Milliken + Co

Milliken Research Corporation

Robert C Kerr

William O Burke, Iii

James N Rockwell, Jr

Amy B Streeton

Bhawan Patel

John H Murray

Geoffrey R Haas

Amy K Streeton

John G Lever

Roy Phillip Demott

Aage Lang

William H Stewart

Seiin Kobayashi

David L Morris

Thomas D Nord

Jenci Kurja

Akihito Suzuki

Flemming Bojstrup

Patrick Morel

Bennie H Reynolds

Peter C Brazier

Thomas A P Brock

William O Burke, Lll

Riley Samuel Whitt, Jr

Amy Katherine Bowlin

Carolina Mateus

William O Burke Iii

This disclosure relates generally to molded rubber articles such as the type used in water contact applications. More particularly, this disclosure is directed to molded rubber articles containing antimicrobial agents that control biofilm growth on the surface of the molded article. The molded rubber article is comprised of curable rubber compounds and a combination of both inorganic silver-containing antimicrobial agents and organic antimicrobial agents. An exemplary molded rubber article comprises ethylene propylene diene monomer rubber, silver-containing ion exchange antimicrobial agent, and an organic antifungal agent such as zinc pyrithione.

Antimicrobial rubber formulations and molded article

A method of making a mat with a textile surface and an elastomer backing is provided. The method includes mixing elastomer crumbs and a binder, depositing the crumb/binder mixture in a layer (), placing a textile surface element () on the layer to form a mat assembly, and pressing the mat assembly in a press () while setting the binder. The elastomer crumbs are consolidated to form an elastomer backing () that includes voids between the elastomer crumbs, and the textile surface element is bonded to the elastomer backing to form the upper textile layer () of the mat.

Method of making a mat

At least one embodiment of this invention relates to a cushioned dust control mat article wherein the mat comprises at least two distinct layers of rubber, one comprising foam rubber, the other comprising solid rubber. The solid rubber layer is present over the foam rubber layer on the side of the mat in which at least one integrated rubber protrusion is present to provide cushioning characteristics. The solid rubber layer acts as a cap or barrier for the foam rubber layer, particularly over the integrated protrusion or protrusions, in order to provide a mat which is resilient, will not easily degrade in its modulus strength after appreciable use and/or washing within industrial cleaning processes, and will not exhibit appreciable cracking or breaking, particularly within the integrated protrusion(s), after standard use for pedestrian traffic. A method of producing such an inventive cushioned floor mat article is also provided.

Cushioned rubber floor mat article and method

The present invention relates to specific methods of producing cleated rubber-backed floor mats (such as dust control or rubber mats) through the utilization of the combination of a perforated coated woven fabric article and a cushioned platen liner between the article and the metal platen of an in-line dust control mat manufacturing machine. Such a procedure permits a more efficient manner of producing cleated anti-creep dust control mats than previously followed. In particular, the fabric article is in the form of a conveyor belt and is preferably constructed from Teflon&reg;-coated woven fiberglass which will not adhere to the tacky rubber component of the target mat and can withstand the extremely high vulcanization temperatures and pressures required during the production of a dust control mat. The cushioned platen liner, which is preferably comprised of or coated with silicon, is utilized as a separator between the metal platen of the manufacturing machine, as well as cushion for the molten rubber as it is pressed through the conveyor belt perforations during vulcanization. Such a cushioned liner material substantially eliminates any problems due to the force of the metal platen against the molten rubber as it passes through the article perforations. Further, a method for utilizing the conveyor belt to produce foam rubber cleated anti-creep mats is disclosed. The cleats of these mats have a thicker skin than the rest of the mat, thereby imparting enough strength and structural integrity so that the foam rubber mats may withstand the daily rigors of use, combined with periodic launderings. The produced mat as well as the woven fabric article/cushioned platen liner combination are also encompassed within this invention.

Cleat-forming woven fabric article for the manufacture of anti-creep floor mats

The present invention relates to specific methods of producing cleated rubber-backed floor mats (such as dust control or rubber mats) through the utilization of the combination of a perforated coated woven fabric article and a cushioned platen liner between the article and the metal platen of an in-line dust control mat manufacturing machine. Such a procedure permits a more efficient manner of producing cleated anti-creep dust control mats than previously followed. The produced mat as well as the woven fabric article/cushioned platen liner combination are also encompassed within this invention.

Cleated anti-creep floor mats

The present disclosure relates to an anti-fatigue flooring article having inherent properties of electrostatic dissipation. Further, this disclosure relates to flooring article having at least two layers, wherein a first layer (comprised of dense rubber) is calendered to a second layer (comprised of foam rubber). Each layer has a different electrical conductivity, thereby creating a mat having an appropriate range of conductivity when combined. The present flooring article may also include a layer of static dissipating scrim, a grounding means, and/or a colored marking.

Electrostatic dissipating flooring article

A flashless floor mat or product and method are provided. At least one embodiment of this invention relates to a flashless cushioned dust control mat article wherein the mat comprises at least two distinct layers of rubber, one comprising foam rubber, the other comprising solid rubber. The solid rubber layer is present over the foam rubber layer on the side of the mat in which at least one integrated rubber protrusion is present to provide cushioning characteristics. The solid rubber layer acts as a cap or barrier for the foam rubber layer, particularly over the integrated protrusion or protrusions, in order to provide a mat which is resilient, will not easily degrade in its modulus strength after appreciable use and/or washing within industrial cleaning processes, and will not exhibit appreciable cracking or breaking, particularly within the integrated protrusion(s), after standard use for pedestrian traffic. A method of producing such an inventive cushioned floor mat article is also provided.

Flashless rubber floor mat and method

The present invention relates to specific methods of producing cleated rubber-backed floor mats (such as dust control or rubber mats) through the utilization of the combination of a perforated coated woven fabric article and a cushioned platen liner between the article and the metal platen of an in-line dust control mat manufacturing machine. Such a procedure permits a more efficient manner of producing cleated anti-creep dust control mats than previously followed. In particular, the fabric article is in the form of a conveyor belt and is preferably constructed from Teflon&reg;-coated woven fiberglass which will not adhere to the tacky rubber component of the target mat and can withstand the extremely high vulcanization temperatures and pressures required during the production of a dust control mat. The cushioned platen liner, which is preferably comprised of or coated with silicon, is utilized as a separator between the metal platen of the manufacturing machine, as well as cushion for the molten rubber as it is pressed through the conveyor belt perforations during vulcanization. Such a cushioned liner material substantially eliminates any problems due to the force of the metal platen against the molten rubber as it passes through the article perforations. The produced mat as well as the woven fabric article/cushioned platen liner combination are also encompassed within this invention.

Apparatus for forming cleated floor mat

This invention relates to a cushioned floor covering article wherein the mat includes a tufted carpet placed on the top side of a foam rubber sheet and at least one foam rubber protrusion integrated within at least a portion of the bottom side of the foam rubber sheet. Such an article provides effective removal of moisture, dirt, and debris from the footwear of pedestrians through the utilization of a carpet pile component. Furthermore, the utilization of a foam rubber backing also allows for either periodic heavy duty industrial-scale laundering in such standard washing machines or periodic washing and drying in standard in-home machines, both without appreciably damaging the inventive floor covering article, such as a floor mat. Additionally, the presence of integrated foam rubber protrusions within the mat structure provides an effective cushioning effect for pedestrian comfort as well as a means to prevent slippage of the article from its contacted surface. A method of producing such an inventive cushioned floor covering article is also provided.

Cushioned carpeted floor covering article comprising at least one integrated rubber protrusion

Certain butadiene and/or natural rubber articles, such as acrylonitrile-butadiene rubber (NBR), natural rubber, and derivatives thereof, that exhibit highly desirable long-term effective antimicrobial characteristics. Such formulations are intended to be vulcanized to provide solid or foam rubber articles which can be utilized in a variety of different applications. Preferably such butadiene rubber formulations comprise silver-based antimicrobial compounds. As such silver-based compounds are deleteriously affected by utilization of standard non-silicone-rubber curing agents, such as sulfur-based catalysts, the ability to provide such an effective antimicrobial vulcanized rubber article is rather difficult. However, the invention encompasses the utilization of different catalyst species that permit vulcanization and silver stability for long-term antimicrobial performance of the silver-based compounds. Articles and specific vulcanizing procedures in accordance with such a novel antimicrobial vulcanized rubber are also included within the scope of this invention.

Antimicrobial articles made from nitrile or natural rubber

The disclosure relates to a floor mat and method for producing the same. The floor mat includes a plurality of tufts extending from a carrier fabric which is joined by a layer of adhesive to a backing having at least one layer of vulcanized thermoplastic elastomer. The process for production of the floor mat includes applying an olefin based adhesive to the back of a primary tufted fabric which has been preheated. The process for production includes the further separate step of applying a sheet of vulcanized thermoplastic elastomer of between about 20 and 40 mils thickness with or without a layer of reinforcing material to the preheated adhesive backed primary tufted fabric. A second layer of vulcanized thermoplastic elastomer may thereafter be applied following another heating step.

Floor mat and continuous process for the manufacture thereof

This invention relates to a cushioned dust control mat article wherein the mat comprises at least two distinct layers of rubber, one comprising foam rubber, the other comprising solid rubber. The solid rubber layer is present over the foam rubber layer on the side of the mat in which at least one integrated rubber protrusion is present to provide cushioning characteristics. The solid rubber layer acts as a cap or barrier for the foam rubber layer, particularly over the integrated protrusion or protrusions, in order to provide a mat which is resilient, will not easily degrade in its modulus strength after appreciable use and/or washing within industrial cleaning processes, and will not exhibit appreciable cracking or breaking, particularly within the integrated protrusion(s), after standard use for pedestrian traffic. A method of producing such an inventive cushioned floor mat article is also provided.

Cushioned rubber floor mat article comprising at least one integrated rubber protrusion and at least two layers of rubber

A launderable dust control mat having antimicrobial properties is provided. The mat includes a pile fiber upper surface and a rubber backing surface. Metal based antimicrobial agent, are disposed within both the fiber forming the upper surface and the rubber forming the backing surface thereby providing antimicrobial character to the mat as a whole.

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LaGrange, GA, United States of America

Robert C Kerr