Washable Multi-Component Magnetic Floor Mat
This invention relates to a washable multi-component magnetic 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 magnetic attraction. The magnetic attraction is provided by incorporation of magnetic particles in both the textile and base components. 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. Alignment and deployment of the textile component with the base component in an efficient manner is also described herein.
1 . A process for cleaning a multi-component floor mat, said process comprising the steps of:
(a) Providing a multi-component floor mat, said mat comprising:
(i) a textile component comprised of a first layer of tufted pile carpet formed by tufting face yarns through a primary backing layer, and a second layer of vulcanized rubber material that contains magnetic particles; and
(ii) a base component comprising an elastomer that contains magnetic particles;
wherein the textile component and the base component are releasably attachable to one another via magnetic attraction;
(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.
2 . A process for making a multi-component floor mat, said process comprising the steps of:
(a) Tufting face yarns 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) Providing a base component comprised of an elastomer that contains magnetic particles; and
(g) Attaching the textile component to the base component via magnetic attraction.
3 . A process for making a multi-component floor mat, said process comprising the steps of:
(a) Tufting face yarns 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) Providing a base component comprised of an elastomer that contains magnetic particles; and
(g) Attaching the textile component to the base component via magnetic attraction.