DE19901989A1 - Door or floor mat is of a fiber nonwoven material with openings cut out by a water jet head to take alphanumerical inserts shaped precisely to fit to form names/logos with a backing carrier and adhesive layer - Google Patents

Abstract

The doormat (1) is of a textile material and especially a fiber nonwoven, with needled structure ribs. The rear side has a carrier layer of an elastomer material. At least one part section (5-10) of the mat (1) is formed by an insert which fits into an opening of a precise complementary shape, bonded in place by an adhesive layer at the rear side of the mat (1). The adhesive layer is applied over the whole surface of the backing layer of the mat (1), with an adhesive or vulcanized or self-adhesive bonding to the backing layer. The adhesive layer can also be formed by the structure of the backing layer. The adhesive layer can also be combined with the background of the mat (1). The inserts (5-10) are in a different color from the mat (1), as alphanumerical symbols. An Independent claim is included for a doormat mfg. process where the part-sections (5-10) are cut out by a water jet head (4). The inserts to be used are cut from another mat (1) of an identical material, and placed into the cut openings (5-10). A bonding layer is applied to the rear side of the mat (1) and the inserts to bond them to the mat (1). Preferred Features: The water for the jet is mixed with abrasive particles, such as sand grains. The uncoated textile material is cut with the water jet, and an elastomer layer containing the adhesive layer is applied to the rear side. The inserts are bonded in place at their rear sides within the mat (1) by a bonding layer, and the bonding layer is vulcanized around the inserts in the mat opening sections (5-10) after the surfaces have been roughened. The structure of the mat (1) material surface is formed by needling, after the inserts have been put in place and the carrier and bonding layers have been secured to the material.

Description

The invention relates to a dirt control mat consisting of a textile Material, in particular a nonwoven fabric with needled structural ribs, which material on its back with a carrier layer made of elastome Rem material is provided, as well as a method for producing a such mat.

The dirt control mats described with a backing layer an elastomer such as rubber are mainly used in the entrance area of Buildings to remove contaminants from the soles of shoes the visitor designed. Also in the footwell of motor vehicles such mats designed as floor mats.

The dust control mats described have a very high mechanical resilience and a very good cleaning effect. she usually consist of non-woven fabrics with very thick synthetic fibers into which on a needle chair structure ribs with a very high pole (3-4 mm) be needled. Even very coarse synthetic fabrics, possibly with gena Deleted areas can be used as a dirt control mat. The back Elastomer coating gives the mats both a high structural Strength as well as good slip resistance.

The object of the invention is to describe the entrance mats on mats the optically distinct areas, especially lettering, Advertising symbols or other symbols to train and one for the Forming such symbols to create a suitable method.

This object is achieved according to the invention in relation to the mat itself solved that at least a portion of the mat from an insert is formed, which in a precisely complementary shaped recess the mat and with a binding layer applied on the back is connected to the mat.  

By inserting an insert, which is preferably a different color based on the mat itself, can be simple way any symbol in the otherwise uniform Realize the surface of the mat. Cutting out the insert as well as the recess from the mat itself compared to a textile Formation of a certain symbol in the textile material of the mat considerable manufacturing advantages. One in the textile manufacturing The process of the textile material realized requires very complex Manufacturing machines. Furthermore, an expensive retrofit is one Such manufacturing machine necessary when changing the figure.

The described dust control mat with insert inserted can - starting from commercially available dirt control mats - with two different and contrasting colors become. By varying the shape of the partial area or the partial areas, that are designed in a different color can flexibly make the difference The best illustrations and symbols in the dirt trap mat become. By inserting several sections in the second or in Different colors can be complex and multicolored symbols or Images can be realized. In addition, whole lettering can be inside half a dirt control mat of the type described can be realized. Also pictograms or symbols in connection with lettering, e.g. B. Arrows with the word "Exit" can be used as a hint in the described Embodiment on an escape route to be included in the mat. So the dirt trap described is suitable for. B. for lining the Floor area of the passenger compartment of an aircraft.

As described in detail below, the invention Dirt trap realized with a manufacturing process in which the section is cut out of the mat using a water jet and from a differently colored dirt control mat with similar cher structure a complementary section cut out and into the Cutout is inserted in the first dirt control mat. Subsequently is the binding layer on the back to connect all parts the dirt control mat applied. Of course, the can from the first dirt mat cut out into the second Dirt trap mat are inserted so that in a manufacturing process  two dirt control mats with the same illustrations and vice versa Colorings are created.

In a preferred embodiment of the dirt control mat Apply the binding layer over the entire surface of the carrier layer. this makes possible the use of commercially available, already provided with the backing layer Dirt trap mats for realizing the dirt according to the invention Doormat with symbol or illustration. The binding layer can on the Carrier layer can be glued or vulcanized.

Alternatively, the binding layer is from the backing layer on the back of the textile material itself. In this case, the section of the Cut out the mat from the uncoated textile material and that Insert also from an uncoated section of a different color bigen textile material formed. After inserting all different colors Partial areas in the corresponding recesses of the mat entire textile fabric on the back with a single Layer, which forms the carrier layer and the binding layer. The Structures in the surface of the dust control mat can either be in front cutting out the different sub-areas or after Application of the carrier layer / binding layer are formed, in particular right if the structures are formed by needled ribs.

The inventive use of water jet cutting for The sections and inserts can be separated out exactly mutually complementary cutting lines are used. Water Beam cutting machines have a cutting width of less than 0.5 mm (e.g. 0.2 mm) and are now mostly numerically controlled. The cut-outs and inserts produced therefore largely fit seamlessly. Another major advantage, which is characterized by the Using a water jet cutting machine results in the fact that the Cannot burn cut edges. Both mechanical cutting tech techniques (sawing etc.) as well as thermal cutting techniques (heating wire or Laser beam) usually lead to excessive heating of the cutting area rich and thereby to smoldering or melting the syntheti textile fibers in the area of the cut edges. This results in a disadvantageous hardening of the textile material in the area of the cut edges and  the contact zones of different colored areas. In addition, by Scorched the color of the mat to be changed. Such a change The material structure is changed by the use of the water jet avoided as a cutting agent. The water jet can in a known manner abrasive particles (e.g. grains of sand) are added to the cutting line increase.

As mentioned, both the finished, can be coated with elastomeric material cut mat and be fitted with inserts, then an additional one on the elastomeric carrier layer Binding layer is applied. The binding layer is on top of the backing glued or vulcanized, where possible before vulcanizing Binding layer is roughened and / or dissolved. Alternatively, it can uncoated textile material can be cut with a water jet, then on the back of the inserts Mat a uniform layer of elastomer is applied, which is the same forms the binding layer and the carrier layer in good time.

Also the structure of the textile material, which is mostly due to needling Ribs with a fairly high pile (about 5 mm) can be formed after Inserting the sections and applying the binding layer incorporated become.

It should be noted that the term mat or dust control mat covers everyone textile surface covering, also any carpet or runner, which can be laid on floors.

In the following, with reference to the drawings, execution examples of the invention explained in more detail. The drawings show in:

Fig. 1 is a plan view of a mat according to the invention during the cutting of a logotype by means of a water jet cutter head,

Fig. 2 is an illustration of FIG. 1 in geschnitte along the section line II-II ner representation,

Fig. 3-4 diagrammatic representations of the embedding of the colored logos,

Fig. 5 is a plan view of the finished dirt mat according to the invention and

Fig. 6 is a section according to the line IV-IV cross-sectional view of the mat of Fig. 5.

As can be seen in FIGS. 1 and 2, from a dirt trap mat 1 , consisting of a textile material layer 2 with a relatively uniform pile and an elastomeric carrier layer 3 by means of a water jet cutting head 4, different partial areas 5-13 are cut out, which form a lettering . Suitable, computer-controlled water jet cutting systems are available from ABB IR Robotized Waterjet AB or INTERSOLL-RAND GmbH, Bad Nauheim, for example. In these systems, a small water nozzle with a diameter of 0.1 to 0.35 mm, which is installed in the cutting head 4 , is supplied by a high-pressure pump at a pressure of several thousand bar. The sections 5-13 can thus be separated from the mat 1 with an extremely small cutting width.

After cutting, the partial areas 5-13 are to be pressed out of the mat 1 , cutouts running in the mat 1 complementary to the partial areas 5-11 . The same procedure is carried out on a similar mat with a different color or with a different visual appearance, so that the mat with cutouts and the separated areas are also created there. The sections 5 '- 13 ' separated from this second are inserted into the mat 1 (cf. FIG. 4). It should be noted that section 12 , which forms the eye of section 11 (small letter e), is inserted into this eye and connected again to mat 1 , so that the lettering can be read in full contrast.

After inserting the sections 5 '- 13 ' shown in Fig. 4 in the mat 1 , the backing layer 3 located on the back of the mat 1 is covered with a bonding layer (not shown), which the sections 5 '- 13 ' in the cutouts the mat 1 fixed.

Alternatively, the textile material 2 , which forms the mat 1 , can be cut in an uncoated form, the back of the mat 1 being coated with an elastomeric layer after the insertion of the differently colored sections, which layer simultaneously supports the carrier layer 3 and the bandage for the Forms sections 5 '- 13 '.

The textile material of the mat shown in FIGS. 1 to 4 has a relatively even pile. With dirt control mats, it is advantageous if the pile of the textile material layer is structured. Therefore, in FIGS. 5 and 6 an alternative embodiment of Schmutzfangmatte 'is shown, the textile material layer 2' 1 has arranged at regular intervals ribs 14. As a rule, the textile material 2 'consists of a nonwoven fabric which passes through a needle chair, the ribs 14 being pulled out of the nonwoven fabric by the needles. In the manufacture of the dirt control mats 1 'according to the invention with ribs 14 , already finished ribbed mats with a backing layer 3 can be processed. It is important to ensure that the mutually complementary sections 5-13 and 5 '- 13 ' have the same ribbing. Otherwise there would be a displacement of the ribs of the partial areas 5-13 , 5 '- 13 ' with respect to the ribs of the mat 1 or 1 '.

Alternatively, a non-ribbed nonwoven fabric can be processed and after the insertion of the partial areas 5 '- 13 ' and the application of the binding layer, the ribs 14 are formed on the surface of the mat 1 'by needling.

Reference list

1

mat

2nd

Textile material

3rd

Carrier layer

4th

Water jet cutting head

5-13

Sub-areas

5

'-

13

'' Insert

14

rib

Claims (15)

1. dirt control mat ( 1 , 1 ') consisting of a textile material ( 2 , 2 '), in particular a non-woven fabric with needled structure ribs, which material is provided on its back with a carrier layer ( 3 ) made of elastomeric material, characterized in that at least a partial area ( 5-13 ) of the mat ( 1 ) is formed by an insert ( 5 '- 13 '), which is inserted into an exactly complementary recess in the mat ( 1 ) and by means of a binding layer applied to the back with the mat ( 1 ) is connected. 2. Mat ( 1 , 1 ') according to claim 1, characterized in that the binding layer is applied over the entire surface of the carrier layer ( 3 ). 3. mat ( 1 , 1 ') according to claim 1 or 2, characterized in that the binding layer is glued to the carrier layer ( 3 ). 4. mat ( 1 , 1 ') according to any one of the preceding claims, characterized in that the binding layer on the carrier layer ( 3 ) is vulcanized. 5. mat ( 1 , 1 ') according to any one of the preceding claims, characterized in that the binding layer of the carrier layer ( 3 ) is formed on the back of the textile material itself. 6. mat ( 1 , 1 ') according to any one of the preceding claims, characterized in that the binding layer is formed by an adhesive layer connecting the mat ( 1 ) to the substrate. 7. mat ( 1 , 1 ') according to any one of the preceding claims, characterized in that the portion ( 5-13 ) has a different color from the color of the mat ( 1 ). 8. mat ( 1 , 1 ') according to any one of the preceding claims, characterized in that the portion ( 5-13 ) has the shape of an alphanumeric character. 9. A method for producing a dirt-absorbing mat ( 1 , 1 '), consisting of a textile material ( 2 , 2 '), in particular a fiber fleece with needled structure ribs, which is provided on its rear side with a carrier layer ( 3 ) made of elastomeric material, characterized in that at least a portion (5-13) is excised with a jet of water from the dirt trapping mat (1) that matte from a second dirt trap (1) with similar structure a complementary insert (5 '- 13') cut with a water jet and is inserted into the cutout in the dirt trapping mat (1) and that on the back of the mat (1) and the portion used - is applied a bonding layer, which the portion (5 '13') (5 '- 13') at the Mat ( 1 ) attached. 10. The method according to claim 9, characterized in that the what abrasive particles, e.g. B. grains of sand are added. 11. The method according to claim 9 or 10, characterized in that the uncoated textile material ( 2 , 2 ') is cut by means of water jet and that a layer of elastomeric material which forms the binding layer and the carrier layer ( 3 ) is then applied. 12. The method according to claim 9 or 10, characterized in that the section and the area surrounding the section of the dirt-absorbing mat ( 1 ) are glued with a bonding layer. 13. The method according to claim 9 or 10, characterized in that on the carrier layer ( 3 ) of the insert ( 5 '- 13 ') and the insert ( 5 '- 13 ') surrounding area of the dirt-absorbing mat ( 1 ), the bonding layer is vulcanized . 14. The method according to claim 13, characterized in that the upper surface of the carrier layer ( 3 ) of the insert ( 5 '- 13 ') and the insert ( 5 '- 13 ') surrounding area of the dirt control mat ( 1 ) before vulcanization the binding layer is roughened and / or dissolved. 15. The method according to any one of claims 9 to 14, characterized in that the structure of the textile material ( 2 ') after the insertion of the insert ( 5 ' - 13 ') and the application of the binding layer is preferably formed by needling.