A method of constructing a large, complex composite panel involves connecting smaller compression molded thermoplastic subpanels, edge to edge using a thermoplastic co-consolidation method. The edges of adjacent subpanels are given complementary surface configurations. The surface configurations are overlapped and heat and pressure are applied to the overlapping surface constructions to co-consolidate the surface constructions in forming a large, composite panel of two or more subpanels.

A mat unit is formed from at least two layers ultrasonically welded together. Each layer is individually formed from non-vinyl nontoxic thermoplastic elastomer (TPE) material. In ultrasonically joining the two layers together, there is no need to use additional materials, such as adhesive (i.e., chemical attachment) or stitched thread (i.e., mechanical attachment) to form the joint/weld point. Once formed from the two layers, the mat unit has four quadrants and a plurality of longitudinal ribs integrally formed in the first layer positioned in the first and third quadrants, and a plurality of transverse ribs integrally formed in the first layer positioned in the second and fourth quadrants. Additionally, there are a plurality of longitudinal ribs integrally formed in the second layer positioned in the second and fourth quadrants, and a plurality of transverse ribs integrally formed in the second layer positioned in the first and third quadrants.

Systems useful for reinforcing a support mat over at least one seam formed between upper and lower panels of the mat include at least one extruder configured to apply weld-forming material over the seam(s) to form at least one weld atop the seam(s) and at least one electronic controller associated with the extruder.

A system to re-configure an input material into an output material includes an input material feeder reconfigurable to accept and feed an input material, an output material spooler, the input material feeder re-configurable relative to the material cutter to cut the input material at a re-configurable cut angle to produce a first intermediate cut section of material, a positioning and alignment system to position and align a leading edge of the first intermediate cut section of material with a trailing edge of a second intermediate cut section of material, a welder having a configurable position to weld the first intermediate cut section of material to the second intermediate cut section of material, and a control system comprising logic to set at least intensity of the welder, a contact pressure of the welder, temperature of the weld-table surface, and a tension applied by the output material spooler.

A welded synthetic floor-covering material which is formed from one or more adjacent pairs of flooring elements wherein each adjacent pair of flooring elements is welded together by a symmetrical lower weld which engages each flooring element substantially equally; and wherein the symmetrical lower weld is substantially free from a metallic element; and a method of preparing a welded synthetic floor-covering material having a layout suitable for covering a pre-determined area wherein the welded synthetic floor-covering material comprises one or more adjacent pairs of flooring elements which have a floor-engaging lower surface and wherein the method comprises the following steps: (a) providing a floor plan for the pre-determined area wherein the floor plan defines a layout of flooring elements including positions of one or more welds; (b) providing a length of flooring and forming a groove on the floor-engaging surface of the flooring at the position of each of the one or more welds; (c) cutting the length of flooring to form the one or more adjacent pairs of flooring elements; and (d) arranging the flooring elements according to the layout and welding together each of the one or more adjacent pairs of flooring elements to form a symmetrical lower weld which engages each flooring element substantially equally such that the welded synthetic floor-covering material is formed.

A method for forming a geomembrane liner testable for leaks by securing adjacent panels together with the conductivity of the lower surface of an overlying panel broken along a line adjacent the panel overlapping edge, and the overlapping edges sealed along the line. A heat welder has slots for the overlapping panel edges, with a heated wedge between the slots and having a projection to break the conductivity of the overlying panel bottom surface as it passes the wedge. The slots merge to press the liner edges together to heat weld them along the line of broken conductivity as the welder is moved along the panel edges.

An off-axis prepreg material manufacturing machine may include a robot configured to position a prepreg piece adjacent to an end of a prepreg layer. The machine may additionally include an alignment system configured to sense a position of the prepreg piece relative to the prepreg layer and generate a position signal representative thereof. The machine may also include a controller configured to receive the position signal and cause the robot to adjust the position of the prepreg piece such that an end edge of the prepreg piece and an end edge of the prepreg layer are in substantially abutting contact.

An automatic welding machine for lap welding the edges of plastic webs, comprising a movable supporting frame, a heating device for partially melting the plastic webs, at least two opposing, counter-rotating pressing rollers and/or advancing rollers, at least one of which being driven, and at least one driving device comprising a drive motor and at least one gearbox for driving the pressing and/or advancing rollers, wherein the pressing rollers and/or advancing rollers are driven by the driving device by way of at least one flexible shaft. Furthermore, the gearbox can be implemented as a worm gear mechanism comprising a worm that is seated directly on a motor shaft of the drive motor and two counter-rotating worm gears driven by the worm.

A hand-held, portable floor seam sealing device is provided that has universal application to many commercially available floor sheet materials, including vinyl, linoleum, rubber, sport floors as well as other flooring sheet materials. The device employs a seam sealing welding gun and a nozzle of unique configuration defining a cavity bounded by a front end with two rows of at least eight air jet apertures directed toward a gap formed between forwardly projecting glue stick receiving flanges. The nozzle also through has a downwardly directed fin that terminates in a multiplicity of downwardly directed air jet discharge apertures. As the device is moved along the length of a seam between adjacent sheets of flooring, hot air from the apertures in the downwardly directed air jet discharge ridge preheats the portion of the seam into which sealant is about to be dispensed while hot air from the air jet apertures in the front end of the nozzle melts the sealant.

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.