Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
1997-09-11
2001-08-21
Ball, Michael W. (Department: 1733)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C156S324000, C015S238000, C428S913300
Reexamination Certificate
active
06277233
ABSTRACT:
FIELD OF INVENTION
The present invention relates to cushioned floor mats and methods for making them, particularly to a cushioned floor mat which has a customizable aesthetic appearance and a method of customizing such mats.
BACKGROUND
Cushioned floor mats are often used on a hard surface to help reduce the physical stress and fatigue of people standing or walking on the surface for prolonged periods of time. In addition, such floor mats may also protect the underlying floor surface from the wear and tear of traffic passing over it.
Such cushioned floor mats are typically made from a cushioning layer of rubber, foam, or other elastomeric or thermoplastic material. However, plain rubber mats do not appear very attractive, particularly when placed in an environment where decor is important. Some prior art mats have tried to improve this appearance by embedding colored plastic in the mat's top surface or by embossing a pattern into the rubber itself.
Other floor mats have provided somewhat better aesthetic appearance by including a layer of carpeting or elastomeric or thermoplastic tile material on top of the cushioning layer. Typically this additional layer provides a tile or carpet finish to the upper surface of the mat more suitable to a room's design. However, such prior art mats do not allow colorful, delicate patterns, or intricate colors to be selected which coordinate with a room's interior design and decor.
Therefore, a new floor mat is needed, which can incorporate patterned and colored materials and fabrics to coordinate the appearance of the mat with a room's interior decor.
SUMMARY OF THE INVENTION
The present invention comprises a cushioned floor mat which incorporates a patterned or colored material layer allowing the floor mat to be customized. Broadly, the present invention has a cushioned backing layer of rubber or other thermoplastic elastomer, and a substantially clear top layer of thermoplastic material such as polyvinyl chloride. The present floor mat further includes an intermediate layer sandwiched between the backing and top layers. This intermediate layer preferably comprises a colorful or patterned substrate material visible through the top layer which provides the mat with an aesthetically pleasing appearance.
In addition, a mat in accordance with the present invention preferably has a scuff-resistant pattern on the top surface of the substantially clear top layer. The pattern may be sand-blasted onto the surface either before or after the layers of the mat are bonded together. Alternatively, the material used for the top layer may be preformed with the pattern thereon, such as during an extrusion rolling process used to make the material, or the pattern may be pressed into the surface when the layers of the mat are fused together.
Preferably, the three layers (backing, intermediate, and top) are fused together under heat and pressure. Because of these manufacturing conditions, a substrate material for the intermediate layer is preferred which the fusing conditions will not adversely affect. Furthermore, the selected material should maintain flexibility during fusing and subsequent use.
Alternatively, all or some of the three layers may be fused together using adhesives which may be sprayed, brushed or otherwise applied onto one or both of the surfaces of the layers being adhered together.
It is, therefore, a primary object of the present invention to provide a new cushioned floor mat with a pleasing aesthetic appearance, and a method of producing such mats.
Another object of the present invention is to provide a cushioned floor mat which incorporates a substrate layer having a colorful and/or patterned appearance visible when looking at an assembled mat, and a method of manufacturing such mats.
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Ball Michael W.
Lyon & Lyon LLP
Musser Barbara J.
Pacific Foam Technologies
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