Cushioned carpeted floor mat with at least one cushioning integrated rubber protrusion

Abstract

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.

What is claimed is:  
     
       1. A cushioned floor covering article comprising, as a single unitary article, 
       a carrier fabric;  
       a pile material tufted into the carrier fabric which forms a pile surface on one side of the carrier fabric; and  
       a vulcanized expanded backing sheet comprised of foam rubber attached to the other side of the carrier fabric, wherein at least one integrated  protrusion comprised of a foam rubber cap and  integrated with said backing sheet is present on the one  side of the backing opposite the side to which the carrier fabric is attached, and wherein said at least one integrated protrusion comprises is comprised of  a foam rubber cap  core capped with solid rubber.  
     
     
       2. The floor covering article of  claim 1  wherein said at least one protrusion integrated within said backing sheet is substantially cylindrical in shape. 
     
     
       3. The floor covering article of  claim 1  wherein a plurality of protrusions integrated within said backing sheet is present. 
     
     
       4. The floor covering article of  claim 1  further comprising at least one solid rubber reinforcing strip around the border edges of the side of the backing sheet attached to said carrier fabric. 
     
     
       5. The floor covering article of  claim 1  wherein said pile fabric comprises yarns selected from the group consisting of nylon, polyester, cotton, wool, and any blends thereof. 
     
     
       6. The floor covering article of  claim 5  wherein said pile fabric comprises solution-dyed nylon. 
     
     
       7. The floor covering article of  claim 1  wherein said carrier fabric is selected from the group of fabric materials consisting of woven fabrics, non-woven fabrics, and knit fabrics. 
     
     
       8. The floor covering article of  claim 7  wherein said carrier fabric is a woven material. 
     
     
       9. The floor covering article of  claim 7  wherein said carrier fabric is a non-woven material.