Floor mat with concealed base member

Abstract

The invention relates to a washable multi-component magnetic floor mat with a concealed base member. The floor mat includes a textile member and a base member. The textile member and the base member are attached to each other by magnetic attraction. Magnetic attraction is provided by incorporating magnetic particles in the textile member and the base member. The textile members are designed to be contaminated, washed, and reused, providing desirable end-use applications in areas such as building access passageways. The invention eliminates the need to wash the base member of the floor mat, which results in environmental, cost and labor savings. Alignment and configuration of the textile member with the base member in an efficient manner are also described herein.

Description

[0001] This application is a divisional application of PCT application filed on July 21, 2017, with application number PCT / US2017 / 043226, Chinese national application number 201780051703.9, entitled "Floor Mat with Concealed Base Member". Technical Field

[0002] This invention relates to a washable, multi-component magnetic floor mat with a concealed base component. The floor mat comprises a textile component and a base component. The textile component and the base component are attached to each other by magnetic attraction. Magnetic attraction is provided by incorporating magnetic particles into both the textile component and the base component. The textile component is designed to be soiled, washed, and reused, thus providing ideal end-use applications in areas such as building entrance passageways. This invention eliminates the need for a washable base component for the floor mat, resulting in environmental, cost, and labor savings. The efficient alignment and configuration of the textile component and base component are also described herein. Background Technology

[0003] High-traffic areas (such as entrances to buildings, restrooms, restrooms, etc.) typically have the highest rates of floor covering contamination. Currently, washable one-piece mats with a plush surface are available in these locations. The washable multi-component magnetic floor mat of this invention is designed to replace these one-piece mats. The use of washable multi-component floor mats in high-traffic, highly contaminated areas is practical because soiled textile components can be easily removed, washed, and reinstalled. This eliminates the need to clean the base portion of the floor mat. The reduction in weight and volume of the textile components from one-piece mats to multi-component mats saves significant amounts of water and energy for cleaning facilities and provides labor savings for service personnel transporting and installing the floor mats.

[0004] Furthermore, because the attachment and / or alignment mechanisms can utilize significant forces to hold the top and bottom components of the floor mat together, the initial alignment and configuration of the top textile component on the base component can be challenging. The large surface area of ​​contact between the two components amplifies this problem. In this respect, even if the adhesion 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 extremely difficult. Without correction, misalignment of the textile with the base component can create tripping hazard within the floor mat and may be aesthetically unappealing.

[0005] This invention overcomes these challenges by using alignment and configuration techniques that rely on temporarily reducing the surface area of ​​the textile components and / or the substrate components and / or temporarily reducing the adhesion between the textile components and the substrate components. Therefore, the washable multi-component magnetic floor mat of this invention is an improvement over prior art one-piece floor mats. Summary of the Invention

[0006] In one aspect, the present invention relates to a multi-component floor mat comprising: (a) a textile component comprising (i) a first layer of tufted carpet formed by tufting face yarns through a main backing layer, and (ii) a second layer of vulcanized rubber material containing magnetic particles; and (b) a base component comprising (i) vulcanized rubber containing magnetic particles or (ii) vulcanized rubber with a magnetic coating. The textile component and the base component are releasably attached to each other by magnetic attraction; and the textile component is at least 5% larger than the base component in both length and width.

[0007] In another aspect, the present invention relates to a method for cleaning a multi-component floor mat, the method comprising the steps of: (a) providing a multi-component floor mat as described herein; (b) removing textile components from a base component; (c) cleaning the textile components in an industrial, commercial or household washing machine; and (d) reinstalling the textile components onto the base component.

[0008] In another aspect, the present invention relates to a method of manufacturing a multi-component floor mat, the method comprising the steps of: (a) tufting face yarns into a main backing material to form a tufted carpet; (b) optionally, printing the tufted carpet; (c) providing an unvulcanized rubber layer containing magnetic particles; (d) adhering the tufted carpet to the unvulcanized rubber layer containing magnetic particles by a rubber vulcanization process to form a washable textile component with a vulcanized rubber backing; (e) cutting the textile component into a shape and size in which the textile component is at least 5% larger in length and width than the base component; (f) providing a base component comprising (i) vulcanized rubber and magnetic particles or (ii) vulcanized rubber and a magnetic coating; and (g) attaching the textile component to the base component by magnetic attraction.

[0009] In another aspect, the present invention relates to a method for installing a floor mat, the method comprising the steps of: (a) providing a base member, wherein the base member includes at least one alignment mechanism; (b) providing a textile member, wherein the textile member comprises a tufted carpet and includes at least one alignment mechanism that functions in correspondence with at least one alignment mechanism of step (a), wherein the base member and the textile member are releasably attachable to each other by said at least one alignment mechanism, and wherein the textile member is at least 5% larger than the base member in length and width; (c) aligning the textile member with the base member, wherein the alignment step is performed by using the alignment mechanism; and (d) configuring the textile member onto the base member.

[0010] In another aspect, the present invention relates to a multi-component floor mat comprising: (a) a textile component comprising (i) a first layer of tufted carpet formed by tufting face yarns through a main backing layer, and (ii) a second layer of vulcanized rubber material containing magnetic particles; (b) a base component comprising (i) vulcanized rubber containing magnetic particles or (ii) vulcanized rubber with a magnetic coating; wherein the textile component and the base component are releasably attached to each other by magnetic attraction, and wherein the textile component is at least 5% larger than the base component in length and width; and (c) at least one alignment or configuration mechanism.

[0011] In another aspect, the present invention relates to a multi-component floor mat comprising: (a) a textile component comprising (i) a first layer of tufted carpet formed by tufting face yarns through a main backing layer, and (ii) a second layer of vulcanized rubber material containing magnetic particles; and (b) a base component comprising (i) a material selected from the group consisting of concrete, cellulose-containing materials, metals, thermoplastic materials, thermosetting materials, and any combination thereof, and (ii) magnetic particles or a magnetic coating applied to the base component; wherein the textile component and the base component are releasably attached to each other by magnetic attraction, and wherein the textile component is at least 5% larger than the base component in both length and width.

[0012] In another aspect, the present invention relates to a multi-component floor mat comprising: (a) a textile component including (i) a first layer of tufted carpet formed by tufting front fibers through a main backing layer, and (ii) at least one surface attachment device; and (b) a base component comprising at least one surface attachment device; and wherein the textile component and the base component are releasably attached to each other by said at least one surface attachment device; wherein the textile component and the base component also contain at least one edge attachment device; and wherein the textile component is at least 5% larger than the base component in both length and width. Attached Figure Description

[0013] Figure 1A This is an extended side view of the textile components of a multi-component floor mat.

[0014] Figure 1B This is an extended side view of another embodiment of the textile component of a multi-component floor mat.

[0015] Figure 1C This is a top perspective view of one embodiment of the back of the textile component of the floor mat.

[0016] Figure 1D This is an extended angle view of one embodiment of a multi-component floor mat, showing... Figure 1C The textile components are partially pulled up from the base components.

[0017] Figure 2 This is a top perspective view of another embodiment of a multi-component floor mat, in which textile components are partially pulled up from the base components.

[0018] Figure 3A This is a top perspective view of the back of the textile component of a multi-component floor mat, illustrating the recessed boundary area along the edge of the textile component.

[0019] Figure 3B This is a top perspective view of a multi-component floor mat, illustrating... Figure 3A The textile components are partially pulled up and combined with the base components.

[0020] Figure 4A This is a top perspective view of another embodiment of the back of the textile portion of an example rounded corner multi-component floor mat.

[0021] Figure 4B This is a top perspective view of a multi-component floor mat, illustrating... Figure 4A The textile components are partially pulled up and combined with the base components.

[0022] Figure 5A This is a top perspective view of the back of a multi-component floor mat, illustrating that the textile component has raised, three-dimensional herringbone rubber protrusions on its back and the base component has a corresponding herringbone receiving area at one end of the base component.

[0023] Figure 5B The example illustrates the alignment of the back of a multi-component floor mat and the textile component with the base component.

[0024] Figure 6AThis is a top perspective view of the back of a multi-component floor mat, illustrating that the textile component has raised, three-dimensional, semi-circular rubber protrusions on its back and the base component has a corresponding semi-circular receiving area at one end of the base component.

[0025] Figure 6B The example illustrates the alignment of the back of a multi-component floor mat and the textile component with the base component.

[0026] Figure 7 This is a schematic diagram of one embodiment of the manufacturing process of a multi-component floor mat.

[0027] Figure 8 This is a schematic diagram illustrating the magnetic arrangement properties of the magnetic particles of the present invention.

[0028] Figure 9A This is a schematic diagram illustrating the steps of installing the multi-component floor mat of the present invention.

[0029] Figure 9B This is a schematic diagram illustrating the steps of installing the multi-component floor mat of the present invention.

[0030] Figure 9C This is a schematic diagram illustrating the steps of installing the multi-component floor mat of the present invention.

[0031] Figure 9D This is a schematic diagram illustrating the steps of installing the multi-component floor mat of the present invention.

[0032] Figure 9E This is a schematic diagram illustrating the steps of installing the multi-component floor mat of the present invention.

[0033] Figure 9F This is a schematic diagram illustrating the steps of installing the multi-component floor mat of the present invention.

[0034] Figure 10A This is an extended side view of the adhesive-containing base component of a multi-component floor mat.

[0035] Figure 10B This is an extended side view of another embodiment of a multi-component floor mat containing an adhesive base component. Detailed Implementation

[0036] The invention described herein is a washable, multi-component magnetic floor mat. The floor mat comprises textile components and a base component. The textile components and the base component are attached to each other by magnetic attraction.

[0037] In this invention, the base component of the floor mat is completely covered by the textile component. Typically, the textile component will be lighter than the base component. Conversely, the base component will be heavier than the textile component.

[0038] like Figure 1AAs shown, textile component 100 may include a tufted carpet 125. The tufted carpet 125 includes a backing layer 117 and face yarns 115. The backing layer 117 is typically included in the tufted carpet to provide stability to the face yarns. The materials comprising the face yarns 115 and the backing layer 117 may be independently selected from synthetic fibers, natural fibers, man-made fibers using natural components, inorganic fibers, glass fibers, and blends of any of the foregoing. By way of example only, synthetic fibers may include polyesters, acrylics, polyamides, polyolefins, polyaramids, polyurethanes, or any blends thereof. More specifically, polyesters may include polyethylene terephthalate, polyethylene terephthalate, polybutylene terephthalate, polylactic acid, or any combination thereof. Polyamides may include nylon 6, nylon 6,6, or combinations thereof. Polyolefins may include polypropylene, polyethylene, or combinations thereof. Polyarylamides may include poly(p-phenylene terephthalamide) (i.e., Kevlar®), poly(m-phenylene terephthalamide) (i.e., Nomex®), or combinations thereof. Exemplary natural fibers include wool, cotton, flax, ramie, jute, sesame, silk, hemp, or any blend thereof. Exemplary man-made materials using natural ingredients include regenerated cellulose (i.e., rayon), lyocell, or any blend thereof.

[0039] The materials comprising the face yarn 115 and the main backing layer 117 may be formed from staple fibers, filament fibers, cut-film fibers, or any combination thereof. The fibers may be exposed to one or more texturing processes. The fibers can then be spun or otherwise combined into yarn, for example, by ring spinning, free-end spinning, air-jet spinning, vortex spinning, or any combination thereof. Therefore, the material comprising the face yarn 115 typically includes interwoven fibers, interwoven yarns, loops, or any combination thereof.

[0040] The materials comprising the face yarn 115 and the main backing layer 117 may include fibers or yarns of any size, including fine denier fibers or yarns (fibers or yarns with a single filament of less than one denier). The denier number of the fibers or yarns can range from less than about 0.1 denier / filament to about 2000 denier / filament, or more preferably from less than about 1 denier / filament to about 500 denier / filament.

[0041] Furthermore, the materials comprising the face yarn 115 and the main backing layer 117 may comprise, in part or in whole, multi-component or bi-component fibers or yarns with various configurations, such as, for example, island-type, core-sheath type, side-by-side type, or pie type. Depending on the configuration of the bi-component or multi-component fibers or yarns, the fibers or yarns may be separated along their length by chemical or mechanical action.

[0042] Additionally, the face yarn 115 and the main backing layer 117 may include additives co-extruded therein, which may be pre-coated with any number of different materials, including those listed in more detail below, and / or may be dyed or colored to provide additional aesthetic features to the end user, said dyeing or coloring using any type of colorant (such as, for example, poly(oxyalkylenated) colorants) as well as pigments, dyes, hues, etc. Other additives may also be present on and / or within the target fibers or yarns, including antistatic agents, brightening compounds, nucleating agents, antioxidants, UV stabilizers, fillers, wrinkle-free finishing agents, softeners, lubricants, and curing accelerators, etc.

[0043] The face yarn 115 can be dyed or undyed. If the face yarn 115 is dyed, it can be solution-dyed. The weight, pile height, and density of the face yarn will vary depending on the aesthetic and performance requirements of the end use of the floor mat. Figure 1A In the center, the front yarn 115 is shown with a terry loop structure. See also Figure 1B The textile component 100 is shown with a cut pile structure using the front yarn 115. Of course, it should be understood that a front yarn structure including a combination of terry loops and cut pile can also be used.

[0044] The main backing layer 117 can be any suitable main backing material. The main backing layer 117 may comprise woven, nonwoven, or knitted materials, or any combination thereof. The general purpose of the main backing layer 117 is to support the tufting of the face yarns 115. In one aspect, the main backing layer 117 is a nonwoven polyester spunbond material. A commercially available example of polyester spunbond material is Lutradur® from Freudenberg Nonwovens of Weinheim, Germany. In another aspect, plain-woven polyester tape, such as Isis™ from Propex of Chattanooga, TN, can be used. Additionally, Colback® nonwoven backing material is also suitable. If desired, a main backing layer made of fabric tape with attached short fibers or nonwoven fabric can be used. Moreover, stitch-bonded and knitted polyester fabrics can be used.

[0045] Tufted carpet 125, comprising the tufted yarns in the front yarns of the main backing layer, can be heat-stabilized to prevent dimensional changes in the finished mat. Heat stabilization, or heat setting, typically involves applying heat to the material above its glass transition temperature but below the melting temperature of the components. The heat causes the polymer components to release internal tension and improves the internal structural ordering of the polymer chains. The heat stabilization process can be carried out under tension or in a relaxed state. Tufted carpets are sometimes also stabilized to allow the yarns and main backing to shrink prior to the mat manufacturing process.

[0046] In one aspect of the invention, a tufted carpet comprises yarn tufted into a fabric, which is then injection- or fluid-dyed and bonded to a rubber layer or washable latex backing. The carpet yarn may be selected from nylon 6; nylon 6,6; polyester; and polypropylene fibers. The yarn is tufted into a woven or nonwoven substrate. The yarn can have any pile height and weight required to support the print. The tufted carpet can be printed using any printing process. In one aspect, injection dyeing may be used to print the tufted carpet.

[0047] The printing ink will contain at least one dye. The dye can be selected from acid dyes, direct dyes, reactive dyes, cationic dyes, disperse dyes, and any mixtures thereof. Acid dyes include azo, anthraquinone, triphenylmethane, and xanthine types. Direct dyes include azo, violet, thiazole, dioxazine, and phthalocyanine types. Reactive dyes include azo, anthraquinone, and phthalocyanine types. Cationic dyes include thiazole, methane, anthocyanin, quinolone, xanthracene, azathene, and triarylmethane. Disperse dyes include azo, anthraquinone, nitrodiphenylamine, naphthimide, naphthoquinone imide, and methane, triarylmethane, and quinoline types.

[0048] As is known in the field of textile printing, the specific dye selection depends on the washable textile component being printed, which contains one or more fiber types. For example, disperse dyes are typically used for printing polyester fibers. Alternatively, cationic dyes can be used for materials made from cationic dyeable polyester fibers.

[0049] The printing method of the present invention uses a jet dyeing machine or a digital printing machine to place printing ink on the surface of a mat at predetermined locations. A suitable and commercially available digital printing machine is the Millitron® digital printing machine, available from Milliken & Company of Spartanburg, South Carolina. The Millitron® machine uses a series of jets having a continuous flow of dye liquid that can be deflected by a controlled air jet. This series of jets, or gunbars, is typically stationary. Another suitable and commercially available digital printing machine is the Chromojet® carpet printing machine, available from Zimmer Machinery Corporation of Spartanburg, South Carolina. In one aspect, tufted carpets prepared according to the methods disclosed in USPN 7,678,159 and USPN 7,846,214 (both Weiner) can be printed using the jet dyeing equipment described and enumerated herein.

[0050] Viscosity modifiers may be included in printing ink compositions. Suitable viscosity modifiers that can be used include known natural water-soluble polymers, such as polysaccharides (e.g., starches derived from corn and wheat, gum arabic, locust bean gum, tragacanth gum, guar gum, guar bean flour, polygalactomannan gum, xanthan gum, alginate, and tamarind); protein substances (e.g., gelatin and casein); tannins; and lignin substances. Examples of water-soluble polymers also include synthetic polymers (e.g., known polyvinyl alcohol compounds and polyethylene oxide compounds). Mixtures of the above-mentioned viscosity modifiers may also be used. Polymer viscosity is measured at elevated temperatures when the polymer is in a molten state. For example, viscosity can be measured in centipoises at elevated temperatures using a Brookfield Thermosel apparatus from Brookfield Engineering Laboratories of Middleboro, MA. Alternatively, polymer viscosity can be measured using a parallel plate rheometer, such as the one manufactured by Haake from Rheology Services of Victoria Australia.

[0051] After printing, the tufted carpet can be vulcanized with a rubber backing. When the base component is supplied in a tray construction, the thickness of the rubber ensures that the height of the finished textile component is substantially the same as the height surrounding the base component. Once vulcanized, the textile component can be pre-shrinked by washing before being installed on the base component.

[0052] The textile component 100 also includes a magnetic coating 110. The magnetic coating 110 is present on the surface of the textile component 100 opposite to the face yarn 115. The magnetic coating is at least one surface attachment device. The application of the magnetic coating 110 to the tufted carpet 125 will be described in more detail below. The resulting textile component 100 is washable and exhibits sufficient tufting lock for normal end-use applications. In an alternative embodiment of the invention, the textile component may be a disposable textile component, which is removed and disposed of or recycled and then replaced with a new textile component for attachment to the base component.

[0053] Once the textile component is manufactured, it will be custom-cut to fit the base component. The textile component can be cut using a computer-controlled cutting device (such as a Gerber machine). Mechanical dye cutters, hot knives, straight blades, rotating blades, water jets, lasers, and combinations thereof can also be used for cutting. 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 than the base component. For example, the textile component will have a greater length and / or width than the base component. In one aspect, the textile component may be at least 5%, at least 10%, at least 20%, or at least 30% wider than the base component. Alternatively, the textile component may be at least 5%, at least 10%, at least 20%, or at least 30% longer than the base component. Any combination of widths and lengths disclosed herein may be suitable for use as the dimensions of the multi-component floor mat of the present invention.

[0054] Figure 1C An embodiment of the textile assembly of the multi-component floor mat of the present invention is illustrated. The back surface 101 of the textile component 100 shows elongated elliptical protrusions 103. The elongated elliptical protrusions 103 are spaced apart along the inner edge of the textile component 100. The elongated elliptical protrusions abut from the flat surface of the textile component 100 and are three-dimensional in space. The elongated elliptical protrusions 103 may be spaced apart from each other in a uniform or non-uniform configuration. In one aspect, the elongated elliptical protrusions 103 comprise rubber and are attached to the textile component 100 by means of a heat and pressure rubber vulcanization process.

[0055] Figure 1D An example is a multi-component floor mat 1 comprising a textile component 100 and a base component 150. An elongated elliptical protrusion 103 of the textile component 100 is aligned with an elongated elliptical receiving area 105 of the base component 150. When the textile component 100 is aligned with the base component 150, the elongated elliptical protrusion 103 engages with the open space provided by the elongated elliptical receiving area 105.

[0056] Although not in Figure 1C and 1D The invention is specifically illustrated, but the floor mat may also include at least one edge attachment device. This at least one edge attachment device may be included in the structure of the floor mat to help secure and align the textile components of the mat to the base component of the mat. Therefore, both the textile components and the base component may further include at least one edge attachment device. Edge attachment and / or alignment devices include hook and loop fastening systems (such as Velcro® fasteners), mushroom-shaped hook fastening systems (such as 3M's Dual Lock), and more. TMFasteners, etc., and combinations thereof. For example, the loop portion of a hook and loop fastening system can be attached to a textile component. A corresponding hook portion of a hook and loop fastening system can be attached to a base component. Alternative arrangements of loop and loop portions are also contemplated within the scope of the invention, wherein the loop portion is attached to the base component and the hook portion is attached to the textile component. Additionally, edge attachment devices (e.g., hook and loop fastening systems) can be used alone without an alignment mechanism to attach the textile component to the base component. Edge attachment devices can be present on one edge, two edges, three edges, or all four edges of the textile component and / or the base component.

[0057] Figure 2 Another embodiment of the multi-component floor mat of the present invention is illustrated. The floor mat 2 includes a textile component 200 and a base component 250. A circular protrusion 203 of the textile component 200 is aligned with a circular receiving area 205 of the base component 250. When the textile component 200 is aligned with the base component 250, the circular protrusion 203 engages with the open space provided by the circular receiving area 205. Any protrusion described herein for securing the textile component to the base component is also referred to as a surface attachment device, together with a magnetic coating, and any combination thereof.

[0058] The base component of the floor mat can be flat and without recessed areas (i.e., the base component is trayless). The flat base component is made from a sheet of material (such as rubber) that has been cut to the desired shape and vulcanized. The base component can be formed as a single integral article in a single molding process. Examples of suitable materials for forming the base component are elastomers, such as natural and synthetic rubber materials, thermoplastic and thermosetting resins, and metals. Rubber materials can be selected from the group consisting of: nitrile rubber (including dense nitrile rubber, foamed nitrile rubber, and mixtures thereof); polyvinyl chloride rubber; ethylene propylene diene monomer (EPDM) rubber; vinyl rubber; thermoplastic elastomers; and any mixtures thereof. In one aspect, the base component typically comprises at least one rubber material. The rubber material may contain 0% to 40% recycled rubber material.

[0059] Figure 3A Another embodiment of the textile component of the floor mat of the present invention is illustrated. Figure 3AThe image shows a textile component 300 with its back surface 301 facing the observer. The textile component 300 is shown with a corner of approximately 90° in shape, i.e., the two sides converge to form an angle of approximately 90°. A boundary 370 is present on the back surface 301. The boundary 370 is attached to the back surface 301. The boundary 370 is a raised three-dimensional region that exists in a continuous arrangement along all the inner edges of the textile component 300. In one aspect, the boundary 370 comprises rubber and is attached to the back surface 301 by a rubber vulcanization process involving heat and pressure. Although the boundary 370 is shown in a continuous configuration around all four inner edges of the textile component 300, it is contemplated that the boundary may exist only on one inner edge of the textile component, only on two inner edges of the textile component, or only on three inner edges of the textile component.

[0060] like Figure 3B As shown, the floor mat 3 exists in an arrangement in which the textile component 300 overlaps with the base component 350. The base component 350 is also shown, its corners formed by the two sides meeting at approximately 90°. The length and width of the textile component 300 are larger than the length and width of the base component 350. The corners of the textile component 300 are turned back to further illustrate how the two components fit together within a boundary 370.

[0061] Figure 4A Another embodiment of the textile component of the floor mat of the present invention is shown. Figure 4A The image shows a textile component 400 with its back surface 401 facing the observer. The textile component 400 is also shown with rounded corners. A boundary 470 is present on the back surface 401. The boundary 470 is attached to the back surface 401. The boundary 470 is a raised three-dimensional region that exists in a continuous arrangement along all edges of the textile component 400. In one aspect, the boundary 470 comprises rubber and is attached to the back surface 401 by a rubber vulcanization process involving heat and pressure. Although the boundary 470 is shown in a continuous configuration around all four edges of the textile component 400, it is conceivable that the boundary may exist only on one edge of the textile component, only on two edges of the textile component, or only on three edges of the textile component.

[0062] like Figure 4BAs shown, the floor mat 4 exists in an arrangement in which the textile component 400 overlaps with the base component 450. The base component 450 is also shown with rounded corners. The length and width of the textile component 400 are larger than the length and width of the base component 450. The base component 450 is visually invisible in its end-use application as a floor mat because it is completely covered by the textile component 400. The corners of the textile component 400 are turned back to further illustrate how the two components fit together within the boundary 470.

[0063] Figure 5A Another embodiment of the multi-component floor mat of the present invention is shown. The floor mat 5 includes a textile component 500 and a base component 550. The textile component 500 is shown with its back surface 501 facing the observer. The textile component 500 includes an alignment mechanism 503. In this case, the alignment mechanism 503 is a V-shaped three-dimensional region located at one end of the floor mat 5. In one aspect, the alignment mechanism 503 comprises rubber and is attached to the back surface 501 by a rubber vulcanization process involving heat and pressure. The base component 550 includes a cut-out area 505, which corresponds in size and shape to the alignment mechanism 503 of the textile component 550.

[0064] like Figure 5B As shown, the cutout area 505 of the base member 550 is tightly fitted onto the alignment mechanism 503 of the textile member 500. The floor mat 5 is arranged such that the textile member 500 is larger in size than the base member 550. Note that, to illustrate how the base member 550 and the textile member 500 are aligned together, the floor mat 5 is shown flipped over, with the front yarn facing the floor and the back facing the observer. The base member 550 is visually invisible in its final application as a floor mat because it is completely covered by the textile member 500.

[0065] Figure 6A Another embodiment of the multi-component floor mat of the present invention is illustrated. The floor mat 6 includes a textile component 600 and a base component 650. The textile component 600 is shown with its back surface 601 facing the observer. The textile component 600 includes an alignment mechanism 603. In this case, the alignment mechanism 603 is a semi-circular three-dimensional region located at one end of the floor mat 6. In one aspect, the alignment mechanism 603 comprises rubber and is attached to the back surface 601 by a rubber vulcanization process involving heat and pressure. The base component 650 includes a cut-out region 605 that corresponds in size and shape to the alignment mechanism 603 of the textile component 650.

[0066] like Figure 6BAs shown, the cutout area 605 of the base member 650 is tightly fitted onto the alignment mechanism 603 of the textile member 600. The floor mat 6 is arranged such that the textile member 600 is larger in size than the base member 650. Note that, to illustrate how the base member 650 and the textile member 600 are aligned together, the floor mat 6 is shown flipped over, with the front yarn facing the floor and the back facing the observer. The base member 650 is visually invisible in its final application as a floor mat because it is completely covered by the textile member 600.

[0067] In summary, the textile components and base components forming the floor mat of the present invention may include discontinuous alignment mechanisms for attaching the textile components to the base components, such as in Figure 1C and 1D The type shown. Alignment mechanisms are used to attach textile components to a base component. Alignment mechanisms may be present on both the textile component and the base component at locations including the inner edge of each component. This inner edge region may begin from the cut edge (or molded edge) of the component and be measured approximately 0.5 inches, or approximately 1.0 inch, or approximately 1.5 inches, or approximately 2.0 inches or greater towards the center of the component. As described above, Figure 1C , 1D Figures 5A to 6B show discontinuous alignment mechanisms present in areas along the inner edge portions of the textile component and the base component. Continuous alignment mechanisms may be present on the textile component of the floor mat of the present invention. As described above, Figure 3A and 3B The continuous alignment mechanism is shown to exist in the area along the inner edge portion of the textile component.

[0068] Alternatively, the alignment mechanism may be located at the outermost edge of the textile component of a multi-component floor mat. Figure 4A and 4B An example is provided of a continuous alignment mechanism present on a textile component of a floor mat. The alignment mechanism is located at the cut edge (or molded edge) of the textile component, forming an rim around the cut edge (or molded edge) of the textile component. The alignment mechanism exists along the periphery of the textile component. In this case, a multi-component floor mat includes a textile component with a continuous alignment mechanism and a smaller base component (i.e., a base component smaller 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 correspondingly provides increased tear resistance to the textile component. This tear resistance provides further wash durability to the textile component.

[0069] It is also contemplated that, within the scope of this invention, any combination of the examples shown in the figures and / or the elements described herein can be used to form the floor mat of this invention. For example, Figure 3A and Figure 5A The features shown in the example can be combined together in a floor mat. Or, in Figure 3A and Figure 6A The features illustrated can be combined together in a floor mat. In another aspect of the invention, Figure 1C Textile components can be combined with Figure 3B The base component assembly.

[0070] A continuous perimeter boundary can be applied to the textile component according to the following procedure. A rubber strip is placed overlapping the edge of a metal plate. The metal plate is placed on top of the sheet rubber and covered on all four sides by the strip rubber. The sheet rubber is bonded to the strip as the metal plate applies force to the rubber. This process can be performed at, for example, a temperature of 370°F and a pressure of 36 psi. However, depending on the rubber material chosen, the temperature can range from 200°F to 500°F, and the pressure can range from 10 psi to 50 psi. Using the recommended settings, the rubber can fully cure within 8 minutes. After the rubber strip is bonded to the sheet rubber, the metal plate is removed, leaving a void (i.e., a recessed area in the textile component) in which the base component will be placed. The textile component can be configured / installed and removed / unloaded from the base component multiple times. The continuous perimeter boundary can have a smooth or cleated surface or any other pattern (e.g., Megahold) to help keep the edges of the textile component on the floor. Note that in one aspect of the invention, at least a portion of the back side of the textile component is in direct physical contact with the floor.

[0071] The textile component and the base component can have the same dimensions (e.g., the same length and width), or the textile component can be larger in dimensions than the base component (e.g., a greater length and / or width). In the case where the textile component is larger in dimensions than the base component, the textile component may further include a visible rubber boundary along the edge (or perimeter) of the textile component. The presence of the boundary makes the floor mat similar to a conventional one-piece floor mat with a rubber boundary along its edge.

[0072] In another construction, the base member can have a gradually changing cross-section, providing a thickness gradient from its center to its edges. Furthermore, if the region defined by the boundary in the textile member is called a unit, a single textile member can have multiple units matching complementary features on the base member. The base member itself can be multi-segmented.

[0073] The textile component and the substrate component are attached to each other by magnetic attraction. Magnetic attraction is achieved by applying a magnetic coating to the textile component and / or the substrate component, or by incorporating magnetic particles into 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 the magnetic particles are contained within the vulcanized rubber of the substrate component. The reverse arrangement is also conceivable.

[0074] Magnetic coatings can be applied to textile components and / or substrate components using several different manufacturing techniques. Exemplary coating techniques include, but are not limited to, blade coating, pad coating, paint coating, spraying, roll-to-roll methods, troweling methods, extrusion coating, foam coating, pattern coating, print coating, lamination, and any combination thereof.

[0075] Figure 7 An embodiment of the manufacturing process of the textile component of the present invention is illustrated. An uncoated tufted carpet 725 is fed into a laminating belt 710. The belt moves through the coating zone to the laminating zone of the laminator. A magnetic coating 720 is fed laterally into the laminating belt 710. As the magnetic coating 720 is fed into the laminating belt 710, it passes under a doctor blade 730. The doctor blade 730 is adjusted to obtain the desired coating thickness. For example, a magnetic coating thickness of 25 mil may be required. After the magnetic coating 720 passes the doctor blade 730, it comes into contact with the tufted carpet 725. The magnetic coating 720 and the tufted carpet 725 are then moved laterally into a laminating press 740. The laminating press 740 is positioned above the laminating belt 710. The laminating press 740 is lowered onto the laminating belt 710, pressing the tufted carpet 725 and the magnetic coating 720 together. The laminating press 740 is heated, thus providing heat and pressure for the lamination process. The heat provided at this point in the lamination process also serves to cure any materials that may be contained within the magnetic coating, such as adhesive materials. After a predetermined amount of time, the laminator 740 is lifted from the lamination belt 710. The magnetic coating 720 is now laminated onto the tufted carpet 725 to form the textile component 750. In one respect, the laminator can operate at temperatures ranging from 200°F to 500°F and pressures from 10 psi to 50 psi, or even at 300°F and 36 psi.

[0076] In achieving magnetic attraction by incorporating magnetic particles into a rubber-containing layer, the following procedure can be used: (a) providing a material containing uncured rubber (such as nitrile rubber, SBR, or EPDM rubber), (b) adding magnetic particles to the uncured rubber, (c) mixing the particles with the rubber, and (d) forming the mixture from step “c” into a sheet and attaching it to the bottom of a textile component and / or representing a base component. The mixing in step “c” can be achieved using a rubber mixing mill.

[0077] supply Figure 8 Some terms used herein to illustrate various types of magnets and magnetization properties. In this application, magnetizability is defined as meaning that particles present in a coating or vulcanized rubber layer are permanently magnetized or can be permanently magnetized using an external magnet or electromagnet. Once the particles are magnetized, they permanently retain their magnetic response. Magnetizability that produces permanent magnetism broadly belongs to 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 to magnetic coatings and / or vulcanized rubber layers.

[0078] As used herein, magnetically receptive is defined as meaning that particles present in a coating and / or vulcanized rubber layer exhibit magnetic responsiveness only in the presence of an external magnet. A component containing magnetic particles is exposed to a magnetic field that aligns the dipoles of the magnetic particles. Once the magnetic field is removed from the vicinity, the particles become nonmagnetic and the dipoles are no longer aligned. Magnetic receptive behavior, or responsive magnetic behavior, broadly pertains to paramagnetic or superparamagnetic materials (particle size less than 50 nm).

[0079] Figure 8 This characteristic of reversible magnetic materials is illustrated in which the dipoles of a superparamagnetic or paramagnetic material are not aligned, but when exposed to a magnet, the dipoles align and point in the same direction, thus making the material magnetic. Non-limiting examples of materials exhibiting these characteristics include iron oxides, steel, iron, nickel, aluminum, or alloys of any of the aforementioned substances.

[0080] Other examples of magnetizable magnetic particles include BaFe3O4, SrFe3O4, NdFeB, AlNiCo, CoSm, and other rare earth metal-based alloys, and any mixtures thereof. Examples of magnetically inductive particles include Fe2O3, Fe3O4, steel, iron particles, and any mixtures thereof. Magnetically inductive particles can be paramagnetic or superparamagnetic. Magnetic particles are typically characterized as non-degradable.

[0081] In one aspect of the invention, the particle size of the magnetically inductive particles is in the range of 1 micrometer to 10 micrometers. For superparamagnetic materials, the particle size of the magnetically inductive particles can be in the range of 10 nm to 50 nm. For paramagnetic and / or ferromagnetic materials, the particle size of the magnetically inductive particles is typically greater than 100 nm.

[0082] Typically, the aforementioned magnetic materials exhibit magnetic attraction at any loading level. However, the magnetic attraction increases with increasing loading of the magnetic material. In one aspect of the invention, the magnetic field strength of the textile component on the substrate 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 at a weight of 25% to 95% by weight. In another aspect, the magnetic particle loading may be present in the magnetic coating applied to the textile component at a weight of 10% to 70% by weight. The magnetic particle loading may be present in the magnetic coating applied to the substrate component at a weight of 10% to 90% by weight.

[0084] Magnetic inductive particles can be present in a substantially uniform distribution within the vulcanized rubber layer of a textile component. In another aspect of the invention, it is contemplated that the magnetic inductive particles are present in a substantially non-uniform distribution within the rubber layer of the textile component. One example of non-uniform distribution includes a functionally graded particle distribution, wherein the particle concentration decreases at the surface of the textile component used for attachment to a substrate component. Alternatively, another example of non-uniform distribution includes a functionally graded particle distribution, wherein the particle concentration increases at the surface of the textile component used for attachment to a substrate component.

[0085] The magnetic attraction between the textile component and the base component can be altered by manipulating the surface area of ​​one or both. The surface of one or both components can be textured in a manner that increases the surface area of ​​the component. This manipulation allows for the customization of the magnetic attraction, which is not directly affected by the amount of magnetic particles present in the floor mat.

[0086] For example, the generally smooth (less surface area) bottom surface of a textile component typically generates a greater magnetic attraction to the top surface of a base component. Conversely, the less smooth (more surface area) bottom surface of a textile component (e.g., those with corrugations or any other deformable surfaces) typically generates a smaller magnetic attraction to the top surface of a base component. Of course, the opposite arrangement can also be considered, where the base component includes deformable surfaces. Furthermore, the two component surfaces can be deformed in such a way that the magnetic attraction is manipulated to suit the final use of the floor mat of the present invention.

[0087] As described above, magnetic particles can be incorporated into the floor mat of the present invention by applying a magnetic coating to the surface of the textile component, or by including the particles in the textile material and / or the rubber material of the base component prior to vulcanization. When introduced by a magnetic coating, an adhesive material is typically included. Therefore, the magnetic coating typically comprises at least one type of magnetic particles and at least one adhesive material.

[0088] Adhesive materials are typically selected from thermoplastic elastomers and / or thermoplastic vulcanized rubbers. Examples include urethane-containing materials, acrylate-containing materials, silicone-containing materials, and any mixtures thereof. Barium ferrite, strontium ferrite, neodymium, and other rare earth metal-based alloys can be mixed with suitable adhesives for coating onto textiles and / or substrates.

[0089] In one respect, the adhesive material will exhibit at least one of the following properties: (a) glass transition temperature (T g (a) below 10°C; (b) Shore A hardness in the range of 30 to 90; and (c) softening temperature above 70°C.

[0090] In one aspect, an acrylate- and / or urethane-containing adhesive system is combined with Fe3O4 to form the magnetic coating of the present invention. The ratio of Fe3O4 to acrylate and / or urethane adhesive is in the range of 40-70%:60:30% (by weight). The thickness of the magnetic coating can be in the range of 10 mil to 40 mil. This magnetic coating exhibits flexibility without any cracking problems.

[0091] After the magnetic particles are applied to or incorporated into textile components and / or substrate components, the particles need to be magnetized. Magnetization can occur during or after the curing process. For the chosen adhesive material and / or for the chosen rubber material, curing is typically required.

[0092] During the curing process, magnetizable particles are mixed with a suitable adhesive and applied to the substrate to be magnetized using a coating technique. Once coating is complete, the particles are magnetized in the presence of an external magnet during the curing process. The component containing the magnetic particles is exposed to a magnetic field that aligns the dipoles of the magnetic particles, locking them in situ until the adhesive cures. The magnetic field is preferably installed online as part of the manufacturing process. However, the magnetic field can exist as a separate entity from the rest of the manufacturing equipment.

[0093] Alternatively, the magnetic particles can be magnetized after the curing process. In this case, magnetizable particles are added to an adhesive material and applied to the textile component and / or substrate 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 can be accomplished through direct or indirect contact with the coated substrate. For example, direct contact with the permanent magnet may occur by rolling the permanent magnet across the coated substrate. The magnet may be rolled once or multiple times (e.g., 10 times). The permanent magnet may be provided online with the manufacturing process or it may be present separately from the manufacturing equipment. Indirect contact may include situations where the coated substrate is close to the permanent magnet but does not contact or touch it.

[0094] Depending on the size, strength, and domains of the magnetic poles on the permanent magnet (or electromagnet), it can magnetize the magnetizable coating to values ​​between 10 and 5000 gauss, or close to the maximum gauss value of the magnetizable medium. Once the coating is magnetized, it typically remains permanently magnetized.

[0095] Within the scope of this invention, it can be further envisioned that the base component of a multi-component floor mat comprises any substance including a magnetic material. The base component does not necessarily contain vulcanized rubber. Instead, the base component can comprise concrete, cellulosic materials (e.g., wood), metal, thermoplastic materials, thermosetting materials, etc., and combinations thereof. In one example, the base component can be the floor itself to which the textile components are to be mounted. Here, the floor will include at least one magnetic material for attaching the textile components to the floor. The textile components can then be laid directly on the floor to which at least one magnetic material is applied. Suitable magnetic materials include any magnetic materials previously described herein. In one aspect, the magnetic material can be incorporated into a coating composition and applied to the floor. Alternatively, electromagnetic forces can be applied to the area where the textile components are to be mounted. Any of these magnetic features will provide the necessary adhesion between the textile components and the floor without requiring a vulcanized rubber base component.

[0096] In another aspect of the invention, the base member can be fixed to the floor surface using an adhesive composition. Figure 10A and 10B Two different embodiments of the adhesive-containing base member 1500 are illustrated. For example... Figure 10A As shown, the substrate member 150 includes magnetic particles 111 and an adhesive layer 153. In another embodiment, Figure 10BAn example is a base member 150, wherein magnetic particles 111 are contained in a magnetic coating 160 on one of its surfaces and an adhesive composition 153 is on its opposite surface (the surface facing the floor). The floor surface can be a hard surface (e.g., concrete, wood, vinyl, tile, etc.), or it can be a carpeted surface (e.g., a pile carpet with cut pile and / or terry loops, a wide-width carpet, etc.). The adhesive composition can be a pressure-sensitive adhesive material (including those that allow the base member to be repositioned), an adhesive material comprising an elastomer of rosin ester and a water-based or solvent-based acrylic polymer, or an elastomer material comprising natural rubber or nitrile rubber or silicone rubber with a suitable tackifier. The adhesive composition can be the sole material used to attach the base member to the floor surface, or it can be combined with additional mechanical or chemical means for attaching the base member to the floor surface.

[0097] The floor mat of the present invention can have any geometry or size required for its end-use application. The longitudinal edges of the floor mat can have the same length and width, thus forming a square. Alternatively, the longitudinal edges of the floor mat can have different dimensions, such that the width and length are not the same. Alternatively, the floor mat can be circular, hexagonal, etc. As a non-limiting example, the floor mat of the present invention can be manufactured in any current industry standard size, including 2 feet × 4 feet, 3 feet × 4 feet, 3 feet × 5 feet, 4 feet × 6 feet, 3 feet × 10 feet, etc.

[0098] The washable floor mats of this invention can be exposed to post-processing steps. For example, chemical treatments such as stain removal, stain inhibition, antibacterial, and anti-bleaching can be applied to the washable mats. Mechanical post-processing may include cutting, shearing, and / or napping the surface of the washable multi-component floor mat.

[0099] Performance requirements for commercial carpets include a mix of extensively documented standards and industry-known tests. Tuft bind of pile yarn floor coverings (ASTM D1335) is one such performance test specified by organizations such as the General Services Administration. Achieving a tuft bind value greater than 4 lbs is desirable, and even more so, greater than 5 lbs.

[0100] Delamination resistance of the second backing of pile yarn floor coverings (ASTM D3936) is another standard test. Achieving a delamination resistance value of more than 2 lbs is desirable, and exceeding 2.5 lbs is even more desirable.

[0101] The pilling and fuzzing resistance test (ITTS 112) is a performance test known in industry and to those skilled in the art. Pilling and fuzzing resistance tests are generally used to predict how quickly a carpet will pill, fuzz, and prematurely age over time. The test uses a small roller covered with hooks and loop fasteners. The hook material is Hook 88 from Velcro of Manchester, NH, and the roller weighs 2 pounds. Without additional pressure, the hook-covered roller rolls back and forth across the tufted carpet surface. Carpets are graded from 1 to 5. A grade of 5 indicates no change or a new carpet appearance. Grades less than 3 generally indicate unacceptable wear performance.

[0102] Other performance / wear tests include the Hexapod Tumbler (ASTM D-5252 or ISO / TR 10361). This test is designed to simulate repeated pedestrian traffic over time. 12,000 cycle counts have been correlated with ten years of normal use. The test is graded on a gray scale of 1 to 5 after 12,000 cycles, with 2.5 = moderate, 3.0 = heavy, and 3.5 = severe. Another performance / wear test includes the radiant panel test. According to ASTM E 648-06, some commercial ceramic tiles struggle to achieve a Class I rating (mean critical radiant flux > 0.45 = Class I, the highest rating).

[0103] The textile components of the floor mat can be washed or cleaned in industrial, commercial, or household washing machines. Ideally, the textile components should withstand 200 commercial washes without structural damage.

[0104] Figures 9A-9F An example of the installation method of the multi-component floor mat of the present invention is provided. Figure 9A A person (“installer”) 901 is shown preparing to install a multi-component floor mat according to the invention. The installer 901 is shown standing on a base member 950 and holding a textile member 910. Arrows indicate the direction of the force applied by the installer 901 to the textile member 910 in order to prepare the components of the floor mat for installation. Figure 9B This is another view of the installation process, showing the textile component 910 moving closer to align with the base component 950. Figure 9C This is another view of the installation process, showing the textile component 910 moving closer to align with the base component 950. The installer 901 holds the textile component 910 such that the pile carpet faces away from the base component 950 and the edge attachment device faces the base component 950. The installer 901 has aligned one edge of the textile component 910 with the base component 950. Figure 9DThe image shows installer 901 lowering textile component 910 onto base component 950. The arrow again indicates the direction of the force applied by installer 901 to textile component 910. Figure 9E The textile component 910 is shown being almost completely lowered onto the base component 950 by the installer 901. The arrow again indicates the direction of the force applied to the textile component 910 by the installer 901. Figure 9F The multi-component floor mat 900 is shown after installation by installer 901. Textile component 910 is properly aligned and configured onto base component 950. Installer 901 can easily install the multi-component floor mat 900 while remaining in a standing position (i.e., feet on the floor; not his / her hands and / or knees) and does not need to adjust and / or realign the textile component 910 with the base component 950.

[0105] like Figures 9A-9F As shown, the installer of the multi-component floor mat simply moves the textile component on top of the base component, aligning it with the left and right alignment marks to achieve horizontal alignment. The textile component then automatically locks onto the alignment end with near-perfect angular and vertical alignment to the base component. Once the alignment end is locked to the base component, the installer can then determine the tension on the textile component by pulling it onto the base component and using a second set of alignment marks to position the textile component near the proximal end of the base component. The result is near-perfect vertical, horizontal, and angular alignment of the textile component with the base component. The installation of the multi-component floor mat is quick and can be achieved by an installer who can remain standing (e.g., with feet flat on the floor).

[0106] like Figures 9A-9F As further exemplified, the installation of the floor mat may include moving the textile component to the base component by dragging it. The textile component may be dragged to the base component until the edge attachment device of the textile component (e.g., the loop portion of the edge attachment device) makes physical contact with the edge attachment device of the base component (e.g., the hook portion of the edge attachment device). In one aspect, the dragging motion may continue until the edge attachment device of the textile component (e.g., the loop portion of the edge attachment device) makes lateral side-by-side contact with the edge attachment device of the base component (e.g., the hook portion of the edge attachment device).

[0107] The following additional alignment and configuration techniques can be used to install multi-component floor mats: In the first case, it has been found that if the upper part is rolled up in a fairly tight roll (facing inwards) and then placed on the substrate, the overall attraction is reduced to the point that the installer can slide the roll sufficiently to allow for proper alignment with the substrate using the exposed end of the roll as a guide. This method is primarily used for small two-part mats. Alignment marks can be placed on the substrate to aid in top alignment.

[0108] The second method uses the first method but incorporates a removable temporary "cover" to reduce the attraction. This is achieved by using a film or paper placed on the base, between the top of the roll and the base, only in the area where the top of the roll will contact. Since the total area is greatly reduced by rolling, and the force per unit area is reduced by the cover, it is now easier to move the roll back and forth to achieve alignment. Once aligned, the film or paper is removed.

[0109] The third method (an improvement on the removable cover method) uses a cover that is permanently installed and selectively covers only the most critical area—the area directly beneath the roll—leaving only the area near the edge of the pad. For example, if a magnetic substrate and an iron-containing top are used, a thin, magnetically inductive material called "FlexIron" can be used. This material significantly reduces magnetic forces while adhering strongly to the magnetic substrate and therefore not shifting; the result is a permanently installed "cover." The size and position of this cover allow it to cover only the magnetic forces directly beneath the roll, leaving only the edges exposed to maintain higher forces where the edges must resist kicking. The roll and its edges can still be manually aligned with the substrate, but alignment is now relatively easy and can be done quickly. Additionally, the substrate components can be selectively magnetized so that the covered portion is not magnetized. The periphery around the covered portion and the periphery of the edge attracting the top sheet can be selectively magnetized.

[0110] The fourth method can be used in conjunction with any of the methods described above or alone. This method relies on positioning pins or rings capable of capturing two or more corners of the carpet. The pin is located on the base or top, and associated with the pin are complementary holes in the top or base. Once inserted, the pin captures one half of the carpet, preventing the two halves from separating without considerable force. Once captured, the top mat can be picked up and gently placed down to align with the base. If the top of the mat is disturbed or misaligned in place, realignment can be performed relatively easily by simply picking up the top and placing it back in place. When used in conjunction with methods 1-3 above, alignment is now not only easy but also quick and accurate. Furthermore, if care is taken to ensure that the covered area is always below the alignment pin and is large enough that alignment / configuration is always easy if the top of the fabric is picked up.

[0111] The fifth method is an improvement on number 4, in which the attachment pin is hidden and not visible from the surface of the top of the pad. This is achieved by molding or bonding a tightly fitting ring or strong magnet into or to the back of the top pad, or by using a ring with a strong magnet—all of which relate to complementary holes in the substrate, with or without magnets. This method can also be used in combination with any of methods 1-3.

[0112] Another variation includes lines or patterns of magnetic pairs on one end of the textile component, which "fasten" the textile component and the substrate component together. These pairs can be spaced apart, making individual alignment highly advantageous than any other attractive force. The magnetic pairs can be arranged with opposing magnetic poles, and the different pairs in the lines or patterns have alternating intervals to prevent misalignment.

[0113] Therefore, the multi-component floor mat of the present invention offers many advantages over the prior art. The textile component is easily configured / installed with the base component by dragging it onto the base component until the alignment mechanism contacts and secures it in place. Furthermore, the textile component can be easily picked up / unloaded from the base component by field service personnel (e.g., installers) by lifting its edge or corner and removing it from the base component. The textile component of the multi-component floor mat can have a rubber edge formed around its perimeter, making it visually similar to a conventional one-piece mat. The rubber edge perimeter can also be used to prevent metal sheets from being attracted to the sides of the magnetically coated base component and / or the textile component.

[0114] Example The invention can be further understood by referring to the following examples, which should not be construed as limiting the scope of the invention.

[0115] Several variables were tested: Test program Commercial washing procedures: 1. Wash at 140 degrees Fahrenheit for 10 minutes.

[0116] 2. Rinse 3 times at 140 degrees Celsius for 3 minutes each time.

[0117] 3. Rinse twice at 90 degrees Celsius for 3 minutes each time.

[0118] 4. Minimize dehydration for 2 minutes.

[0119] 5. Dehydrate for 10 minutes.

[0120] Some samples were evaluated based on a "pass" or "fail" rating. A "pass" rating indicates that the textile components did not separate, but maintained their structural integrity and were suitable for their intended purpose. A "fail" rating indicates that one or more layers of the textile components separated, the textile did not maintain its structural integrity, and / or the textile was unsuitable for its intended purpose.

[0121] Fatigue (torture) washing: 1. Wash at 190 degrees Fahrenheit for 30 minutes.

[0122] 2. Rinse twice at 90 degrees Celsius for 3 minutes each time.

[0123] 3. Minimal dehydration for 2 minutes.

[0124] 4. Dehydrate for 10 minutes.

[0125] One fatigue wash is equivalent to 10 commercial washes.

[0126] Lateral movement test: The lateral movement test is used to measure the amount of movement of the floor mat. First, a piece of tape is typically used to mark the location on the floor. The floor mat is then placed at that mark. For the lateral movement walking test, the person conducting the test walks 150 times on the test piece. Each walk must be in the same direction to ensure accurate measurement of movement. Once 150 walks in the same direction are completed, the person conducting the test must measure how far the test piece is from its original position. This should be done at both front corners. After the walking test is completed, a second lateral movement trolley test is run. This test involves the same procedure but requires a 100lb trolley. The load is rolled 50 times on the test piece. The distance is then measured and recorded.

[0127] Thickness measurement: The thickness of each sample was measured using a Starrett pocket micrometer. The specific model was Starrett No. 1010. The pocket micrometer used was accompanied by a certificate of conformity (Form 804) to ensure accuracy.

[0128] Tufting Lock-in Test: Tufting lock tests were performed by cutting approximately 6” x 10” samples of finished textile components. Once the samples were cut, they were placed in a TensiTech tensile testing machine. The tensile testing procedure was then performed, allowing the machine to grip individual tufts on the carpet. Once the machine locked onto an individual tuft, the force required to pull the tuft from the rubber backing of the textile component was recorded. This data was then recorded and run four more times, for a total of five pulls. Once all tests were completed, the data were evaluated to ensure that all recorded tensile force values ​​were above 4.0 lbf.

[0129] Body tear test: The body tear test was performed by cutting a finished textile component sample of approximately 4” x 7” with a 2” slit at one end. Once the sample was cut, it was placed in a TensiTech tensile testing machine with one side of the slit in the top clamp and the other side in the bottom clamp. The tensile test procedure was then performed, pulling the top clamp upwards. The force required to pull the top clamp was recorded when the sample tore in half. This data was then recorded and run twice more, for a total of three pulls. Once all tests were completed, the data was evaluated to ensure that all recorded tensile force values ​​were above 13.0 lbf.

[0130] Cut out an 8” x 8” sample of the finished textile component with a smooth, magnetically responsive backing for magnetic retention strength testing. Once the sample is cut, clamp it in the top clamp of the Instron tensile testing machine, ensuring the entire width of the pad is at least 1” long within the 9” wide top clamp. Mount a 6” x 2” magnetic strip with a magnetic strength of 200 Gauss onto a 10” x 8” rigid metal plate with its long side facing vertically. Mount the metal plate in a fixed clamp on the machine base, parallel to and aligned with the textile component, ensuring the magnetic strip is in close contact with the magnetically responsive backing of the finished textile component. Then run the test procedure to pull the top clamp upwards. Record the force required to pull the top clamp upwards as the sample traverses the length of the magnetic strip. Record this data and run the test twice more, for a total of three pulls. Once all tests are complete, evaluate the data in 0.1” traverses, thus assessing magnetic retention strength in lbf / inch.

[0131] Example 1: In this example, the textile component of the floor mat is approximately 3 inches wide by 5 inches long, and the base component is approximately 4 inches shorter in both width and length, causing the textile component on each side to overlap by 2 inches and conceal the base component. The underside of the textile component and the top of the base component are smooth without protrusions, and the textile component is configured in a sweeping motion, keeping the contact area between the textile component and the base component small until the textile component is mostly on top of the base component. The textile component is then placed on the base component. Since the textile component is substantially larger than the base component, alignment of the textile component is not critical, resulting in the base component being concealed beneath the textile component. The presence of the base component prevents unwanted movement of the textile component during use.

[0132] Example 2: In this example, the floor mat of Example 1 is modified such that it has Velcro hooks on the short edge of the base member and matching loop Velcro strips on the underside of the textile member. These two strips are positioned such that they align when the textile member is aligned with the base member. When the textile member is dragged onto the base member, as in Example 1 above, the two Velcro strips make physical contact and lock together, thereby preventing movement of the textile member and ensuring correct front-to-back alignment.

[0133] Example 3: In this example, the Velcro of Example 2 is replaced with a rubber ridge approximately 1 / 8” high, which extends along the short edge of the textile component and is molded to the underside of the textile component; it is located in the same position as the Velcro in Example 2. The Velcro on the base component of Example 2 is removed, and the rubber ridge of the textile component engages with the edge of the base component to provide the same alignment capability as in Example 2.

[0134] Example 4: This example is the same as Example 2, except that a mushroom-shaped fastener (such as 3M DualLock) is used instead of a Velcro strip.

[0135] Evaluation of backing materials Example A - A pad with a nitrile rubber backing The mat is prepared as follows: A tufted surface assembly was prepared comprising tufting nylon 6,6 yarn into a pre-shrinked Lutrador 52 nonwoven master backing. The nylon 6,6 yarn was 1 / 8-inch gauge and tufted at 8.70 needles per inch. The tuft was cut to a pile height of 18 / 64 inches, resulting in a textile weight of 20.0 oz / yard square. The tuft roll was measured 145 inches from one outer pile row to the other.

[0136] The tufted roll is then printed using a Millitron® digital printer. The tufted assembly passes through the Millitron® digital printer at a speed of 25 feet per minute. Dye is dispensed onto the tufted assembly using a combination of 12 gun bars at a dye flow rate set to 36. The tufted assembly is then exposed to a first steam step in a steam oven at 209°F, followed by a post-steam / stain blocker step at 150°F. The printed tufted assembly is then dried at 240°F.

[0137] The printed tufted assembly is then cut into 3.2' wide rolls. These rolls are placed on top of 0.130" thick nitrile rubber. The uncured nitrile rubber is then fed into a press with the printed tufted assembly on top. Once the printed assembly is in the pressurization zone, the press is heated to 365°F from the bottom. The press then applies pressure at 35 psi to the top of the printed tufted assembly to push it into the rubber. The printed tufted assembly is then held in the press for 8 minutes before being removed. After removal, it is pre-shrinked in a dryer at 290°F to form a washable rug in roll form. The washable rug in roll form is then cut into the desired shape and / or size.

[0138] In another embodiment, the mat is made with a 0.030” thick nitrile rubber backing loaded with magnetically responsive filler. The mat has solution-dyed yarn (SDN) yarn tufted in a polyester nonwoven master backing layer. This is bonded to the backing at 370°F and 35 psi pressure and cured for 4 minutes. No further pre-shrinking is performed. However, the backing layer is then exposed to a needle-punching process to make it porous.

[0139] Evaluation of backing style Smooth nitrile backing pad A smooth rubber backing has no protrusions on the rubber surface of the mat (e.g., the surface of the mat that contacts the magnetic substrate). In other words, a smooth backing has no protrusions. Protrusions are typically added to the magnetic substrate to help prevent unintended lateral movement of the mat.

[0140] The washable mat is constructed in the same way as the mat manufactured in Example A. When placing the nitrile rubber on the press, it is laid on a Teflon-coated belt without any indentations. The top of the belt is smooth, which results in a smooth surface on the bottom of the rubber as well.

[0141] Nitrile backing for anti-slip (standard high-tread) materials used in magnetic substrate components. The nitrile rubber used as the base is constructed by laminating magnetic rubber and rubber without any magnetic filler, wherein the latter forms the anti-slip base. The anti-slip rubber backing is characterized by having (1) a grid pattern on the non-protruding rubber surface and (2) protrusions in the internal spaces between the non-protruding areas. The protrusions exist in a square pattern. Thus, the anti-slip backing contains a repeating pattern of small protrusions in an area of ​​7 / 8 inch by 1 inch square. The protrusions are approximately 1 / 16 inch high. The protrusions cover approximately 70% of the surface of the rubber backing.

[0142] The washable mat has the same structure as the mat manufactured in Example A. When the nitrile rubber is placed on a press, it is placed on a Teflon-coated belt with 1 / 16-inch recesses in a small square pattern. When the press reaches 365°F, it softens the rubber considerably. Once 35 psi of pressure is applied to the top of the washable mat assembly, it pushes the soft rubber into the recesses to form a “non-slip” pattern.

[0143] Megahold nitrile backing for magnetic substrate components The nitrile rubber used for the base is constructed by laminating magnetic rubber and rubber without any magnetic fillers, with the latter forming the megahold base. Compared to anti-slip backing, the megahold rubber backing is characterized by having fewer and larger depressions on the rubber surface. The depressions exist in groups of four and are spaced apart in a square pattern. Therefore, the megahold pattern contains a repeating pattern of four large depressions within a 3.625 inch × 3.875 inch square area. The depressions are approximately 1 / 8 inch deep. The depressions cover approximately 40% of the rubber backing surface.

[0144] The washable mat has the same structure as the mat manufactured in Example A. Before placing the rubber on the Teflon belt, the operator places a metal plate on the belt. The metal plate contains circles on its top surface. Each circle includes a hole drilled in the center to form the rubber inside. Nitrile rubber is then placed on top of the metal plate, with the textile / carpet on top. When the press reaches 365°F, it softens the rubber considerably. Once 35 psi of pressure is applied to the top of the washable mat assembly, it pushes the soft rubber around the metal plate and into it, forming the “Megahold” backing.

[0145] Evaluation of the thickness of magnetic coatings on textile components The thickness of the magnetic back coating was varied. Samples were prepared with magnetic back coatings of 20 mils, 25 mils, and 30 mils. The back coating was applied to Forever® mats obtained from Milliken & Company of Spartanburg, SC. ​​These mats were then subjected to standard washing and body tear tests, as well as magnetic shear retention tests.

[0146] To perform the magnetic shear retention test, a test apparatus was created in which the bottom handle of the Instron was replaced by a vertical aluminum plate with a permanent magnet plate attached. The permanent magnet plate is similar in structure and magnetic strength (measured in Gauss) to the magnetic substrate of a textile component on which a magnetic back-coated element is mounted. The textile component with the magnetic back-coated element is clamped in the top jaws of the test frame, such that the magnetic back-coated element is attached to the permanent magnet plate. The assembly is adjusted to ensure that the textile component with the back-coated element moves parallel to the surface of the magnetic plate on the aluminum plate as the top jaws move at a speed of 12 inches per minute. The force on the pressure measuring unit after a 1” traverse is recorded as the magnetic shear force.

[0147] The results of testing the back-coated textiles under 1X, 10X and 20X fatigue washing are shown in Table 1 below.

[0148] Table 1: Assessment of the thickness of magnetic coating on textile components after washing

[0149] All references cited in this article (including publications, patent applications and patents) are incorporated herein by reference, which is equivalent to each reference being individually and explicitly mentioned and incorporated into this article by reference and described in its entirety here.

[0150] Unless otherwise stated herein or explicitly contradicted by the context, the terms “a,” “an,” and “the,” and similar pronouns used in the context of describing the subject matter of this application (particularly in the context of the following claims) should be interpreted as encompassing both singular and plural forms. Unless otherwise stated, the terms “comprising,” “having,” “including,” and “containing” should be interpreted as open-ended terms (i.e., meaning “including but not limited to”). Unless otherwise stated herein, the description of numerical ranges herein is intended only as a simplified method of individually referring to each individual value falling within that range, and each individual value is included in this specification as if it were separately recorded herein. Unless otherwise stated herein or explicitly contradicted by the context, all methods described herein may be performed in any suitable order. The use of any and all instances or exemplary language provided herein (e.g., “such as”) is intended only to better illustrate the subject matter of this application and, unless otherwise stated, does not constitute a limitation on the scope of the subject matter. No language in the specification should be construed as indicating that any unclaimed element is essential to the practice of the subject matter described herein.

[0151] This document describes preferred embodiments of the subject matter of this application, including the best methods known to the inventors for implementing the claimed subject matter. Variations of those preferred embodiments will become apparent to those skilled in the art after reading the foregoing description. The inventors expect those skilled in the art to appropriately employ these variations, and the inventors desire to practice the subject matter described herein in ways different from those specifically described herein. Therefore, this disclosure includes all modifications and equivalents of the subject matter described in the appended claims as permitted by applicable law. Furthermore, unless otherwise stated herein or where the context clearly contradicts, this disclosure covers any combination of the foregoing elements in all possible variations.

Claims

1. A multi-component floor mat, comprising: (a) A textile component comprising (i) a first layer of tufted carpet formed by tufting face yarns through a main backing layer and present on the entire surface of the textile component, and (ii) a second layer of vulcanized rubber material containing magnetic particles, the second layer having the same length and width as the first layer, wherein the textile component has no continuous three-dimensional edging. (b) A base member comprising (i) a vulcanized rubber containing magnetic particles or (ii) a vulcanized rubber with a magnetic coating applied. The textile component and the base component are releasably attached to each other by magnetic attraction; and The textile component is at least 10% larger than the base component in both length and width; and The textile component includes at least one alignment mechanism and the substrate component includes at least one alignment mechanism that functions in a corresponding relationship with at least one alignment mechanism of the textile component; the alignment mechanism relies on temporarily reducing the surface area of ​​the textile component and / or the substrate component and / or temporarily reducing the adhesion between the textile component and the substrate component; The alignment mechanism is present on the textile component and the base component at a location including the inner edge of each component; The textile component and the base component further include at least one edge attachment device, and the at least one edge attachment device is present on one edge, two edges, three edges, or all four edges of the textile component and the base component.

2. The multi-component floor mat of claim 1, wherein the textile component is magnetically inductive.

3. The multi-component floor mat of claim 1, wherein the base component is permanently magnetized.

4. The multi-component floor mat of claim 1, wherein the textile components of the floor mat are capable of withstanding at least one washing cycle in a commercial or household washing machine, thereby adapting the textile components for reuse after exposure to the at least one washing cycle.

5. The multi-component floor mat of claim 1, wherein the front yarn is selected from the group consisting of: synthetic fibers, natural fibers, man-made fibers using natural ingredients, inorganic fibers, glass fibers, and any mixture thereof.

6. The multi-component floor mat of claim 1, wherein the front yarn is selected from nylon 6; nylon 6,6; polyester; polypropylene; or any combination thereof.

7. The multi-component floor mat of claim 1, wherein the front yarn comprises cut pile, terry pile, or a combination thereof.

8. The multi-component floor mat of claim 1, wherein the front yarn is dyed, undyed, printed, or any combination thereof.

9. The multi-component floor mat of claim 1, wherein the main backing layer is selected from the group consisting of: woven materials, nonwoven materials, knitted materials, or any combination thereof.

10. The multi-component floor mat of claim 1, wherein the main backing layer is selected from the group consisting of: synthetic fibers, natural fibers, man-made fibers using natural components, inorganic fibers, glass fibers, and any mixtures thereof.

11. 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 elastomers, and any mixtures thereof.

12. The multi-component floor mat of claim 1, wherein the size of the magnetic particles is in the range of 1 micrometer to 10 micrometers.

13. The multi-component floor mat of claim 1, wherein the magnetic particles are magnetizable magnetic particles selected from the group consisting of: Fe3O4, SrFe3O4, NdFeB, AlNiCo, CoSm and other rare earth metal-based alloys, and any mixtures thereof.

14. The multi-component floor mat of claim 1, wherein the magnetic particles are magnetically inductive particles selected from the group consisting of: Fe2O3 particles, Fe3O4 particles, steel particles, iron particles, and any mixture thereof.

15. The multi-component floor mat of claim 1, wherein the magnetic coating further comprises an adhesive material.

16. The multi-component floor mat of claim 15, wherein the adhesive material is selected from thermoplastic elastomers, thermoplastic vulcanized rubbers, and any mixtures thereof.

17. The multi-component floor mat of claim 16, wherein the adhesive material is selected from the group consisting of: urethane-containing materials, acrylate-containing materials, silicone-containing materials, and any mixtures thereof.

18. The multi-component floor mat of claim 1, wherein the base component further comprises an adhesive composition.

19. The multi-component floor mat of claim 18, wherein the adhesive composition is selected from the group consisting of: pressure-sensitive adhesive materials, adhesive materials containing rosin esters, and elastomer materials containing natural rubber, nitrile rubber or silicone rubber and tackifiers.

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