Source: http://www.google.com/patents/USRE36677?dq=7,321,221
Timestamp: 2014-03-12 06:13:48
Document Index: 264083097

Matched Legal Cases: ['Application No. 4', 'Application No. 92401240', 'Application No. 92', 'Application No. 92401240', 'Application No. 92401240', 'Application No. 92401240', 'Application No. 92401240', 'Application No. 92401240', 'Application No. 92401240', 'Application No. 92401240', 'Application No. 92401240', 'Application No. 4', 'Application No. 4', 'Application No. 92', 'Application No. 92', 'Application No. 92', 'Application No. 4', 'Application No. 92401240']

Patent USRE36677 - Method of making a floor mat having a channel - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsThe floor mat of the present process is a pliable multilayer structure having an upper face layer and a base layer. The base layer has a main body section bordered by an edge section. Preferably, the main body section is relatively thin and the edge section is relatively thick. A surface of the base...http://www.google.com/patents/USRE36677?utm_source=gb-gplus-sharePatent USRE36677 - Method of making a floor mat having a channelAdvanced Patent SearchPublication numberUSRE36677 EPublication typeGrantApplication numberUS 09/163,995Publication dateMay 2, 2000Filing dateSep 30, 1998Priority dateMay 3, 1991Also published asUS5154961, US5362544Publication number09163995, 163995, US RE36677 E, US RE36677E, US-E-RE36677, USRE36677 E, USRE36677EInventorsHarold ReubenOriginal AssigneeCollins & Aikman Accessory Mats, Inc.Export CitationBiBTeX, EndNote, RefManPatent Citations (41), Non-Patent Citations (28), Referenced by (10), Classifications (38), Legal Events (9) External Links: USPTO, USPTO Assignment, EspacenetMethod of making a floor mat having a channelUS RE36677 EAbstract The floor mat of the present process is a pliable multilayer structure having an upper face layer and a base layer. The base layer has a main body section bordered by an edge section. Preferably, the main body section is relatively thin and the edge section is relatively thick. A surface of the base layer is adapted to confront flooring overlaid by the mat. The edge section has a channel extending longitudinally thereof, and preferably opening from the bottom surface of the edge section. A portion of the main body section can have a channel molded therein such that a portion of the main body section is disposed above the remainder of the main body section to provide a decorative and aesthetically pleasing design in the main body section.
10. A method of forming an integral raised portion is an edge section of a floor mat; said floor mat having a pliable multilayer structure having an upper face layer of tufted pile carpeting and overlying a base layer of a heat curable elastomeric material and having a relatively thin main body section bordered by a relatively thick edge section; said edge section having an integrally molded channel extending longitudinally thereof and opening from the bottom surface thereof, and having an upper surface disposed at an elevation above the elevation of said main body section of said base layer so as to form an integral raised portion in said edge section, said method comprising:contacting a top surface of the base layer to a bottom surface of the face layer; placing the base layer and the face layer under a compressive molding pressure selected from the range of about 50 psi to about 250 psi, where the compressive molding pressure is applied to a bottom surface of the base layer and a top surface of the face layer to mold a channel in and opening from the edge section and extending longitudinally thereof while the base layer and the face layer form a relatively thin main body section bordered by a relatively thick edge section; embedding a portion of the bottom surface of the face layer in the top surface of the base layer; heating the base layer to a temperature within the range of about 250 elastomeric material of the base layer while the face layer and the base layer are under the compressive molding pressure; cooling the face layer to a temperature less than about 100 maintain the pile carpeting of the face layer below a temperature at which the carpet pile becomes substantially permanently deformed under the applied molding pressure so as to maintain the resiliency of the carpet pile upon release of the compressive molding pressure, the cooling being conducted simultaneously while the face layer and the base layer are under pressure; and maintaining the heating of the base layer for a period of time selected from the range of about one minute to about twenty minutes until the heat curable elastomeric material of the base layer is cured, so as to form an integral raised portion in the edge section of the floor mat, defined by said integrity molded channel. 11. A method according to claim 10, wherein said molding step includes molding rib members disposed within and extending transversely across the channel.
Another problem is that the mats have a tendency to move or shift due to the action of feet on the mat. Various efforts have been made to prevent slippage by use of permanent retention means such as hooks, snap fasteners, Velcro commercially successful because they tend to distract from the aesthetics of the mat. Another solution, particularly for mats used in automobiles, is to use an array of downwardly extending projections or "nibs" to reduce slippage such as proposed, for example in commonly assigned U.S. Pat. No. 4,174,991 to Reuben. An alternative solution is to use a tacky adhesive on the undersurface of the mat such as proposed in U.S. Pat. No. 4,609,850 to Rockett et al. A combination of nibs and tacky adhesive has also been proposed in commonly assigned U.S. Ser. No. 07/642,926 filed Jan. 18, 1991, and a combination of nibs and polyurethane foam has been proposed in commonly assigned U.S. Ser. No. 07/687,234 filed Apr. 18, 1991.
The method of the present invention includes contacting the upper or top surface 17 of a base layer 15 to the bottom surface of the upper face layer 12 followed by placing the base layer 15 and face layer 12 under compressive molding pressure, (e.g., a pressure selected from the range of 50 psi to about 250 psi). Preferably, if a tufted pile tufted carpet is the upper face layer 12, the pile is crushed while the face layer 12 and the base layer 15 are under the compressive molding pressure. A channel 22 or channel 22a is molded in, and preferably opens from the bottom surface 19 of the base layer 15 or the bottom surface 19a of the main body portion 20 while the upper face layer 12 and base layer 15 are under compressive molding pressure. A portion of the bottom surface of the face layer 12 becomes embedded in the base layer during heating and curing of the base layer 15 at a temperature of from about 250 400 molding pressure. The face layer of the multilayered mat 10 is cooled to a temperature of less than 100 carpet yarns below a temperature at which the pile become substantially permanently deformed under the applied molding pressure and so as to maintain the resiliency of the face layer 12 upon release of the molding pressure. The cooling is conducted simultaneously while the face layer 12 and base layer 15 are under pressure. The heating of the base layer 15 is maintained until the elastomeric material or the thermoplastic material of the base layer are cured. A suitable molding apparatus is described more fully in U.S. Pat. No. 4,174,991, although other molding techniques, particularly if thermoplastic materials are used, will be apparent to one skilled in the art.
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Whitney Catalog No. 515J, p. 96, MAT No. 1 of 4 Piece Carpet Mat Set. Bottom Center of Page.17 *J.C. Whitney Catalog No. 515T, p. 97, Plush Carpet Mat No. 1, Lower Left Center of Page and Customer tailored Carpet Mat No. 3. Left Center of Page.18J.C. Whitney Catalog No. 515T, p. 97, Plush Carpet Mat No. 1, Lower Left Center of Page and Customer-tailored Carpet Mat No. 3. Left Center of Page.19 *Letter from Ronald J. Snyder to F. Michael Sajovec dated Dec. 20, 1996 (including 6 sheets of color photographs).20 *Letter from Thomas M. Berry to Mr. James Lockwood dated Dec. 15, 1997.21 *Memo from Kathy Au to Mr. Ernie De La Motte dated Jan. 23, 1993.22 *Observations and Answer to Official Action, re: EPO Application No. 92 401 240.4, dtd. Oct. 5, 1995; from A. Hurwic et al.23 *Observations and Answer to the Official Action, re: EPO Application No. 92 401 240.4, dtd. 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Jul. 15, 1997; re: Application No. 92401240.428 *Untitled photographs of rubber mat (6 sheets, 11 photographs, labeled with reference No. 49), date unknown.* Cited by examinerReferenced byCiting PatentFiling datePublication dateApplicantTitleUS6382350Apr 2, 2001May 7, 2002Collins & Aikman Products Corp.Molded acoustic and decorative mats and methods for forming the sameUS6595321Mar 28, 2002Jul 22, 2003Collins & Aikman Products Co.Floor mats having peripheral apertures with acoustic absorbing materialUS6986547 *Sep 30, 2002Jan 17, 2006Lear CorporationHybrid vehicle interior componentUS7011181Jul 8, 2003Mar 14, 2006Lear CorporationSound insulation systemUS7182172 *Jan 16, 2006Feb 27, 2007Lear CorporationSound insulation systemUS7182994Jan 8, 2003Feb 27, 2007Pretty Products, Inc.Acoustic floor matUS7261361 *Feb 13, 2007Aug 28, 2007Simons Matthew L WVehicle utility matUS7464791 *Jan 27, 2005Dec 16, 2008Pretty Products, LlcAcoustic mats and methods for making the sameUS8309198Feb 3, 2010Nov 13, 2012Product Bliss, LlcRugs with a mat portionUS20130146734 *Jun 8, 2012Jun 13, 2013Waxman Consumer Products Group Inc.Protection stand* Cited by examinerClassifications U.S. Classification156/219, 156/72, 264/294, 428/83, 428/82, 428/95, 428/88, 264/293, 264/319, 264/243, 428/89International ClassificationB29C67/00, B29D99/00, B29C59/02, A47L23/26, B29C43/18, B60N3/04Cooperative ClassificationB29D99/0057, B29C43/18, B29C67/0044, A43B3/0078, B29C59/025, B29L2031/7324, B60N3/044, B60N3/048, B29K2995/0026, B29L2031/3017, A43B23/24, A47L23/266European ClassificationA43B23/24, A43B3/00S80, B29C67/00K, B29D99/00L, B60N3/04C, B60N3/04F, B29C59/02C2, B29C43/18, A47L23/26CLegal EventsDateCodeEventDescriptionJun 7, 2011ASAssignmentEffective date: 20110603Free format text: SECURITY AGREEMENT;ASSIGNOR:INTERNATIONAL AUTOMOTIVE COMPONENTS GROUP NORTH AMERICA, INC., A DELAWARE CORPORATION;REEL/FRAME:026404/0069Owner name: THE BANK OF NEW YORK MELLON, AS COLLATERAL AGENT,Dec 10, 2010ASAssignmentEffective date: 20101110Free format text: SECURITY AGREEMENT;ASSIGNOR:INTERNATIONAL AUTOMOTIVE COMPONENTS GROUP NORTH AMERICA, INC.;REEL/FRAME:025882/0019Owner name: GENERAL ELECTRIC CAPITAL CORPORATION, AS AGENT, CODec 10, 2010XASNot any more in us assignment databaseFree format text: SECURITY INTEREST;ASSIGNOR:INTERNATIONAL AUTOMOTIVE COMPONENTS GROUP NORTH AMERICA, INC;REEL/FRAME:025845/0193Dec 28, 2007ASAssignmentOwner name: INTERNATIONAL AUTOMOTIVE COMPONENTS GROUP NORTH AMFree format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:COLLINS & AIKMAN ACCESSORY MATS, LLC;REEL/FRAME:020299/0240Effective date: 20071011Dec 12, 2007ASAssignmentOwner name: COLLINS & AIKMAN ACCESSORY MATS, LLC, MICHIGANFree format text: CHANGE OF NAME;ASSIGNOR:COLLINS & AIKMAN ACCESSORY MATS, INC.;REEL/FRAME:020234/0196Effective date: 20070928Mar 25, 2002ASAssignmentOwner name: JPMORGAN CHASE BANK, AS COLLATERAL AGENT, TEXASFree format text: SECURITY INTEREST;ASSIGNOR:COLLINS & AIKMAN ACCESSORY MATS, INC. (DE CORPORATION);REEL/FRAME:012691/0720Effective date: 20011220Owner name: JPMORGAN CHASE BANK, AS COLLATERAL AGENT P.O. BOXFree format text: SECURITY INTEREST;ASSIGNOR:COLLINS & AIKMAN ACCESSORY MATS, INC. (DE CORPORATION) /AR;REEL/FRAME:012691/0720Jan 30, 2002ASAssignmentOwner name: COLLINS & AIKMAN ACCESSORY MATS, INC., MICHIGANFree format text: TERMINATION AND RELEASE OF SECURITY INTEREST IN PATENTS RECORDED AT REEL/FRAME 11828/0511;ASSIGNOR:JPMORGAN CHASE BANK (F/K/A THE CHASE MANHATTAN BANK);REEL/FRAME:012513/0441Effective date: 20020110Owner name: COLLINS & AIKMAN ACCESSORY MATS, INC. 5755 NEW KINFree format text: TERMINATION AND RELEASE OF SECURITY INTEREST IN PATENTS RECORDED AT REEL/FRAME 11828/0511;ASSIGNOR:JPMORGAN CHASE BANK (F/K/A THE CHASE MANHATTAN BANK) /AR;REEL/FRAME:012513/0441May 22, 2001ASAssignmentOwner name: CHASE MANHATTAN BANK, AS COLLATERAL AGENT, THE, TEFree format text: GUARANTEE AND COLLATERAL AGREEMENT;ASSIGNOR:COLLINS & AIKMAN ACCESSORY MATS, INC.;REEL/FRAME:011828/0511Effective date: 20010223Owner name: CHASE MANHATTAN BANK, AS COLLATERAL AGENT, THE P.OFree format text: GUARANTEE AND COLLATERAL AGREEMENT;ASSIGNOR:COLLINS & AIKMAN ACCESSORY MATS, INC. /AR;REEL/FRAME:011828/0511Feb 7, 2000ASAssignmentOwner name: COLLINS & AIKMAN ACCESSORY MATS, INC., OHIOFree format text: CHANGE OF NAME;ASSIGNOR:AKRO CORPORATION, THE;REEL/FRAME:010525/0565Effective date: 19990423Owner name: COLLINS & AIKMAN ACCESSORY MATS, INC. 1212 SEVENTHRotateOriginal ImageGoogle Home - Sitemap - USPTO Bulk Downloads - Privacy Policy - Terms of Service - About Google Patents - Send FeedbackData provided by IFI CLAIMS Patent Services©2012 Google