Continuous mat making process and product
The present disclosure relates to a continuous process for making floor mats having a textile upper surface and a rubber or rubber-like backing. In the one embodiment of the present process, a continuous roll of unvulcanized rubber is joined to a continuous roll of textile material during vulcanization. In an alternate embodiment, textile panels are positioned onto a continuous roll of unvulcanized rubber, later being joined during vulcanization. After vulcanization of either a textile roll or textile panels to a rubber backing, the resultant mat composite is cut into individual mat units.
Latest Patents:
This application is a divisional of co-pending U.S. patent application Ser. No. 10/015,205 filed on Dec. 4, 2001. This parent application is herein entirely incorporated by reference.
TECHNICAL FIELDThe present disclosure relates to a continuous process for making floor mats having a textile upper surface and a rubber or rubber-like backing. In the one embodiment of the present process, a continuous roll of unvulcanized rubber is joined to a continuous roll of textile material during vulcanization. In an alternate embodiment, textile panels are positioned onto a continuous roll of unvulcanized rubber, later being joined during vulcanization. After vulcanization of either a textile roll or textile panels to a rubber backing, the resultant mat composite is cut into individual mat units.
BACKGROUNDDust control mats, which have a textile side and a rubber or rubber-like backing, are generally used in access ways where people tend to brush or scrape their feet to prevent carrying moisture and/or dirt into other areas of the premises. Normally, these mats are located in areas of high pedestrian traffic such as doorways. In many cases, these mats are part of an industrial laundry inventory, being rented to customers and serviced by the laundry. On some frequency (e.g., weekly), the laundry collects soiled mats, launders them, and then returns them to the customer. It is important, therefore, that these mats be capable of withstanding rigorous and routine laundering.
In the past, manufacture of these textile-rubber mats has been a time-consuming, labor-driven process. Both the textile material and the unvulcanized rubber sheeting must be cut to the desired dimensions. The textile panel is positioned over the rubber panel on a conveyor belt, and the stacked pair is carried into a vulcanizing chamber. After vulcanization, the individual mat units are created. In some instances, the mats must be trimmed to remove rubber that has spread unevenly during vulcanization.
The present process provides for the feeding of continuous rolls of textile material and unvulcanized rubber into the vulcanization chamber. Once vulcanized, the mat composite is carried through a cutting station where individual mat units are created. Such a process provides greater mat making efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
The stacked panels 6, 8 are conveyed into a vulcanization chamber 60 where rubber panel 8 is softened and subsequently hardened to secure rubber panel 8 to textile panel 6. The first twelve to fifteen inches of vulcanization chamber 60 will be described herein as entry area 58. Entry area 58 is not subject to the pressures realized in vulcanization chamber 60, because of the shape of the diaphragm of the vulcanization press.
It was believed, heretofore, that entry area 58 needed to be a pre-heat area, designed to raise the temperature of textile panel 6 for improved cycle time. Therefore, as shown in
Turning now to
In
Textile material 22 and textile panels 6 are shown as tufted substrates, although other textile constructions may be utilized, including woven, non-woven, and knitted constructions. Textile material 22 and textile panels 6 may be comprised of nylon, polyester, polypropylene, cotton, and other natural and synthetic fibers as may be known in the art. A preferred fiber is nylon. Textile material 22 and textile panels 6 may be printed before or after incorporation into mat 40 or mat 42, respectively. Further, textile material 22 and textile panels 6 may be comprised of solution-dyed yarns.
Rubber layer 32, as used in the process of
Turning again to
During vulcanization, rubber layer 32 softens; pressure is applied to layers 22, 32, thereby pressing textile layer 22 into rubber layer 32; and then rubber layer 32 hardens, securing layers 22, 32 together. Similarly, textile panels 6 are also pressed into rubber layer 32 and are secured. Vulcanization typically occurs at a temperature in the range of about 280° F. to about 440° F., with a preferred temperature of about 360° F. The pressures used in vulcanization are typically in the range of about 15 p.s.i. to about 50 p.s.i., with a preferred pressure of about 40 p.s.i. With the temperatures and pressures described herein, cycle time for vulcanization is typically between about 2 minutes and about 20 minutes, with a cycle time of 4 minutes being expected under preferred vulcanization conditions.
Having undergone vulcanization, textile substrate 22 and rubber layer 32 comprise a mat composite 34. Mat composite 34 is then conveyed through a backing perforation station 65 into a cutting station 70, in which composite 34 is cut into individual mats 40. In
A printed mat may be created in a number of ways. In one embodiment, the roll 20 of textile material 22 is printed before the mat assembly process. In an alternate embodiment, composite 34 is printed before entering cutting station 70. In yet another embodiment, mats 40 are printed after assembly is completed. Printing may be included as part of the continuous process of the present disclosure.
Because of the pressures of vulcanization, it is not abnormal for textile component (either 22 or 6) to appear crushed. This is particularly true when textile component 22 or 6 is comprised of a tufted substrate. Pile height may be restored by washing, brushing, or vacuuming finished mat 40 or 42.
One cut pattern for mats 40 is shown in
Claims
1. A dust control mat composite having a continuous textile upper surface that is vulcanized to a continuous rubber lower surface, said textile surface and said rubber surface having approximately the same dimensions, such that said textile surface substantially covers said rubber surface.
2. The mat composite of claim 1 wherein said textile upper surface is comprised of fibers selected from the group consisting of nylon, cotton, polyester, and polypropylene.
3. The mat composite of claim 2 wherein said textile upper surface is comprised of nylon.
4. The mat composite of claim 1 wherein said rubber surface is comprised of a rubber selected from the group consisting of acrylonitrile-butadiene rubber (NBR), styrene-butadiene rubber (SBR), carboxylated NBR, carboxylated SBR, ethylene-propylene-diene monomer rubber (EPDM), and blends thereof.
5. The mat composite of claim 4 wherein said rubber surface is comprised of acrylonitrile-butadiene rubber (NBR).
6. The mat composite of claim 1 wherein said rubber surface is comprised of multiple layers of rubber.
7. The mat composite of claim 6 wherein said rubber surface includes at least one foam rubber layer.
8. A dust control mat composite having a plurality of textile upper surfaces that are vulcanized to a continuous rubber lower surface, said textile upper surfaces comprising panels of a textile material that are positioned in spaced relation over said rubber lower surface.
9. The mat composite of claim 8 wherein said textile material is comprised of fibers selected from the group consisting of nylon, cotton, polyester, and polypropylene.
10. The mat composite of claim 9 wherein said textile upper surface is comprised of nylon.
11. The mat composite of claim 8 wherein said rubber surface is comprised of a rubber selected from the group consisting of acrylonitrile-butadiene rubber (NBR), styrene-butadiene rubber (SBR), carboxylated NBR, carboxylated SBR, ethylene-propylene-diene monomer rubber (EPDM), and blends thereof.
12. The mat composite of claim 11 wherein said rubber surface is comprised of acrylonitrile-butadiene rubber (NBR).
13. The mat composite of claim 8 wherein said rubber surface is comprised of multiple layers of rubber.
14. The mat composite of claim 8 wherein said rubber surface includes at least one foam rubber layer.
Type: Application
Filed: Sep 24, 2004
Publication Date: Feb 17, 2005
Applicant:
Inventors: Amy Streeton (LaGrange, GA), William Burke (LaGrange, GA)
Application Number: 10/950,229