# US 2017/0282497 A1 · Surface and Edge Attachment for Installation of Multi-Component Floor Mat

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- Number: US 2017/0282497 A1
- Document ID: US20170282497A1
- Status: Published application
- Kind: A1
- Application number: 15/458,094
- Filed: 2017-03-14
- Published: 2017-10-05
- Earliest claimed: 2016-03-29
- Assignees: Milliken & Company
- Applicants: Milliken & Company
- Inventors: Franklin S. Love; Padmakumar Puthillath; Dale S. Kitchen
- Web page: https://patentgrep.com/patent/US20170282497A1

## CPC

- A47L 23/266: {Mats}
- B32B 3/06: for securing layers together; for attaching the product to another member, e.g. to a support {, or to another product, e.g. groove/tongue, interlocking}
- B32B 3/08: characterised by added members at particular parts {(layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18)}
- B32B 5/022: {Non-woven fabric}
- B32B 5/06: characterised by a fibrous {or filamentary} layer {mechanically connected, e.g. by needling} to another layer, e.g. of fibres, of paper
- B32B 7/06: permitting easy separation
- B32B 25/10: next to a fibrous or filamentary layer
- B32B 25/16: comprising polydienes {homopolymers} or poly-halodienes {homopolymers (B32B25/12 takes precedence)}
- B32B 37/02: characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
- B32B 37/10: characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
- B32B 37/182: {one or more of the layers being plastic}
- B32B 38/0004: {Cutting, tearing or severing, e.g. bursting; Cutter details (cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence)}
- B32B 38/0012: {Mechanical treatment, e.g. roughening, deforming, stretching}
- B32B 38/145: {Printing}
- D05C 15/08: Tufting machines {(D05C15/06 takes precedence)}
- D06B 3/10: of fabrics (D06B3/24, D06B3/28, D06B3/32 take precedence; jiggers D06B3/32)
- D06B 5/22: through fabrics
- D06N 7/0094: {Fibrous material being coated on one surface with at least one layer of an inorganic material and at least one layer of a macromolecular material}
- B32B 2037/1081: {using a magnetic force}
- B32B 2250/02: 2 layers
- B32B 2250/24: All layers being polymeric
- B32B 2262/0253: Polyolefin fibres
- B32B 2262/0261: Polyamide fibres
- B32B 2262/0276: Polyester fibres
- B32B 2264/102: Oxide or hydroxide
- B32B 2264/105: Metal
- B32B 2305/30: Fillers, e.g. particles, powders, beads, flakes, spheres, chips
- B32B 2305/72: Cured, e.g. vulcanised, cross-linked
- B32B 2307/748: Releasability
- B32B 2311/30: Iron, e.g. steel
- B32B 2323/10: Polypropylene
- B32B 2323/16: EPDM, i.e. ethylene propylene diene monomer
- B32B 2355/02: ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
- B32B 2367/00: Polyesters, e.g. PET, i.e. polyethylene terephthalate
- B32B 2377/00: Polyamides
- B32B 2471/02: Carpets
- B32B 2471/04: Mats
- D05D 2207/06: Permanent magnets
- D05D 2305/08: Cutting the workpiece
- D06B 2700/19: Passing bleaching, washing or dyeing liquid through fibrous materials by centrifuging
- D06N 2205/20: Cured materials, e.g. vulcanised, cross-linked
- D06N 2209/045: Magnetic, paramagnetic
- D06N 2211/066: Floor coverings
- D06N 2213/068: Releasability between at least two of the layers
- D10B 2321/022: polypropylene
- D10B 2331/02: polyamides (D10B2331/08 takes precedence)
- D10B 2331/04: polyesters, e.g. polyethylene terephthalate [PET]
- D10B 2503/041: Carpet backings
- E04F 15/02144: {by magnets}
- A47L: DOMESTIC WASHING OR CLEANING (brushes A46B; cleaning quantities of bottles or of other hollow articles of one kind B08B9/00; laundry D06F); SUCTION CLEANERS IN GENERAL (cleaning in general B08)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- D05C: EMBROIDERING; TUFTING (making non-woven fabrics D04H; sewing D05B)
- D06B: TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS (mechanical treatment of natural fibrous or filamentary material to obtain fibres or filaments D01B)
- D06N: WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D05D: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES D05B AND D05C, RELATING TO SEWING, EMBROIDERING AND TUFTING
- D10B: INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)

## Abstract

This invention relates to a washable multi-component floor mat. The floor mat contains a textile component and a base component. The textile component and the base component are attached to one another by at least one surface attraction means and at least one edge attachment means. The textile component is designed to be soiled, washed, and re-used, thereby providing ideal end-use applications in areas such as building entryways. The present invention eliminates the need to wash the base component of the floor mat which results in environmental, cost and labor conservation.

## Claims

### Claim 1

A multi-component floor mat comprising:
(a) A textile component comprising (i) a first layer of tufted pile carpet formed by tufting face fibers through a primary backing layer and (ii) at least one surface attachment means; and
(b) A base component, wherein the base component contains at least one surface attachment means; and
wherein the textile component and the base component are releasably attachable to one another via the at least one surface attachment means; and
wherein the textile component and the base component further contain at least one edge attachment means.

### Claim 2 (depends on 1)

The multi-component floor mat of claim 1, wherein the at least one surface attachment means is selected from magnetic attraction, mechanical attachment, adhesive attraction, and combinations thereof.

### Claim 3 (depends on 1)

The multi-component floor mat of claim 1, wherein the at least one edge attachment means is selected from the group consisting of hook and loop fastening systems, mushroom-type hook fastening systems, and combinations thereof.

### Claim 4 (depends on 1)

The multi-component floor mat of claim 1, wherein the at least one edge attachment means of the textile component is narrower in width than the edge attachment means of the base component.

### Claim 5

A multi-component floor mat comprising:
(a) A textile component comprising (i) a first layer of tufted pile carpet formed by tufting face fibers through a primary backing layer and (ii) a second layer of vulcanized rubber material that contains magnetic particles;
(b) A base component comprised of (i) vulcanized rubber that contains magnetic particles or (ii) vulcanized rubber having a magnetic coating applied thereto; and
wherein the textile component and the base component are releasably attachable to one another via magnetic attraction; and
wherein the textile component and the base component further contain at least one edge attachment means.

### Claim 6 (depends on 5)

The multi-component floor mat of claim 5, wherein the textile component is magnetically receptive.

### Claim 7 (depends on 5)

The multi-component floor mat of claim 5, wherein the base component is permanently magnetized.

### Claim 8 (depends on 5)

The multi-component floor mat of claim 5, wherein the textile component of the floor mat can withstand at least one wash cycle in a commercial or residential washing machine whereby the textile component is suitable for re-use after exposure to the at least one wash cycle.

### Claim 9 (depends on 5)

The multi-component floor mat of claim 5, wherein the face fibers are selected from the group consisting of synthetic fiber, natural fiber, man-made fiber using natural constituents, inorganic fiber, glass fiber, and mixtures thereof

### Claim 10 (depends on 5)

The multi-component floor mat of claim 5, wherein the face fibers are selected from nylon 6; nylon 6,6; polyester; polypropylene; or combinations thereof.

### Claim 11 (depends on 5)

The multi-component floor mat of claim 5, wherein the face fibers comprise cut pile, loop pile, or combinations thereof.

### Claim 12 (depends on 5)

The multi-component floor mat of claim 5, wherein the face fibers are dyed, undyed, printed, or combinations thereof.

### Claim 13 (depends on 5)

The multi-component floor mat of claim 5, wherein the primary backing layer is selected from the group consisting of woven material, nonwoven material, knitted material, and combinations thereof.

### Claim 14 (depends on 5)

The multi-component floor mat of claim 5, wherein the primary backing layer is selected from the group consisting of synthetic fiber, natural fiber, man-made fiber using natural constituents, inorganic fiber, glass fiber, and mixtures thereof.

### Claim 15 (depends on 5)

The multi-component floor mat of claim 5, 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 elastomer, and mixtures thereof.

### Claim 16 (depends on 5)

The multi-component floor mat of claim 5, wherein the magnet particles are non-degradable.

### Claim 17 (depends on 5)

The multi-component floor mat of claim 5, wherein the magnetic particles are in an oxidized state.

### Claim 18 (depends on 5)

The multi-component floor mat of claim 5, wherein the magnetic particles are in the size range of from 1 micron to 10 microns.

### Claim 19 (depends on 5)

The multi-component floor mat of claim 5, 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 mixtures thereof.

### Claim 20 (depends on 5)

The multi-component floor mat of claim 5, wherein the magnetic particles are magnetically receptive particles selected from the group consisting of Fe2O3, Fe3O4, steel, iron particles, and mixtures thereof.

### Claim 21 (depends on 5)

The multi-component floor mat of claim 5, wherein the magnetically receptive particles are paramagnetic or superparamagnetic.

### Claim 22 (depends on 5)

The multi-component floor mat of claim 5, wherein the magnetic particle loading is in the range from 10% to 70% by weight in the textile component.

### Claim 23 (depends on 5)

The multi-component floor mat of claim 5, wherein the magnetic particle loading is in the range from 10% to 90% by weight in the base component.

### Claim 24 (depends on 5)

The multi-component floor mat of claim 5, wherein at least one of the textile and base components is characterized as having a functionally graded magnetic particle distribution.

### Claim 25 (depends on 5)

The multi-component floor mat of claim 5, wherein the magnetic particles are ferrite.

### Claim 26 (depends on 5)

The multi-component floor mat of claim 5, wherein the strength of magnetic attraction is greater than 50 gauss.

### Claim 27 (depends on 5)

The multi-component floor mat of claim 5, wherein the vulcanized rubber contains 0% to 40% recycled rubber material.

### Claim 28 (depends on 5)

The multi-component floor mat of claim 5, wherein the at least one edge attachment means is selected from the group consisting of hook and loop fastening systems, mushroom-type hook fastening systems, and combinations thereof.

### Claim 29 (depends on 5)

The multi-component floor mat of claim 5, wherein the at least one edge attachment means of the textile component is narrower in width than the edge attachment means of the base component.

### Claim 30

A multi-component floor mat comprising:
(a) A textile component comprising (i) tufted pile carpet wherein face fibers are tufted through a primary backing layer and (ii) a magnetic coating wherein the magnetic coating is comprised of magnetic particles and a binder material;
(b) A base component comprised of (i) vulcanized rubber that contains magnetic particles or (ii) vulcanized rubber having a magnetic coating applied thereto;
wherein the textile component and the base component are releasably attachable to one another via magnetic attraction; and
wherein the textile component and the base component further contain at least one edge attachment means.

### Claim 31 (depends on 30)

The multi-component floor mat of claim 30, wherein the binder material is selected from a thermoplastic elastomer material, a thermoplastic vulcanite material, and mixtures thereof.

### Claim 32 (depends on 31)

The multi-component floor mat of claim 31, wherein the binder material is selected from the group consisting of urethane-containing materials, acrylate-containing materials, silicone-containing materials, and mixtures thereof.

### Claim 33 (depends on 30)

The multi-component floor mat of claim 30, wherein the magnetic coating is applied to at least one of the textile component and base component via knife coating, pad coating, paint coating, spray application, roll-on-roll methods, troweling methods, extrusion coating, foam coating, pattern coating, print coating, lamination, and mixtures thereof.

### Claim 34 (depends on 30)

The multi-component floor mat of claim 30, wherein the at least one edge attachment means is selected from the group consisting of hook and loop fastening systems, mushroom-type hook fastening systems, and combinations thereof.

### Claim 35 (depends on 30)

The multi-component floor mat of claim 30, wherein the at least one edge attachment means of the textile component is narrower in width than the edge attachment means of the base component.

### Claim 36

A multi-component floor mat comprising:
(a) A textile component comprising (i) a first layer of tufted pile carpet wherein face fibers are tufted through a primary backing layer and (ii) a second layer of vulcanized rubber material that contains magnetic particles or a second layer of magnetic coating;
(b) A base component comprised of (i) vulcanized rubber and magnetic particles or vulcanized rubber and a magnetic coating and (ii) electronic sensors;
wherein the textile component and the base component are releasably attachable to one another via magnetic attraction; and
wherein the textile component and the base component further contain at least one edge attachment means.

### Claim 37 (depends on 1)

A process for cleaning a multi-component floor mat, said process comprising the steps of:
(a) Providing the multi-component floor mat of claim 1;
(b) Removing the textile component from the base component;
(c) Laundering the textile component in an industrial, commercial, or residential washing machine; and
(d) Re-installing the textile component on or within the base component.

### Claim 38

A process for making a multi-component floor mat, said process comprising the steps of:
(a) Tufting face fibers into a primary backing material to form a tufted pile carpet;
(b) Optionally, printing the tufted pile carpet;
(c) Providing a layer of unvulcanized rubber that contains magnetic particles;
(d) Adhering the tufted pile carpet to the layer of magnetic particle-containing unvulcanized rubber via a rubber vulcanization process to form a washable textile component having a vulcanized rubber backing;
(e) Cutting the textile component into a desired shape and size;
(f) Adhering at least one edge attachment means to the washable textile component;
(g) Providing a base component comprised of (i) vulcanized rubber and magnetic particles or (ii) vulcanized rubber and a magnetic coating;
(h) Adhering at least one edge attachment means to the base component; and
(i) Attaching the textile component to the base component via magnetic attraction and edge attachment means.

### Claim 39

A process for making a multi-component floor mat, said process comprising the steps of:
(a) Tufting face fibers into a primary backing material to form a tufted pile carpet;
(b) Optionally, printing the tufted pile carpet;
(c) Providing a magnetic coating comprised of magnetic particles and a binder material;
(d) Adhering the magnetic coating to the tufted pile carpet to form a washable textile component;
(e) Cutting the textile component into a desired shape and size;
(f) Adhering at least one edge attachment means to the textile component;
(g) Providing a base component comprised of (i) vulcanized rubber and magnetic particles or (ii) vulcanized rubber and a magnetic coating;
(h) Adhering at least one edge attachment means to the base component; and
(i) Attaching the textile component to the base component via magnetic attraction and edge attachment means.

### Claim 40

A method for installation of a floor mat comprising the following steps:
(a) Providing a base component, wherein the base component contains (i) at least one magnetic attachment means and (ii) at least one edge attachment means;
(b) Providing a textile component, wherein the textile component is comprised of: (i) tufted pile carpet, (ii) at least one magnetic attachment means that works in corresponding relationship with the at least one magnetic attachment means of step “a,” and (iii) at least one edge attachment means that works in corresponding relationship with the at least one edge attachment means of step “a;” and
(c) Attaching the textile component to the base component, wherein attachment is accomplished via the at least one magnetic attachment means and the at least one edge attachment means, and wherein the base component and the textile component are releasably attachable to one another.

### Claim 41 (depends on 40)

The method of claim 40, wherein the step of attaching the textile component to the base component is further accomplished by dragging the textile component onto the base component until the edge attachment means of the textile component comes into physical contact with the edge attachment means of the base component.