David E Oaks

US Patent:

56183739, Apr 8, 1997

Filed:

Apr 13, 1995

Appl. No.:

8/421804

Inventors:

Stephen J. Redwine - Knoxville TN
David K. Oaks - Knoxville TN

Assignee:

Plastic Floor Mats Inc. - Clinton TN

International Classification:

D04H 316
B29C 4734
B29C 4788
B29C 4792

US Classification:

156361

Abstract:

A multiplicity of closely spaced thermoplastic polymer filaments are extruded from an elongated orifice plate through a draft protected free-fall zone onto a rotating cylinder surface, landing between about 30. degree. before and after upper dead center of rotation. Filament extrusion velocity and cylinder rotational velocity are coordinated to pile the filament into a mat continuum of accumulated filament laps. Filament temperature and viscosity are coordinated to provide thermoplastic bonding at the filament lap crossings to integrate the continuum. The rotating cylinder carries the matted continuum over an arc of about 150. degree. to 210. degree. to about lower dead center of rotation where the mat peels from the cylinder surface. After separation from the cylinder surface, the mat is supported by a transitional air jet on to a horizontal run surface of a traveling endless belt for consolidated support until the lap crossing bond joints are securely set.

US Patent:

54568765, Oct 10, 1995

Filed:

Oct 26, 1993

Appl. No.:

8/143273

Inventors:

Stephen J. Redwine - Knoxville TN
David K. Oaks - Knoxville TN

Assignee:

Plastic Floor Mats, Inc. - Powell TN

International Classification:

D04H 302

US Classification:

264555

Abstract:

A multiplicity of closely spaced thermoplastic polymer filaments are extruded from an elongated orifice plate through a draft protected free-fall zone onto a rotating cylinder surface, landing between about 30. degree. before and after upper dead center of rotation. Filament extrusion velocity and cylinder rotational velocity are coordinated to pile the filament into a mat continuum of accumulated filament laps. Filament temperature and viscosity are coordinated to provide thermoplastic bonding at the filament lap crossings to integrate the continuum. The rotating cylinder carries the matted continuum over an arc of about 150. degree. to 210. degree. to about lower dead center of rotation where the mat peels from the cylinder surface. After separation from the cylinder surface, the mat is supported by a transitional air jet on to a horizontal run surface of a traveling endless belt for consolidated support until the lap crossing bond joints are securely set.