GB1091523A - Composite flock-coated mats - Google Patents

Abstract

A composite mat suitable for car floors comprises a non-planar shaped moulded mat having a flexible base sheet with an adherent pile surface of fibrous flock and attached thereto one or more sections of moulded mat comprising a vulcanized natural or synthetic rubber composition. The composite mat may be made by coating the surface of a flexible base sheet with a curable natural or synthetic rubber latex adhesive, electrostatically depositing flock on the adhesive, drying the adhesive, placing the flock-coated section on an electrically-heated vacuum mould and applying vacuum so that the section is drawn into position, curing the base sheet and the adhesive and attaching moulded mats comprising a natural or synthetic rubber composition to the flock-coated section. After moulding, the mat may be provided with a resilient under-layer which can be attached to part or all of the under surface of the mat. The flexible base sheet may comprise a thermoplastic material, bonded-fibre fabric, or a vulcanizable natural or synthetic rubber composition. In order to avoid undue porosity, oil-dispersed quicklime may be included in the vulcanisable composition. If, however, a cellular base is required, a blowing agent may be incorporated therein. The base sheet may have depressions in which the ends of the flock are bonded in tufts. The flock may be of rayon or nylon. The moulded mats, which may be attached to the flock coated section by adhesives, stitching, or press-button means, may comprise a base layer of a vulcanised natural or synthetic rubber composition having adherent thereto a coloured surface layer of a thermoset composition containing a vulcanised oil-resistant elastomer and a polymer derived from vinyl chloride or vinylidene chloride.