WO2004037063A1

WO2004037063A1 - Floor mat

Info

Publication number: WO2004037063A1
Application number: PCT/GB2003/004539
Authority: WO
Inventors: Terence Michael Hedley
Original assignee: Milliken Industrials Ltd
Current assignee: Milliken Industrials Ltd
Priority date: 2002-10-24
Filing date: 2003-10-21
Publication date: 2004-05-06
Anticipated expiration: 2005-04-24
Also published as: GB0224670D0; AU2003274343A1

Abstract

The present disclosure relates to floor mats (100) and, in particular, to washable dust control mats, in which a rubber backing sheet (10) is cured and heat-bonded under pressure to the back of a tufted fabric layer (12) that includes a removably attached encapsulated presentation module (40). The encapsulated presentation module includes any presentation image (34) desirable for display on the upper surface of a mat. The presentation image (34) is formed from or is carried by a presentation medium (32), such as paper. A process for manufacturing floor mats (100) having a rubber backing (10) and a textile upper surface (12) that incorporates an encapsulated presentation composite (40) removably attached thereto is also described.

Description

FLOOR MAT HAVING REMOVABLE ENCAPSULATED PRESENTATION MODULE

TECHNICAL FIELD The present disclosure relates to floor mats and, in particular, to washable dust control mats, in which a rubber backing sheet is cured and heat-bonded under pressure to the back of a tufted fabric layer that includes a removably attached encapsulated presentation module. The encapsulated presentation module includes any presentation image desirable for display on the upper surface of a mat. A process for manufacturing floor mats having a rubber backing and a textile upper surface that incorporates an encapsulated presentation composite removably attached thereto is also described.

BACKGROUND The terms "mat" and "dust control mat" are used herein to describe rugs, carpets, and other removable floor coverings that capture dust, dirt, and moisture from users' footwear. A dust control mat is generally characterized as having a textile upper surface, for example, a tufted pile surface. The term "upper surface" describes that part of the mat over which individuals walk (in this case, including a tufted portion and an image portion). The term "rear surface" describes that part of the mat that is adjacent to and normally in contact with the flooring surface (in this case, a rubber layer).

The term "washable" describes a characteristic of mats that can withstand washing by immersion and agitation in water or other cleaning fluids. Washing may include the spin extraction of moisture. Washing is usually followed by tumble drying. The term "cavity" is intended to describe an area of the textile upper surface that is devoid of pile yarns and is adapted to receive a rubber layer and an encapsulated presentation module. The cavity is bounded by pile yarns, while the bottom of the cavity contains either an area of tufting substrate that is devoid of yarn tufts or a secondary support substrate having approximately the same dimension as the cavity.

Subsequent layers are preferably attached to the substrate-covered bottom of the cavity, as will be discussed herein. For this reason, the cavity may also be considered an attachment area.

The term "encapsulated presentation module" describes one mat component of the present disclosure, formed by encapsulating (for example, by laminating) between plastic sheets a presentation image formed from or printed on a presentation medium. A "presentation medium" is a thin sheet material such as may be comprised of paper, cardboard, textile fabric, rubber, or the like that either carries or forms the desired presentation image. The presentation medium can be said to carry the. image when an image is printed or created on the surface thereof. The presentation medium can be said to form the image when the presentation medium is cut or configured to create an image. The "presentation image" may be comprised of one or more of the following: printed images, photographs, stencils, cut-outs, drawings, or the like. The encapsulated presentation module itself is a unit that is removably attached to the mat's upper surface during use, but is removed before the mat is laundered.

Other terms will be defined herein, as needed to explain the present article.

Manufacturers of washable rubber-backed, dust-control mats sell their mats to the textile rental industry, which then rents or sells the mats to end users such as retail stores, factories, hospitals, and the like. Users typically place mats at the entrances of buildings where the mats serve to remove dirt and moisture from the shoes of pedestrians entering the buildings. On a predetermined frequency (e.g., weekly, monthly, etc.), the laundry service replaces the soiled mats with clean mats and returns the soiled mats to the laundry for cleaning.

Mats of this variety frequently carry a message of some type, such as a company logo or trademark. The message is typically created by forming the fabric layer from a mosaic of tufted materials of different colors. The resulting mats have a desirable appearance, provide good dust control properties, and exhibit long durability through use and laundering.

However, users have expressed a desire to have mats that carry a temporary, or readily replaceable, message (such as an advertisement for a sales promotion or a customized welcome message). Use of the dust control mats described above would not be economical or suitable for use where such temporary messages were desired.

To this end, others have addressed the problem of creating a durable dust control mat having a user-changeable message portion. WO 00/65980 describes an "advanced" floor mat in which a graphic message may be incorporated in either, or both, the base portion or insert portion of the mat. In one embodiment, the graphics are visible through a transparent insert portion. The problem with this approach is the tendency of the graphics to sustain damage from incidental contact with water tracked onto the mat surface by users. Therefore, this approach is not wholly satisfactory.

Another approach, described in WO 02/061719, uses a floor mat having removable advertising sheets, which are positioned in a recess in a textile upper surface. Various embodiments are described in which a raised reinforcing portion, sometimes having an arcuate top surface, is used to heighten the advertising sheet. The advertising sheet may be made of plastic. Further, the application states that an advertising print is made onto the upper side of the advertising sheet.

The invention described in the WO 02/061719 application has several shortcomings. First, because the advertising print is on the top surface of the advertising sheet, the print is susceptible to wear and damage from soil and water tracked onto the mat. Second, the inventors have failed to realize a problem created from cutting a recess or aperture in a textile surface material. Specifically, if left unfilled, the differential shrinkage between the textile surface material and the rubber will cause the mat to ripple or pucker during vulcanization. The mat of the present disclosure addresses these shortcomings.

SUMMARY The present disclosure relates to a floor mat having a rubber backing sheet to which is attached a textile upper surface that includes a cavity into which an encapsulated presentation module may be removably adhered. The textile upper surface is preferably a pile surface including an area (that is, the cavity or attachment area) devoid of pile yarns and adapted for receipt of a protective rubber layer and an encapsulated presentation module. In one embodiment, the encapsulated presentation module will comprise less than half the mat's upper surface, leaving sufficient room for users to clean their shoes. A protective rubber layer and, optionally, a secondary support substrate are used to create and maintain a stable cavity floor on which to support and attach the encapsulated presentation module.

The encapsulated presentation module, which has the same approximate size as a cavity formed in. the textile upper surface, may comprise any presentation medium that carries or itself forms a presentation image. The presentation medium — that is, the material that creates the presentation image — is encapsulated between plastic sheeting. The presentation image may include one or more of the following: printed images, characters, graphics, symbols, letters, or the like and combinations thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 A is an exploded view of a first embodiment of the present mat;

FIG. 1B is an exploded view of a second embodiment of the present mat;

FIG. 2 is a plan view of a mat according to the present disclosure in which an encapsulated presentation module has been inserted;

FIG. 3 is a cross-sectional view of the mat of FIG. 1A;

FIG. 4 is a close-up of one portion of the cross-sectional view of FIG. 3; and

FIG. 5 is a schematic representation of the side section of a vulcanization press, showing the base portion of the mat of FIG. 1A as laid-up in the press before vulcanization.

DETAILED DESCRIPTION

As shown in FIG. 1A, there is provided a floor mat assembly 100 having a base 8 including a textile upper layer 12, in which a generally rectangular cavity 14 is formed, and a rubber backing layer 10. Cavity 14 may be formed, for example, by die cutting through textile upper layer 12 or by "tufting out", a process in which tufts are not placed in an area which will form cavity 14. An encapsulated presentation module 40, comprising a presentation medium 32 enveloped by plastic sheeting _30, may be removably inserted into cavity 14. Encapsulated presentation module 40 may be removed and replaced easily with another encapsulated presentation module

40 having a different presentation image 34, as desired by the user.

Cavity 14 in base 8 need not be rectangular, but may have any shape. In particular, instead of square comers, the corners may be rounded, thereby reducing the risk of tearing, especially during laundering. The external shape of base 8 may also be modified. For example, it may be rectangular, square, circular, oval, or any other desired shape.

As further shown in FIG. 1A, the bottom or base of cavity 14 includes a protective rubber layer 20 and, optionally, a secondary support substrate 16. Secondary support substrate 16 and protective rubber layer 20 provide several benefits. First, secondary support substrate 16 prevents mat 100 from rippling or puckering during vulcanization due to the differential shrinkage of textile upper layer 12 and rubber backing layer 10.

However, in cases where cavity 14 is formed by "tufting out" (as described above), an additional secondary support substrate 16 may not be required. As shown in FIG. 1 B, no yarns have been tufted in one area of textile upper surface 12, thereby exposing the underlying tufting substrate 4 and forming cavity 14. In this embodiment, protective rubber layer 20 is adhered to tufting substrate 4 during the vulcanization process.

One benefit of protective rubber layer 20 is that it protects secondary support substrate 16 (or exposed tufting substrate 4) from damage during laundering and use. Specifically, vigorous laundering conditions, as might be experienced at a rental laundry, might damage secondary support substrate 16 or tufting substrate 4, if the substrate 16, 4 were left exposed. This would decrease the aesthetic appearance of the mat, as well as negatively impact its useful life.

Finally, protective rubber layer 20 provides a suitable surface to which an adhesive (for example, a releasable adhesive or a hot-melt adhesive) may be applied to removably secure encapsulated presentation module 40. If protective rubber layer 20 were not present, the placement and removal of encapsulated presentation module 40 would be difficult. It would be likely that adhesives, tapes, glue, or the like used to secure encapsulated presentation module 40 to the mat would result in damage to secondary substrate layer 16 (or tufting substrate 4) when encapsulated presentation module 40 was subsequently removed.

Preferably, textile upper layer 12 is a tufted surface, in which yarns 6 are tufted through a primary tufting substrate 4. Yarns 6 may comprise any natural or man- made fiber type, including, without limitation, polyester, nylon, cotton, wool, and blends thereof. The tufted pile can be cut, looped, or a combination of both, but typically consists of cut pile. Tufting substrate 4 is preferably a nonwoven polyester material, although other fiber types and constructions known in the art may be used. In general, the density of tufting substrate 16 should be in the range of about 80 g/m² to about 200 g/m², preferably within the range of about 90 g/m² to about 150 g/m², and with one preferred density being about 100 g/m².

In the embodiments shown in FIGS. 1A, 1B, and 2, textile upper layer 12 is slightly smaller than rubber backing layer 10, leaving an exposed border on the upper face of mat 100 (or 100') around its periphery. Alternatively, textile upper layer 12 and rubber backing layer 10 can be of substantially the same size to create a borderless mat (not shown). Rubber backing layer 10 is preferably made from nitrile rubber and advantageously has a thickness in the range of about 0.8 mm to about 3.0 mm, preferably in the range of about 1.0 mm to about 2.0 mm, and with one preferred thickness of about

1.5 mm. This thickness is preferred because it imparts durability and functionality for its intended purpose.

Protective rubber layer 20 is preferably comprised of the same material as rubber backing layer 10. However, the thickness of protective rubber layer 20 may be in the range of about 0.3 mm to about 2.0 mm, preferably in the range of about 0.5 mm to about 1.75 mm, and with one preferred thickness of about 1.5 mm. In one potentially preferred embodiment, protective rubber layer 20 is perforated, for example, with a pin roller, to prevent air from being trapped between protective rubber layer 20 and rubber backing layer 10 during vulcanization.

Textile upper layer 12 is bonded to rubber backing layer 10 in a heated press (such as a vulcanization oven), where the layers are subjected to temperatures and pressures appropriate to cure the rubber and to adhere the layers to one another. During this process, optional secondary support substrate 16 and protective rubber layer 20 are also bonded to layers 10, 12. Representative curing parameters include a temperature of about 175 °C and a pressure of about 30 pounds per square inch (gauge), applied for a cycle time in the range of about 5 to about 25 minutes.

Cavity 14 may be formed, for example, by die cutting or by tufting out. If formed by cutting, the inner portion removed from textile upper surface 12 may be recycled for other applications. Cavity 14 is shown as substantially rectangular, although other shapes and sizes may be used. Corresponding mat components to be added to cavity 14 (that is, optional secondary support substrate 16. protective rubber layer 20, and encapsulated presentation module 40) should be configured accordingly. Encapsulated presentation module 40 includes a presentation medium 32 that is enveloped by transparent sheeting 30. Presentation medium 32 may comprise any one of a number of materials, including, but not limited to, paper, cardboard, rubber, and textile materials that either form or carry the desired presentation image 34. The preferred presentation medium is paper because of availability, cost, and ease of printing. The preferred thickness of presentation medium 32 is about 1 mm, with a maximum thickness estimated to be about 2 mm, being limited only by the lamination equipment available. Any printing equipment suitable for presentation medium 32 may be used, including, but not limited to, ink jet printers, laser printers, and the like.

Presentation medium 32 is enveloped by, for example, a standard laminating process in which layers of transparent sheeting 30 are heated and softened to provide a closed composite structure. This closed structure protects presentation medium 32 from damage as might be caused by water contacting the surface of encapsulated presentation module 40. The laminate sheets 30 are typically transparent and may be comprised of polyester or other suitable laminate materials. The thickness of laminate sheets 30 is preferably in the range of about 0.04 mm (about 1.5 thousandths of an inch) to about 0.25 mm (about 10 mils). Further, it may be preferable for laminate sheets 30 to have a textured surface to reduce the likelihood that water deposited onto the mat will create a slippery surface.

Laminating pouches are commercially available and are well suited for this purpose. As has been described, individual laminating sheets 30 also function well. As an alternative to the lamination process, transparent contact paper (having an adhesive on one side) may also be used. In this case, contact paper would be applied in a similar manner to the laminating sheets 30, but without the application of heat needed to fuse laminating sheets 30. One benefit of the lamination process is the ease with which it rriay be carried out. Specifically, the needed equipment is common in many work environments, and the component materials are generally readily available. This provides to users of the present mat a wealth of opportunities to customize presentation medium 32 to meet whatever needs they have.

Another benefit of the lamination process is the relative ease with which encapsulated presentation module 40 may be attached to and removed from cavity 14 (and, specifically, from protective rubber layer 20). Encapsulated presentation module 40 may be attached to protective rubber layer 20 by means of hot glue, releasable pressure-sensitive adhesive, double-sided tape, or the like. In addition, options such as hook-and-loop fasteners, metal or plastic clips, nuts and bolts, or the like may also be used, but are less preferred because of their potential to damage either base layer 8 or encapsulated presentation module 40.

In the case of hot glue, the adhesive 50 is applied (as shown in FIG. 4) in beads between protective rubber layer 20 and encapsulated presentation module 40. When the components contact one another and the glue hardens, a semi-permanent seal is created. This seal is sufficient, during use, to keep encapsulated presentation module 40 in the position to which it is affixed. However, the seal is not sufficient to prevent encapsulated presentation module 40 from being removed by, for example, the application of direct heat, heated air, or properly directed peeling force.

The method or materials used for attachment are preferably easily reusable or releasable, allowing encapsulated presentation module 40 to be removed and replaced easily. Encapsulated presentation module 40 can therefore be replaced whenever a different presentation image (34) is required or desired. Likewise, encapsulated presentation module 40 should also be removed when mat 100 is laundered. Because the presentation medium 32 may be relatively inexpensive, encapsulated presentation module 40 is suitable for displaying messages on a temporary basis and can be disposed of when no longer required. Textile upper surface 12 provides the dust control function of mat 100, while also serving to support encapsulated presentation module 40 and retain encapsulated presentation module 40 in the desired position.

FIG. 2 shows an assembled mat 100, according to the embodiment shown in FIG.1A. Rubber backing layer 10 forms a border around the periphery of textile upper surface 12. Encapsulated presentation module 40, having a presentation image 34, is shown positioned upward of the mat's horizontal axis of symmetry. In one embodiment, encapsulated presentation module 40 comprises less than 50% of the surface of mat 100. This combination of printed and tufted surfaces ensures that mat 100 maintains its functionality as a dust control article. Other relative proportions are foreseeable, depending upon the need for a larger or smaller message area or dust control surface.

FIG. 3 shows a cross-sectional view of mat 100 of FIG. 1A. As has been described, mat 100 comprises a rubber backing layer 10 which is covered by a textile upper surface 12, having yarns 6 that are tufted through tufting substrate 4. A cavity 14 is cut in the textile upper surface 12 before mat assembly. An encapsulated presentation module 40, having a shape corresponding to that of cavity 14 and being formed of a presentation medium 32 that is encapsulated by laminating sheets 30, is removably attached to mat 100. To maintain the dimensional stability of mat 100 during vulcanization, a secondary support substrate 16 may be used. Protective rubber layer 20 is positioned over secondary support substrate 16 to create a suitable surface to which encapsulated presentation module 40 may be attached. Protective rubber layer 20 also prevents secondary support substrate 16 from being damaged by the adhesive used to attach encapsulated presentation module 40 to mat 100.

In the embodiment illustrated, secondary support substrate 16 is inserted into cavity 14 to provide dimensional stability to the mat assembly during vulcanization. Secondary support substrate 16 may be the same material as tufting substrate 4 or may be a lighter density material. One preferred secondary support substrate 16 material is a nonwoven polyester fabric having a density of about 80 g/m².

FIG. 4 illustrates, in cross-section, a more detailed view of the assembly of FIG. 3. Specifically, FIG. 4 shows secondary backing substrate 16 beneath protective rubber layer 20, to which an adhesive 50 has been applied. Encapsulated presentation module 40 is secured to protective rubber layer 20 by contact with the adhesive. Suitable adhesive materials have been described previously herein.

A process for making mat 100 will now be described, with reference to FIG. 5, which is a schematic exploded cross-section of the mat as laid up in a press during manufacture. The press includes a heated metal platen 70, over which there is an inflatable diaphragm 74, mounted on a frame 76. Frame 76 may be either fixed or moveable, depending on whether the vulcanizing press has a fixed or variable opening aperture. The lay-up comprises the following items placed in order on heated platen 70: a layer of uncured rubber 10, a textile upper surface 12 having a cavity formed therein, a sheet of secondary support substrate material 16 having approximately the same dimension as the cavity, and a protective rubber sheet 20, also having approximately the same dimension as the cavity. The phrase "same dimension" is intended to mean having substantially the same measurements in the x- and y- planes (that is, length and width as opposed to length, width, and height). The mat components may be transported through the vulcanization press by a conveyor belt 72, although such equipment is not required. In addition, release sheets (not shown) may be used under rubber backing layer 10 and over the laid-up mat components. These release sheets, which are made from PTFE-coated woven glass fabric, prevent rubber backing sheet 10 from sticking to heated platen 70 and to diaphragm 74. They also impart an imprint of a woven fabric to the exposed surfaces of rubber backing layer 10 for improved aesthetic appearance.

Textile upper surface 12 is substantially rectangular and has a rectangular aperture 14 formed therein, either from die cutting or from tufting out. Textile upper surface 12 is preferably a tufted cut or loop pile, whose yarns 6 are tufted through tufting substrate 4. One suitable tufting substrate 4 is a nonwoven polyester material, as has been described.

The press is heated to a temperature of about 175 °C. The laid-up mat components are positioned between platen 70 and diaphragm 74 (for example, on conveyor belt 72), and diaphragm 74 is then inflated. One suitable inflation pressure is about 30 pounds per square inch (gauge), pressing the laid-up components against heated platen 70, typically for a cycle time of about five to about 25 minutes.

The heat from platen 70 softens and cures rubber layer 10, and the pressure from diaphragm 74 presses textile upper surface 12 into rubber layer 10, bonding the two layers together. Further, protective rubber layer 20 is also pressed into secondary support substrate 16 to create a suitable horizontal surface to which encapsulated presentation module 40 may be attached. Rubber layers 10, 20 are both cured during the vulcanization process. After completion of the vulcanizing process, diaphragm .74 is deflated, and the rubber-backed mat 100 is removed from the press and allowed to cool. If necessary, the edges of rubber backing layer 10 may be trimmed.

Mat 100', shown in FIG. 1A, is formed by a similar process. In this embodiment, an exposed area of tufting substrate 4 is visible within cavity 14 during lay-up. Protective rubber sheet 20 is positioned within cavity 14, and again the mat components are vulcanized. In this case, the need for secondary support substrate 16 has been eliminated.

Once vulcanized, the mat (100 or 100') is ready for attachment of encapsulated presentation module 40. The mat owner can create a presentation image of his choosing (including graphics, text, pictures, artwork, or the like) on a presentation medium, such as paper. The presentation medium is then encapsulated in layers of polyester or plastic sheeting, for example, laminating sheets. Such encapsulation may occur either with heat, as in a laminating machine, or without heat, as with contact paper. The encapsulated presentation module is then ready for attachment to the mat base. Adhesive is applied to either protective rubber layer 20 or to encapsulated presentation module 40 or both, and encapsulated presentation module 40 is pushed into position on protective rubber layer 20.

If a hot melt glue is used as an adhering medium, it may be necessary to warm the mat surface to effect removal of encapsulated presentation module 40. Warming may be accomplished by means of localized heating of the mat surface, such as by warming plate or by hot air gun. Alternatively, properly applied peeling force may be used to remove the encapsulated presentation module from the mat. Once encapsulated presentation module 40 has been removed, the mat base may be laundered using conventional washing techniques.

Claims

What is claimed is:

1. A floor mat assembly comprising a base portion having a rubber backing layer and a textile upper surface attached to said rubber backing layer, said textile upper surface including a plurality of pile yarns and further including at least one attachment area devoid of said pile yarns and adapted to receive a protective rubber sheet and an encapsulated presentation module, said mat assembly further comprising said encapsulated presentation module removably attached to said base portion in said attachment area, characterized in that said attachment area includes said protective rubber sheet secured thereto and said encapsulated presentation module comprises a presentation medium encapsulated in transparent sheet material.

2. The floor mat of Claim 1 wherein said textile upper surface is a tufted pile fabric.

3. The floor mat assembly of Claim 1 wherein said attachment area includes a secondary support substrate.

4. The floor mat assembly of Claim 3 wherein said secondary support substrate is a polyester nonwoven material.

5. The floor mat of Claim 1 wherein said attachment area, said protective rubber sheet, and said encapsulated presentation module have substantially the same dimensions.

6. The floor mat of Claim 3 wherein said attachment area, said secondary support substrate, said protective rubber sheet, and said encapsulated presentation module have substantially the same dimensions.

7. The floor mat of Claim 1 wherein said encapsulated presentation module is attached to said attachment area by releasable adhesive.

8. The floor mat of Claim 1 wherein said encapsulated presentation module is attached to said attachment area by hot-melt adhesive.

9. The floor mat of Claim 1 wherein said presentation medium is selected from the group consisting of paper, cardboard, textile materials, and rubber.

10. The floor mat of Claim 9 wherein a presentation image is formed from said presentation medium.

11. The floor mat of Claim 9 wherein said presentation medium is paper.

12. The floor mat of Claim 11 wherein said presentation medium carries a presentation image.

13. The floor mat of Claim 12 wherein said presentation image is printed.

14. The floor mat of Claim 1 wherein said presentation medium includes a presentation image selected from the group consisting of letters, characters, symbols, artwork graphics, and combinations thereof.

15. The floor mat of Claim 1 wherein said presentation medium has been laminated between laminating sheets.

16. The floor mat of Claim 15 wherein said laminating sheets have a textured surface.

17. The floor mat of Claim 1 wherein said attachment area and said encapsulated presentation module are substantially rectangular.

18. The floor mat of Claim 1 wherein said mat has an upper surface, less than fifty percent of said upper surface comprising said attachment area.

19. The floor mat of Claim 18 wherein said attachment area is positioned upward of a horizontal axis of symmetry of said mat.