The mat of the present invention includes a main body integrally formed by a plastic material. The main body at least has a first surface and a second surface adjacent to the first face. The first face and the second face have different surface physical characteristics. The first surface and the second surface are shaped into a third surface and a fourth surface respectively. The third surface and the fourth surface have a substantially same surface physical characteristic. An angle between the third surface and the fourth surface outside the main body is a specific value.

The present invention provides a flexible mat with fluid conduit, methods of manufacture thereof and apparatus for the manufacture thereof. In an embodiment, the mat comprises a base layer, one or more fluid conduits and a thermoplastic bonding tape that attaches the fluid conduits to the base layer. The base layer can be a textile fabric, mesh or netting, or a flat flexible sheet. The base layer is preferably also formed of a thermoplastic layer. The fluid conduits can carry heated or cooled fluid, such as water, that can be used for heating or cooling an environment in which the device is deployed. For example, the device can be used for heating or cooling in a greenhouse environment. The fluid conduits can additionally or alternatively carry irrigation fluids, such as water or treated water, for irrigating plants and crops. The fluid conduits can additionally or alternatively carry gases, such as carbon dioxide (CO.sub.2) or carbon dioxide mixed with other gasses, for treating plants and crops.

An anti-fatigue mat is made by placing a top surface layer member upside down on a mold surface having a contiguous raised portion that defines the perimeter of the anti-fatigue mat. The raised portion surrounds a region into which a major portion of the surface layer sits, resulting in a depression formed relative to the height of the raised portion in the area surrounded by the raised portion. A frame member fit around the raised portion and holds the top surface layer member in place. A gel material is dispensed onto the back side, which is facing upward in the mold, of the top surface layer member. A substrate material is then dispensed onto the gel material and a press head is lowered onto the mold to apply pressure and heat. After the press head is removed, the rough mat can be removed and trimmed to form an anti-fatigue mat. The composition of the gel and substrate materials are carefully selected to achieve the desired bonding of the layers as well as the desired resilience and compressibility of the mat to provide the anti-fatigue effect.

A method of forming aligned patterns on a mat contains steps of: (1). providing a main die configured to mold a body on a substrate; (2). forming multiple patterns on the body so as to produce a decoration portion; (3). forming a toothed cutting line on the body by ways of the alignment mark line so as to form multiple connection units on which multiple patterns are formed respectively, thus producing the mat; and (4). aligning the multiple patterns on the mat so as to provide or design the decoration portion on the multiple patterns, wherein the mat is disassembled to multiple coupling parts, and the multiple coupling parts of the mat are connected with another mat, thus producing an expandable mat.

The invention relates to a method for manufacturing a pellet, comprising a) providing residual rubber powder from i rubber disintegration process; b) providing a pelletizing system, including a pelletizer and a cooling device; c) feeding the residual rubber powder as at least part of a feed material, into a pelletizer; d) providing the rubber powder in an amount between 50% and 100%; i) applying a pressure to the residual rubber for a predetermined process duration; f) releasing the pelletized rubber and cooling the pelletized rubber at a cooling rate dependent on the operational temperature of the pelletizer.

An anti-fatigue mat is disclosed including a foam member and a gel member that each exhibit a different durometer. The foam member includes a support surface that supports the gel member atop the foam member. The foam member includes a foam ramp that extends outwardly downward from the gel member to a bottom surface of the foam member. A flexible cover layer is situated above the gel member and extends over the foam ramp so that the foam member and the flexible cover layer together encapsulatively seal the gel member therein. The flexible cover layer includes an indentation region situated substantially adjacent a gel/foam interface between the gel member and the foam member and further situated a predetermined distance from the peripheral edge of the mat in one embodiment. The bottom surface of the mat may include a non-slip surface to stabilize the mat on the particular surface that the mat covers.

A method of reinforcing a support mat includes at least one extruder applying at least a first stream of weld-forming material over at least one seam formed between upper and lower, interconnected, at least partially overlapping, panels on the top of the mat and at least one automated extruder applying at least a second stream of weld-forming material over at least one seam formed between the panels on the bottom of the mat.

A two part floor covering useful for entranceway is provided having a mat overlaying a base. A fastening system incorporating a mushroom-type fastener is provided, whereby the mat can be laid on the base and positioned as desired, without the fastening system engaging. When the mat is aligned with the base, downward pressure on the mat engages the fastening system and restricts the mat from slipping laterally or lifting vertically. Alignment and deployment of the textile component with the base component in an efficient manner is also described herein.

A mat unit includes a plurality of gaps defined by a first layer that are in open communication with gaps defined by a second layer so as to permit debris to fall entirely through both gaps to pass completely through the mat unit. The mat unit is part of an omnidirectional mat cleaning system that includes a first direction of travel above the mat unit extending through a door opening defined by a building structure. A different second direction of travel is above the mat unit extending through the door opening or another door opening defined by the building structure. The mat unit is installed on a floor adjacent the door opening. The mat unit cleans shoes regardless of the direction of travel traveled above the mat unit.

Apparatus and methods for improved composition of floor coverings, utilizing bio-renewable materials, is disclosed. Floor coverings, or tacky mats, may be used in cleanroom environments to capture particulate matter from foot and equipment traffic. Bio-renewable materials may include thermoplastic starch (TPS) blends made from sustainable raw materials such as corn, tapioca, or the like. These bio-renewable materials may be blended and coextruded with synthetic or petro-based polymers. This reduces the environmental impact on production and disposal of the floor mat, while maintaining the physical and mechanical properties demonstrated by pure synthetic polymers.