elastomers, a metal material, a cellulose-containing
material, and combinations thereof, wherein the material contains
magnetic particles or has 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
at least two multi-component floor mats are releasably attachable
to one another via at least one attachment means.
[0009] In yet another aspect, the invention relates to a flooring
system comprised of at least two multi-component floor mats,
wherein the multi-component floor mat is comprised of: (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 at least one polymer selected from the
group consisting of thermoplastic and thermoset elastomers, wherein
the at least one polymer contains magnetic particles; (b) a base
component comprised of a material selected from the group
consisting of: at least one polymer selected from the group
consisting of thermoplastic elastomers and thermoset elastomers, a
metal material, a cellulose-containing material, and combinations
thereof, wherein the material contains magnetic particles or has a
magnetic coating applied thereto; wherein the textile component and
the base component are releasably attachable to one another via
magnetic attraction; and (c) at least one alignment and deployment
mechanism; and wherein the at least two multi-component floor mats
are releasably attachable to one another via at least one
attachment means.
[0010] In another aspect, the invention relates to a flooring
system comprised of at least two multi-component floor mats,
wherein the floor mat is comprised of: (a) a textile component
comprising (i) tufted pile carpet wherein face yarns are tufted
through a primary backing layer and (ii) a magnetic coating wherein
the magnetic coating is comprised of magnetic particles and a
binder material; (b) a base component comprised of a material
selected from the group consisting of: at least one polymer
selected from the group consisting of thermoplastic elastomers and
thermoset elastomers, a metal material, a cellulose-containing
material, and combinations thereof, wherein the material contains
magnetic particles or has a magnetic coating applied thereto;
wherein the textile component and the base component are releasably
attachable to one another via magnetic attraction; and (c) at least
one alignment and deployment mechanism; and wherein the at least
two multi-component floor mats are releasably attachable to one
another via at least one attachment means.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1A is a schematic diagram of one embodiment of the
flooring system of the present invention.
[0012] FIG. 1B is a schematic diagram of one portion of the
flooring system shown in FIG. 1A.
[0013] FIG. 1C is an expanded side view of a floor mat comprising
the flooring system of FIG. 1A.
[0014] FIG. 2A is a schematic diagram of one embodiment of the
flooring system of the present invention.
[0015] FIG. 2B is an expanded side view of a floor mat comprising
the flooring system of FIG. 2A.
[0016] FIG. 3A is a schematic diagram of one embodiment of the
flooring system of the present invention.
[0017] FIG. 3B is an expanded side view of a floor mat comprising
the flooring system of FIG. 3A.
[0018] FIG. 4 is a partial view of a floor mat comprising the
flooring system of the present invention illustrating an attachment
means.
[0019] FIG. 5A is a schematic diagram of one embodiment of the
flooring system of the present invention.
[0020] FIG. 5B is an alternate view of the flooring system of FIG.
5A illustrating grommet attachment means.
[0021] FIG. 5C is an expanded side view of a floor mat comprising
the flooring system of FIG. 5B.
[0022] FIG. 6A is a schematic diagram of one embodiment of the
flooring system of the present invention.
[0023] FIG. 6B is an expanded side view of a floor mat comprising
the flooring system of FIG. 6A.
[0024] FIG. 7A is a schematic diagram of one embodiment of the
flooring system of the present invention.
[0025] FIG. 7B is an expanded side view of a floor mat comprising
the flooring system of FIG. 7A.
[0026] FIG. 8A is a schematic diagram of one embodiment of the
flooring system of the present invention.
[0027] FIG. 8B is a top perspective view of a floor mat comprising
the flooring system of FIG. 8A.
[0028] FIG. 8C is a schematic diagram of a portion of the flooring
system of FIG. 8A illustrating the frame and grommet attachment
means.
[0029] FIG. 8D is an expanded side view of a portion of the floor
mat comprising the flooring system of FIG. 8C.
DETAILED DESCRIPTION
[0030] The present invention described herein is a flooring system
comprised of a plurality of washable, multi-component floor mats.
The mats are comprised of a textile component and a base component.
The textile component and the base component are attached to one
another via a variety of attachment means, including magnet
attraction.
[0031] As illustrated in FIG. 1A, the present invention describes a
flooring system 600 comprised of a plurality of floor mats 610. As
used herein, "plurality" is intended to mean more than one. For
example, a plurality of floor mats indicates more than one floor
mat. In other words, a plurality of floor mats indicates at least
two floor mats. Floor mats 610 may be attached to one another
through a variety of attachment means. As illustrated in FIG. 1B,
one attachment means includes a bow tie-shaped attachment mechanism
630 that overlaps a portion of each of two floor mats adjacent to
one another. The attachment mechanism 630 may function via the use
of magnetism and/or mechanical interlocking means (such as
Velcro.RTM. or mushroom-shaped protrusions).
[0032] As previously described herein, floor mats 610 are comprised
of a textile component 611 and a base component 615, as shown in
FIG. 10. The textile component 611 is comprised of a layer of
tufted pile carpet 612 and a magnetic coating 613. The textile
component 611 and base component 615 are attached to one another
via magnetic attraction. At least a portion of the textile
component is magnetically receptive and at least a portion of the
base component is magnetized. When attached together to form the
floor mat of the present invention, they may be contained within a
frame 690. Frame 690 may be comprised of any material that is
suitable for holding the floor mat, such as, for example, metal,
plastic, cellulose-containing materials (such as wood) and the
like.
[0033] FIG. 2A is the same as FIG. 1A, except that an additional
feature is present. FIG. 2A illustrates another attachment means
that may be used in conjunction with the aforementioned bow
tie-shaped attachment means or by themselves. Flooring system 700
includes bow tie-shaped attachment means 730 and grommet attachment
means 740. The grommet attachment means 740 are useful for
attaching the floor mat 710 to the frame 790, as illustrated in
FIG. 2B. In this instance, the floor mat 710 includes an opening
741 so that the grommet attachment means can be inserted into the
hole thereby holding the floor mat in the frame 790. While a bow
tie-shaped attachment means is illustrated, it is merely exemplary;
any suitable shape may be used for attaching the border edges
together to form the flooring system.
[0034] FIG. 3A illustrates a flooring system 800 comprised of a
plurality of floor mats 810 that may be connected to one another
via magnetic edge attachment means 850. The floor mats 810 may
include magnets 860 for attaching the floor mat to frame 890. In
this illustration magnets 860 are small, spot magnets covering only
a portion of the frame 890. This is in contrast to the base
component 615 illustrated in FIG. 10 which covers substantially the
whole surface of the frame 690. While magnetic attraction is
described herein with respect to the Figures, it is contemplated to
be within the scope of the present invention that other attachment
means may be suitable for use, such as Velcro.RTM. material and/or
the mushroom-shaped protrusions mentioned herein.
[0035] Looking now to FIG. 4, another attachment means is
illustrated. A partial view of flooring system 900 is shown with
floor mat 910 containing a female portion of a corner grommet
attachment means 971 and frame 990 containing a male portion of a
corner grommet attachment means 972. Female portion 971 of the
corner grommet contains a recessed area for accepting the
protrusion of male portion 972. Female portion 971 may be located
in the floor mat and male portion 972 may be located in the frame
990, as shown in FIG. 4. However, an alternative arrangement may
also be suitable wherein the female portion 971 is located in the
frame and male portion 972 is located in the floor mat. Once parts
971 and 972 are secured together, the floor mat 910 is attached to
the frame 990.
[0036] FIG. 5A illustrates yet another embodiment of a flooring
system of the present invention. Flooring system 1000 is comprised
of a plurality of floor mats 1010. Floor mats 1010 may be arranged
in a configuration via attachment of one portion of the floor mat
to a spline 1085. The floor mats 1010, in one aspect, may of
rectangular shape having triangular shape between each floor mat
when attached to the spline 1085. The floor mat 1010 is illustrated
in FIGS. 5A and 5B in such a way that the floor mat 1010 may not be
contained within a frame per se. Rather, floor mat 1010 may be
attached to a spline 1085 via grommets 1040. Two grommet attachment
means 1040 are shown in FIG. 5B. Alternatively, FIG. 5C illustrates
the floor mat 1010 contained within a frame 1090. One or more
grommet attachment means 1040 may be ideal for attaching the floor
mat 1010 the frame 1090.
[0037] FIGS. 6A and 6B illustrate yet another embodiment of the
present invention. FIG. 6A shows a flooring system 1100 wherein the
floor mats 1110 are contained within frame 1190 and attached to the
frame 1190 via grommet attachment means 1140 on both ends of the
floor mats. An expanded side view of one of the floor mats 1110 of
FIG. 6A is shown in FIG. 6B. Note here again, the rectangular shape
of the floor mats results in a triangular shape between each floor
mat.
[0038] Looking to FIGS. 7A and 7B, therein is shown a flooring
system 1200 comprising trapezoidal-shaped floor mats 1210 attached
at both ends to a frame 1290 via grommets 1240. An expanded side
view of one of the floor mats 1210 of FIG. 7A is shown in FIG. 7B.
In contrast to the rectangular-shaped floor mats of FIGS. 5A and
6A, the trapezoidal-shaped floor mats of FIG. 7A do not contain a
triangular shape between the floor mats.
[0039] FIG. 8A illustrates a flooring system 1300 comprised of
floor mats 1310 contained within a frame 1390. The floor mats 1310
are attached to the frame 1390 via corner grommets 1340. Each
individual floor mat 1310 is contained within its own individual
frame 1390. The individual frames 1390 may be attached to one
another to form the flooring system 1300 via magnet attraction.
[0040] Note the coloration of the individual floor mats in this
particular embodiment as it exhibits color gradation from light to
dark. Such an arrangement of floor mats for this flooring system
may be ideal for use in building entryways wherein the darker
colored floor mats are present closest to the entryway in order to
catch and disguise the majority of the dirt and moisture that is
carried into the building. In this configuration, the lighter
colored floor mats are present furthest from the entryway after the
majority of dirt and moisture has been deposited on the previously
presented darker floor mats.
[0041] Additionally, the varying coloration present on the floor
mats comprising the flooring system may result from different fiber
types and constructions. For example, the first floor mat (closest
to the entry door) may include fibers suitable for use as scraper
fibers (thereby forming a scraper floor mat) for removing debris
from items entering through the door. The second floor mat
encountered may include more absorbent material, while the third
mat is merely for decorative purposes. One can envision any
combination of scraper floor mats, absorbent floor mats, and
decorative floor mats used to create a flooring system of the
present invention.
[0042] FIG. 8B shows the frame 1390 being comprised of longitudinal
piece 1391 that fits together with corner piece 1393 to form the
frame 1390. As illustrated in FIG. 8C, the floor mat 1310 is
inserted into/onto the frame 1390 and held in place via an
attachment means such as corner grommets 1340. Note that the floor
mat 1310 contains a floor mat attachment portion 1341 that works in
corresponding relation to the frame attachment portion 1343. An
expanded view of the floor mat 1310 attached to frame 1390 via
frame attachment portion 1343 is illustrated in FIG. 8D.
[0043] Any of the embodiments shown and illustrated by the Figures
of the present application or described herein may be combined with
one another to form additional embodiments contemplated to in the
scope of the present invention. For example, any floor mat shape
may be combined with other shapes (e.g. circles and hexagons) to
form a flooring system of the present invention, and any
combination of attachment means (e.g. bow tie-shaped attachments,
magnetic side attachments, hole grommets, etc.) for attaching the
floor mats to one another and/or to a frame may be utilized
herein.
[0044] Additionally, the flooring system may be comprised of a
number of interconnected multi-component floor mats in the range
from at least two to less than twenty. In another aspect, the
flooring system may be comprised of a number of interconnected
multi-component floor mats in the range from two to ten, or in the
range from two to eight, or in the range from two to six, or in the
range from two to four.
[0045] The base component of the floor mat may be partially or
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.
[0046] The textile component may be comprised of tufted pile
carpet. Tufted pile carpet is comprised of a primary backing layer
and face yarns. The primary backing layer is typically included in
the tufted pile carpet to give stability to the face yarns. The
materials comprising the face yarns and the primary backing layer
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.
[0047] The material comprising the face yarns and primary backing
layer 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 the face yarns will
generally be comprised of interlaced fibers, interlaced yarns,
loops, or combinations thereof.
[0048] The material comprising the face yarns and primary backing
layer 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.
[0049] Furthermore, the material comprising the face yarns and
primary backing layer 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.
[0050] Additionally, the face yarns and the primary backing layer
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.
[0051] The face yarns may be dyed or undyed. If the face yarns 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. The
face yarns constructions include loop pile, cut pile, and
combinations of loop pile and cut pile.
[0052] The primary backing layer can be any suitable primary
backing material. The primary backing layer may be comprised of a
woven, nonwoven or knitted material, or combinations thereof. The
general purpose of the primary backing layer is to support the
tufts of the face yarns. In one aspect, the primary backing layer
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.
[0053] The tufted pile carpet 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.
[0054] Examples of suitable compositions for forming the second
layer (i.e. the layer having direct contact with the base
component) of the textile component include at least one polymer
selected from the group consisting of thermoplastic and thermoset
elastomers. Thermoplastic elastomers include thermoplastic
vulcanizate, styrenic block co-polymer, thermoplastic
polyurethanes, thermoplastic copolyesters, thermoplastic
copolyamides, polyolefinic blends and mixtures thereof. Thermoset
elastomers include natural rubber, synthetic rubber, and mixtures
thereof. Thermoset elastomers include nitrile rubber (including
dense nitrile rubber and foam nitrile rubber), polyvinyl chloride
rubber, ethylene propylene diene monomer (EPDM) rubber, vinyl
rubber, and mixtures thereof. In one aspect, the backing layer of
the textile component is typically comprised of at least one rubber
material. The rubber material may contain from 0% to 40% of a
recycled rubber material.
[0055] 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.
[0056] 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.
[0057] 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.
[0058] 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.
[0059] 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.
[0060] 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.
[0061] The textile component may further comprise a magnetic
coating layer. The magnetic coating layer is typically present on
the surface of the textile component that is opposite the face
yarns. Application of the magnetic coating layer to the tufted pile
carpet will be described in greater detail below. The resulting
textile component 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.
[0062] After the textile component has been made, it will be custom
cut to fit into the recessed area of the base component (for
instances in which the base component is in the form of a tray) or
onto the base component (for instances wherein the base component
is substantially flat/trayless/without recessed area). 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, or rotary blade. In one aspect
of the invention, the thickness of the textile component will be
substantially the same as the depth of the recessed area when the
base component is in the form of a tray.
[0063] The base component typically contains a recessed area
surrounded by a border. In one aspect, the border slopes gradually
upward from outer perimeter to inner perimeter, to create a recess
within the base, corresponding to the recessed area. The recessed
area of the base component possesses a certain amount of depth,
thereby defining it as "recessed."
[0064] The base component is a planar-shaped tray, which is sized
to accommodate the textile component. The base component may also
include a border surrounding the tray, whereby the border provides
greater dimensional stability to the tray, for example, because the
border is thicker, i.e. greater in height relative to the floor.
Additionally, the border may be angled upward from its outer
perimeter towards the interior of the base component, so as to
provide a recessed area where the tray is located, thereby creating
a substantially level area between the inner perimeter of the
border and the textile component, when the textile component
overlays the tray. Additionally, the gradual incline from the outer
perimeter of the border to the inner perimeter of the border
minimizes tripping hazards and the recess created thereby protects
the edges of the textile component.
[0065] It can be understood that the base component may be
subdivided into two or more recessed trays, by extending a divider
from one side of the border to an opposite side of the border,
substantially at the height of the inner perimeter. Accordingly, it
would be possible to overlay two or more textile components in the
recesses created in the base component.
[0066] The base component, including the border, may be formed in a
single molding process as a unitary article. Alternatively, the
border and the tray may be molded separately and then bonded
together in a second operation. The tray and border may be made of
the same or different materials.
[0067] In general, the base component may be comprised of any
dimensionally stable material, as long as the material is durable
and can be laid flat or otherwise conforming to the floor surface.
Examples of suitable materials for forming the base component
include: (a) at least one polymer selected from the group
consisting of thermoplastic and thermoset elastomers, (b) a metal
material, (c) a cellulose-containing material (such as wood), and
(d) combinations thereof. Thermoplastic elastomers include
thermoplastic vulcanizate, styrenic block co-polymer, thermoplastic
polyurethanes, thermoplastic copolyesters, thermoplastic
copolyamides, polyolefinic blends and mixtures thereof. Thermoset
elastomers include natural rubber, synthetic rubber, and mixtures
thereof. Thermoset elastomers include nitrile rubber (including
dense nitrile rubber and foam nitrile rubber), polyvinyl chloride
rubber, ethylene propylene diene monomer (EPDM) rubber, vinyl
rubber, 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.
[0068] The base component may also include sensing mechanisms
selected from the group consisting of electronic sensors,
mechanical sensors, and combinations thereof. The sensing
mechanisms may be used for transmitting tactile information to an
electronic or analog receptor for further processing. These sensors
may also include pressure sensors.
[0069] In one aspect, the base component may be formed into a tray
shape 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 mat is pressed, 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 mat 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 base
component) in which to place the textile component. The textile
component has the ability to be inserted and removed from the base
component multiple times.
[0070] In one aspect, the floor mat may be presented in an
arrangement wherein the textile component overlays the recessed
area of the base component. As previously discussed herein, the
base component of the floor mat may be in the form a tray. However,
in one alternative embodiment, 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.
[0071] The back surface of the base component is the surface which
lies on the floor and therefore has direct contact with the surface
of the floor. Various patterns and/or protrusions on the back
surface of the base component may be present so as to facilitate
the base component's adherence to the floor. The protrusions may be
present in a repeating pattern such that a three dimensional array
of protrusions is formed having a uniform pattern.
[0072] The textile component and the base component may be attached
to one another by magnetic attraction. Commonly owned U.S. Patent
Application Ser. No. 62/201,148 filed on Aug. 5, 2015, describes a
washable multi-component floor mat having magnetically attractive
properties, as is entirely incorporated by reference herein.
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.
[0073] 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.
[0074] 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.
[0075] 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.
[0076] 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).
[0077] Materials being reversibly magnetic is exemplified when 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.
[0078] 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.
[0079] 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.
[0080] 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.
[0081] 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.
[0082] 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.
[0083] 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.
[0084] 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.
[0085] 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.
[0086] 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.
[0087] 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.
[0088] 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.
[0089] 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.
[0090] 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.
[0091] 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.
[0092] 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.
[0093] Other attachment means may be utilized for attaching the
textile component to the base component and forming a
multi-component mat. For example, mushroom-shaped protrusions as
disclosed in commonly owned U.S. patent application Ser. No.
14/818,402 filed on Aug. 5, 2015, which is entirely incorporated by
reference herein, may be suitable attachment means.
[0094] 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.
[0095] 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.
[0096] 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.
[0097] 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.
[0098] 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.
[0099] 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).
[0100] 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.
[0101] The following alignment and deployment techniques may be
used for installing the multi-component floor mat:
[0102] 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. This alignment and deployment technique
relies upon the property of surface area reduction between magnetic
coatings. By rolling up the textile component prior to placing it
(or deploying it) onto the base component, magnetic attraction
between the components is reduced.
[0103] 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, paper, or other
sheeting material 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, paper or other sheeting
material is slid out.
[0104] 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.
[0105] 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.
[0106] 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.
[0107] 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. Many of these alignment and
deployment techniques are described in commonly owned U.S. Patent
Application Ser. No. 62/201,149 filed on Aug. 5, 2015, which is
entirely incorporated by reference herein.
[0108] 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.
[0109] 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.
[0110] 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.
* * * * *