Cushioned carpeted floor mat with at least one cushioning integrated rubber protrusion

Abstract

This invention relates to a cushioned floor covering article wherein the mat includes a tufted carpet placed on the top side of a foam rubber sheet and at least one foam rubber protrusion integrated within at least a portion of the bottom side of the foam rubber sheet. Such an article provides effective removal of moisture, dirt, and debris from the footwear of pedestrians through the utilization of a carpet pile component. Furthermore, the utilization of a foam rubber backing also allows for either periodic heavy duty industrial-scale laundering in such standard washing machines or periodic washing and drying in standard in-home machines, both without appreciably damaging the inventive floor covering article, such as a floor mat. Additionally, the presence of integrated foam rubber protrusions within the mat structure provides an effective cushioning effect for pedestrian comfort as well as a means to prevent slippage of the article from its contacted surface. A method of producing such an inventive cushioned floor covering article is also provided.

Description

FIELD OF THE INVENTIONThis invention relates to a cushioned floor covering article wherein the mat includes a tufted carpet placed on the top side of a foam rubber sheet and at least one foam rubber protrusion integrated within at least a portion of the bottom side of the foam rubber sheet. Such an article provides effective removal of moisture, dirt, and debris from the footwear of pedestrians through the utilization of a carpet pile component. Furthermore, the utilization of a foam rubber backing also allows for either periodic heavy duty industrial-scale laundering in such standard washing machines or periodic washing and drying in standard in-home machines, both without appreciably damaging the inventive floor covering article, such as a floor mat. Additionally, the presence of integrated foam rubber protrusions within the mat structure provides an effective cushioning effect for pedestrian comfort as well as a means to prevent slippage of the article from its contacted surface....

AI Technical Summary

Benefits of technology

to provide a carpeted floor covering article for which the portion which provides the cushioning characteristics simultaneously provides non-slip benefits. An additional object of this invention is to provide a non-slip, cushioned, antifatigue carpeted floor covering article in which the cushioning aspects are provided by at least one integrated rubber protrusion produced during the necessary vulcanization process. Still a further object of the invention is to provide a non-slip, cushioned carpeted floor covering article which possesses sufficient flexibility to withstand periodical laundering in industrial washing and drying machines. Yet another object of this invention is to provide a floor covering article which can substantially reduce a person's fatigue after standing on such an article for appreciable periods of time as compared with other standard floor covering articles.

Floor mats and other like floor covering articles have exhibited general problems arising from frequent washings and harsh environments of use. First, the energy required to wash and dry a typical floor mat is significant due to the overall mass of the mats. This overall mass is made up of the mass of the mat pile, the mass of the carrier fabric into which the mat pile is tufted, and most significantly, the mass of the rubber backing sheet which is integrated to the carrier fabric under heat and pressure. As will be appreciated, a reduction in the overall mass of the floor mat will result in a reduced energy requirement in washing and drying the mat. Moreover, a relative reduction in the mass of the rubber backing sheet (i.e. the heaviest component) will provide the most substantial benefit. Thus, the utilization of a lighter weight rubber composition, such as foam rubber, in at least a portion of the dust control mat of the present invention includes a rubber backing sheet which may possess a specific gravity which is approximately 25-35 percent less then the solid rubber sheets of typical prior floor mats. Accordingly, a foam rubber is preferably, though not required, as the rubber structure of the inventive mat's rubber backing sheet. This lighter weight thus translates into a reduced possibility of the mat harming either the washing or drying machine in which the mat is cleaned, or the mat being harmed itself during such rigorous procedures. Although the inventive floor mat must withstand the rigors of industrial machine washing, hand washing and any other manner of cleaning may also be utilized. Overall, the inventive floor mat provides an article which will retain its aesthetically pleasing characteristics over a long period of time and which thereby translates into reduced costs for the consumer.

Furthermore, a significant problem exists within this field concerning the deterioration of the carbon-carbon double bonds in the matrix of the rubber backing sheet due to the exposure of the sheets to an oxidizing environment during use and cleaning. Specifically, the exposure of the mats to oxidizing agents during the washing and drying process tends to cleave the carbon-carbon double bonds of the rubber sheet thereby substantially embrittling the rubber which leads to cracking under the stress of use. In addition to the laundering process, the exposure of the mats to oxygen and ozone, either atmospheric or generated, during storage and use leads to cracking over time. The mat of the present invention may thus include an ozone-resistance additive, such as ethylene-propylene-diene monomer rubber (EPDM), as taught within U.S. Pat. No. 5,902,662, to Kerr, which provides enhanced protection to the rubber backing sheet against oxygen in order to substantially prolong the useful life of the mat. Such an additive also appears to provide a reduction in staining ability of such rubber backed mats upon contact with various surfaces, such as concrete, wood, and a handler's skin, just to name a few, as discussed in U.S. patent application Ser. No. 09 / 113,842 to Rockwell, Jr.

The inventive mat provides a long-lasting non-slip, cushioned carpeted article which provides comfort to users as well as significantly reduced changes of slipping, all in a one-step procedure. All of this translates into reduced cost for the consumer as costs to produce are lower and possible medical and insurance costs may also be reduced with the utilization of such specific mats which also work to remove dirt and moisture from the pedestrians' footwear.

Problems solved by technology

Moisture, dirt, and debris from out of doors easily adhere to such footwear, particularly in inclement weather and particularly in areas of grass or mud or the like.

Such unwanted and potentially floor staining or dirtying articles need to be removed from a person's footwear prior to entry indoors.

Such cleats are formed during a vulcanization step and have required a time-consuming procedure of placing the green (unvulcanized) rubber sheet on a molded silicone pad and then removing the same after vulcanization.

As a result, and particularly if the covered area is hard, the mat does not appreciably cushion the pedestrian's foot.

Such mats do not also provide cushioning characteristics with the same non-slip components, however.

To date, the prior art has neither taught nor fairly suggested such a combination of elements in a cushioned carpeted floor covering article.

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