Continuous mat making process and product

Abstract

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.

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.