WO2010056234A1 - Dual-colored mulch mat with realistic appearance - Google Patents

Dual-colored mulch mat with realistic appearance Download PDF

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Publication number
WO2010056234A1
WO2010056234A1 PCT/US2008/083114 US2008083114W WO2010056234A1 WO 2010056234 A1 WO2010056234 A1 WO 2010056234A1 US 2008083114 W US2008083114 W US 2008083114W WO 2010056234 A1 WO2010056234 A1 WO 2010056234A1
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WO
WIPO (PCT)
Prior art keywords
mat
layer
rubber
colored
mulch
Prior art date
Application number
PCT/US2008/083114
Other languages
French (fr)
Inventor
Richard C. Moore, Jr.
Original Assignee
Easy Gardener, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Easy Gardener, Inc. filed Critical Easy Gardener, Inc.
Priority to PCT/US2008/083114 priority Critical patent/WO2010056234A1/en
Publication of WO2010056234A1 publication Critical patent/WO2010056234A1/en

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Classifications

    • AHUMAN NECESSITIES
    • A01AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01GHORTICULTURE; CULTIVATION OF VEGETABLES, FLOWERS, RICE, FRUIT, VINES, HOPS OR SEAWEED; FORESTRY; WATERING
    • A01G13/00Protecting plants
    • A01G13/02Protective coverings for plants; Coverings for the ground; Devices for laying-out or removing coverings
    • A01G13/0256Ground coverings
    • A01G13/0281Protective ground coverings for individual plants, e.g. for plants in pots

Definitions

  • the present disclosure relates to dual-colored, decorative ground cover useful for the protection of trees and plants and for covering other outdoor areas (such as walkways). More particularly, the disclosure is directed to reversible rubber mat products that provide a realistic appearance characteristic of natural mulch and that exhibit different colors on opposite sides. Aiso provided herein are natural-looking rubber mat products that may include fertilizer compounds, which nurture the plants surrounded by the mat products. Processes for producing such dual-colored mat products are also provided.
  • Natural mulching systems such as natural bark, wood products, peat, pine needles, and the like — are commonly used for mulching around trees, plants, and other items, in addition to their aesthetic function, these natural mulching systems protect the root systems of the surrounded plant life from sometimes harsh environmental conditions and also inhibit weed and grass growth in the areas that have been mulched. As a result, the need for mowing or trimming in close proximity to the surrounded plant life is minimized, thereby reducing the risk that the plant life may be damaged by these activities.
  • Natural mulching systems have several attendant disadvantages, however.
  • Natural mulching elements may further be eroded by hard rains, routine watering, or wind, for example, leaving the ground thereunder subject to erosion and other environmental conditions. Consequently, the mulch systems require on-going maintenance and replenishment to ensure an adequate level of protection and to preserve a groomed appearance. Such continuing care may be expensive and cumbersome to maintain, leaving some areas exposed for some period of time.
  • Another disadvantage of some mulching systems may be the tendency of the mulching systems themselves to absorb water, thereby preventing water from seeping through the mulching system to the underlying roots. Afternateiy, or in addition, some mulching systems exhibit a tendency to draw water or moisture away from the underlying roots by capillary action. In each instance, the risk of damage to the plants may be increased, if such conditions exist for a long period.
  • the rubber chips or granules are secured with a binder composition to form a mulch mat, as described, for example, in US Patent No. 5,396,731 to Byrne.
  • the production process for manufacturing these and similar rubber mats may sometimes lead to an unnatural appearance, either because the binder causes the finished mat to appear shiny or because the mat surfaces are smoothed to create a mat of a substantially uniform thickness.
  • the present disclosure is directed in general to dual-colored mats made from rubber, and, particularly, from recycled rubber.
  • the mats may be used to create natural but manicured edges around trees, shrubbery, flower beds, posts, poles and the like to define lawn boundaries and to inhibit grass and weed growth in the covered areas.
  • the mats may also be used to create larger manicured edges or areas for walkways or for situating water hose storage carts, outdoor garden supply sheds, playground equipment and the like in order to render mowing or trimming around or under such items unnecessary.
  • the present mulch mats exhibit a realistic appearance and have different colors on opposite sides.
  • the present efastomeric mulch mats are thus reversible, and each side includes rubber components, a binder holding the components together, and a coloring agent.
  • the rubber components may be rubber buffings and/or rubber granules, for example.
  • the mat features a perimeter edge, a lower surface, and an upper surface opposite the lower surface, the upper and lower surfaces having different colors.
  • the first and second colors in this aspect may be red, white, brown, green, blue, sandstone, black, or some other color, the first color being different from the second color.
  • the first and second colors are derived from respective coloring pigments.
  • the rubber buffings may be randomly oriented within the mat, resulting in the angular positioning of the rubber buffings relative to each other and in the creation of uneven, or jagged, surfaces.
  • the thickness of the mat as measured from the lower surface to the upper surface, varies from point to point, due to the irregular texture produced by the randomly projecting rubber buffings. The rough texture and variable thickness produce an appearance more characteristic of natural mulch.
  • the mulch mats may exhibit different textures on opposite sides, in addition to, or instead of, different colors.
  • one side may include rubber buffings, binder, and a first colorant to resemble shredded wood mulch or pine needles, while the opposite side may include rounded rubber granules, binder, and a second colorant to resemble small pebbles.
  • the first side may be brown or reddish in color, and the second side may be gray.
  • the mulch mat may include rubber buffings, rubber granules, fibers, an anti-gloss agent, a fertilizer compound, and various combinations of the above.
  • the fertilizer may be in granular form.
  • the fertilizer may be primarily located on a single surface of the mat, may be localized on both outer surfaces of the mat, or may be intimately mixed with the rubber components within the mat.
  • rubber components i.e., buffings or granules
  • a first coloring agent e.g., a pigment
  • a second rubber matrix is similarly produced, using at least rubber components, a binder, and a second coloring agent having a color different from that of the first coloring agent.
  • the second rubber matrix may be introduced onto the first layer, via a cap placed over the mold, or may be molded separately and then secured to the first layer.
  • the rubber matrices are roughly distributed (e.g., manually) to preserve an uneven texture and, thus, a more natural appearance. Catalysts may be used to promote curing.
  • the dual-colored mats may have a variety of color combinations; for instance, brown on one of their sides and red on the opposite side. Accordingly, a home improvement store, garden store or the like is able to offer a choice of at least two colored products to consumers while using only one section of limited floor or shelf space. Whereas one consumer may want a brown mat and another consumer may want a red mat, both consumers can each purchase one of the brown-red mats and simply place the desired color facing up to create their respective mulch-like areas.
  • the store can now offer another coior combination (such as mats having green on one side and black on the other), thus doubling consumer choices, in this example to four colors, using the same two sections of floor or shelf space.
  • FIG. 1 is a perspective view of a flexible mulch mat shown in an intended use, according to one aspect of the disclosure
  • FIG. 2 is a top plan view of the flexible mulch mat of FIG. 1;
  • FIG. 3A is a perspective view of a mulch mat, according to one aspect of the disclosure.
  • FIG. 3B is a schematic cross-section of the mat of FIG. 3A;
  • FIG. 4A is a perspective view of a mulch mat, according to another aspect of the disclosure;
  • FIG. 4B is a schematic cross-section of the mat of FIG. 4A;
  • FIG. 5A is a perspective view of yet another mulch mat, according to yet another aspect of the disclosure.
  • FIG. 5B is a perspective view of the mat of FIG. 5A, as installed proximate a building;
  • FiG. 6 is a schematic view of a manufacturing line showing a process of forming the rubber components of the present mulch mats
  • FIG. 7 provides plan and eievational views of a mold used in the manufacturing lines of FIGS. 8 and 9, according to other aspects of the disclosure;
  • FIG. 8 is a schematic view of a manufacturing line showing one process of forming the mulch mats of the present disclosure
  • FIG. 9 is a schematic view of another manufacturing line showing additional processes of forming the mulch mats of the present disclosure.
  • FIG. 10 is an eievational view of a cross-section of the mulch mat of FIG. SA.
  • the term “dual-coiored”, as used herein, refers to products that exhibit different colors on opposite sides thereof.
  • reversible refers to a characteristic of the present products, attributable to their dual colors, in which either side of the products may be displayed.
  • the present muich mats may comprise rubber buffings (or shavings) and/or rubber granules that are adhered together by a binder and that have opposite sides colored with different pigments.
  • the rubber buffings and/or rubber granules may be obtained by chipping, cutting, or chopping used tires or other post-industrial rubber, or synthetic materials, as shown in FIG. 6, into rubber components 12, which are made to appear as wood chips, wood shreds, wood nuggets, pebbles, stones, pine needles, or other natural materials. Such process will be described below, in reference to FIGS. 6-9.
  • the mulch mat may be shaped as a ring, or skirt, which encircles trees, shrubbery, posts, poles, and the like (as shown in FIG. 1), or the mulch mat may be shaped as a longitudinal pane! (e.g., as a rectangle) that may be used to cover larger outdoor areas (as shown in FIGS. SA and 5B).
  • the muich mat is configured as a tree ring (that is, as a surround for trees or plants)
  • the mulch mat (10) features a hole (30) therethrough and a slit (33) that extends from the perimeter edge to the hole (30) to permit the mulch mat to be fitted around a plant (55) or other object.
  • FIG. 1 iilustrates a representative use of a dual-colored mulch mat, according to the present disclosure, in which a muich mat 10 is placed around a tree 55 or other piant to function as a tree ring or skirt.
  • the mulch mat 10 may be generally circular in shape and may include a centrally located hole, or aperture, 30 that may be fitted around a tree trunk 57.
  • a slit 33 permits the mulch mat 10 to be positioned properly around the trunk 57.
  • the mulch mat 10 may include fertilizer disposed about the rubber components comprising the mat 10, as will be discussed in greater detail herein.
  • the mulch mat 10 provides a protective border around the tree 55, preventing grass 59 from growing too close to the trunk 57 and thereby reducing the likelihood of the tree 55 being damaged from mowers, flexible line trimmers, edgers, and the like.
  • the mulch mat 10 may have a thickness of between about 1 inch and about 4 inches.
  • the mulch mat 10 includes opposite sides, or layers, 102, 104 of different colors, which may be produced by combining the respective rubber components and binder with different coloring agents, such as pigments.
  • the first and second layers may be one of brown, red, white, green, black, sandstone, blue, or some other color, the first and second layers being of different colors to maximize consumer options.
  • the consumer may reverse, or flip, the mulch mat 10 to display the color and/or texture associated with the previously ground-contacting side (for instance, using FIG. 1 as an example, layer 102 may be placed in contact with the ground and layer 104 may be displayed).
  • FIG. 1 as an example, layer 102 may be placed in contact with the ground and layer 104 may be displayed.
  • FIG. 2 shows the dual-colored mulch mat 10 from one surface (for example, a surface having the appearance of shredded, natural mulch).
  • this surface of the mulch mat 10 features an irregular (i.e., non-uniform) texture and perimeter.
  • Such perimeter results from the random and angular orientation of the rubber components, resulting in an irregular arrangement and an irregular spacing between the rubber components with some of the rubber components extending beyond the perimeter edge. Further, this irregular spacing leads to voids between the rubber components, thereby creating passageways for water to flow through the mulch mat 10 and for moisture to evaporate upward from beneath the mulch mat 10.
  • the mat 10 is shown in a generally circular shape, other shapes having curved or straight sides may also be manufactured to meet user preferences (for example, long rectilinear panels that may be used to cover larger areas, as shown in FIGS. 5A and 5B).
  • the hole, or aperture, 30 may be centrally located within the mulch mat 10, though other placements may be possible as needs dictate. As shown in FIGS. 1 and 2, the hole, or aperture, 30 may be circular in shape. However, the hole 30 may be formed or cut into any suitable or desired shape, such as a square, for instance, in the event that the mulch mat is to be placed around a square-shaped post, such as those used to support a mailbox. In the event that the hole or aperture 30 is too small to fit around the trunk of the tree or plant to be protected, the mulch mat 10 may be cut by the user to remove an additional portion of the mulch mat 10. The mulch mat 10 is sufficiently pliable to permit cutting.
  • the slit 33 extends from the hole 30 to the perimeter edge, such that the mulch mat 10 may be fitted around a tree trunk, as shown in FIG. 1 , or some other object.
  • the slit 33 may be cut from one surface of the mulch mat 10, using any suitable means, such as a heated wire cutter. By stopping short of the opposite surface, uncut areas remain, which facilitate handling before installation.
  • the tearing of the mulch mat 10 along the slit 33 results in an uneven appearance along the opposite surface of the mulch mat 10, further enhancing its resemblance to natural mulch. Due to the irregular surface contours of the mulch mat 10, the slit 33 is rejoinable to impart a seamless (and more realistic) appearance to the mat 10.
  • the pre-formed slit 33 may have a tortuous or serpentine shape (not shown), which is relockable by virtue of interlocking members formed when the mulch mat 10 is torn along the slit 33.
  • the uneven edges along the upper surface of the mat 10 when locked together around a tree or plant, produce the visual appearance of a continuous natural surface.
  • FIG. 3A provides a perspective view of the irregular mass of rubber components - and, specifically, rubber buffings - that produce one configuration of the present mulch mats 10.
  • a portion of the rubber components project from layer 102, resulting in a non-uniform, rough texture and a realistic appearance.
  • the rubber components are similarly randomly oriented in the layer 104.
  • the angular orientation of the rubber buffings within the mat 10 forms an interlocking matrix that enhances the structural integrity of the mat 10.
  • the use of rubber components of different sizes further contributes to the random contours of the mat and to the creation of non-linear channels throughout the body of the mat for water and moisture transport.
  • FIG. 3B A schematic cross-section of the dual-colored mulch mat 10 of FIGS. 2 and 3A is shown in FIG. 3B.
  • the mat 10 includes rubber components (primarily buffings, in this example), which are held together with a binder material and which are colored, in layer 102, with a first pigment and, in layer 104, with a second pigment.
  • the first pigment may be brown, and the second pigment red to create the appearance of two different mulch products.
  • the first pigment may be brown to resemble mulch and the second pigment green to resemble freshly mown grass.
  • fertilizer granules may be disposed about the rubber components, either throughout the mat layers or disposed proximate to one surface of the mat.
  • the mulch mat 10 may be described as occupying a plane defining an x-axis and a y-axis.
  • the rubber buffings are randomly oriented and occupy various angular positions relative to the central planar surface (that is, the area where layer 102 and layer 104 meet). Said differently, the rubber buffings may be affixed in an irregular arrangement, in which the buffings extend, or project, at a variety of angles (i.e., in the "z"-direction) relative to the central planar surface (i.e., the "x-y" plane). As a result of this random orientation, the thickness of the mat varies from point to point
  • the mulch mats 10 may feature different textures on opposite sides.
  • the mulch mat 10 may have a first layer 102 made of rubber buffings colored with a first color to resemble shredded wood mulch, pine needles, or cut grass and a second layer 106 made of rubber granules colored with a second, different color to resemble small pebbles.
  • Representative colors for such a construction include brown, red, or black for the mulch-resembling layer (or green to resemble cut grass), and gray, black, or brown for the pebble-resemb ⁇ ng layer.
  • the perimeter edges may define a rectangular, or other polygonal, shape, suitable for covering a large area.
  • a mat may be Tollable for easy handling and may be useful in creating a walkway, a patio, or an area for storage of water hoses, outdoor equipment, or outdoor sheds.
  • the mulch mat or pad may have an irregular shape bounded by straight edges, curved edges, or a combination of straight and curved edges.
  • a lawn and garden mulch mat 20 is shown, which is constructed of the same materials as those used for the mulch mats 10.
  • the mulch mat 20 is a dual-colored ground cover, in which opposite sides, or layers, 202, 204, exhibit different colors and/or textures.
  • one of the layers (202 or 204) may be comprised of rubber buffings.
  • one of the layers (202 or 204) may include rubber components of a different shape (e.g., rounded granules) and/or color to resemble small pebbles, stones, or wood chips.
  • Such mats 20 may have a square shape (for example, of about 18 square inches, although sizes up to 40 square inches may instead be used) or a rectangular shape, in which the width of the mat 20 may be from about 18 inches to about 36 inches and the length of the mat 20 may be from about 24 inches to about 48 inches, the width and length being independently selected from within these ranges.
  • any combination of colors may be used for the iayers 202, 204.
  • different colors are used for layers 202, 204.
  • the layer 202 may be brown to resemble shredded wood mulch and the layer 204 may be red to resemble shredded cedar wood mulch.
  • different textures may be used.
  • the layer 202 may include rubber buffings and be brown to resemble pine needles and the layer 204 may include rubber granules and also be brown to resemble small pebbles.
  • different colors and textures may be used.
  • the layer 202 may have rubber buffings and a green pigment to resemble cut grass, while the layer 204 may include rounded rubber chunks and a gray pigment to resemble small river rocks.
  • FIG. 5B shows that the mat 20 may be used to park or store lawn and garden equipment, such as a wheelbarrow 701. Accordingly, because the mat 20 is configured to prevent grass or weed growth in the covered areas, the need for mowing or trimming grass and weeds around the equipment 701 is eliminated. [0050] Moreover, by virtue of the substantially straight edges or sides of the mats 20, a plurality of the mats 20 may be abutted against each other to form a relatively large area, such as a patio-type area, in which the mats 20 are adjacent along a seam 22 without any significant gaps between neighboring mats 20 (as shown in FIG. 5A).
  • Such a large assembly of the mats 20 may be useful in any number of locations, including use as a patio, an underlayment for a bench-type swing, a base for an outdoor shed or equipment storage area, or a ground cover beneath a deck, where it is desirable to inhibit weed growth but where mulch installation and maintenance is difficult.
  • any or all of the sides of the mats 10, 20 may be irregularly shaped (or cut to an irregular shape) to mimic natural stones and pavers or to conform to the shape of existing landscaping or structural elements, such as ponds, stones, driveways, and the like.
  • the mulch mat 10 may include rubber shavings or buffings 613 and may also include rubber granules 611 (the production of which is shown in FIG. 6), generically and, optionally, collectively referred to herein as the rubber components 12.
  • the rubber buffings 613 and rubber granules 611 may be combined, in various proportions, in the separate layers 102, 104 (or 202, 204) of the mulch mats 10 (20), or may be segregated to one of the layers 102, 104 (202, 204).
  • the mulch mat 10 (20) may include two layers 102, 104 (202, 204) of a single type of rubber component, it should be understood that the rubber components 12 (whether granules 611 or buffings 613) may vary in size within a given layer or a given mat construction, if desired.
  • the rubber components 12 may be obtained from used tires 610, which are processed to produce rubber shavings or buffings 613 and/or rubber granules 611.
  • the rubber components may be derived from used tires or retread pieces, although other rubber sources (including virgin sources) may be used instead of, or in conjunction with, tires.
  • the shavings or granules may be made of any of various types of rubber, including acrylonitrile-butadiene rubber (NBR), styrene-butadiene rubber (SBR), carboxylated NBR, chlorinated rubber, silicone containing rubber, ethylene- propylene-diene monomer (EPDM) and the like.
  • the buffings 613 or granules 611 may be made of an elastomer material other than rubber.
  • the majority of the rubber components 12 of the given layer of the mulch mat 10 may be rubber shavings or buffings, which provide relatively more strength and flexibility to the mat 10.
  • a buffing machine 617 is rotated about the tire 610 (or vice versa) to shed the buffings 613.
  • the rubber buffings, or shavings are characterized as having a length greater than their width (e.g., about % inch to about 3 inches in length and about 1/8 inch to about 1 inch in width).
  • the buffings 613 and/or granules 611 are of non-uniform size and shape to enhance the natural appearance of the mulch mat 10.
  • the discrete fibers 14 of such materials may also be the byproduct of shredding, mulching, granulating, or buffing the tires 610.
  • Such fibers may have a length of about 1 inch.
  • these fibers 14 may be included with the rubber components 12 in the manufacturing process.
  • virgin fibers 14 may also, or instead, be used in the mulch mat 10.
  • FIG. 7 illustrates a mold 50 and a complementary cap, or frame, 56 that may be used in the manufacture of the present mat products (e.g., 10, 20).
  • the mold 50 may have a height (as indicated by a top edge 52) that is about half the desired thickness of the finished mat product and that ranges from about 0.5 inches to about 2 inches.
  • the mold 50 includes a peripheral lip 60 from which a projection, or anchor, 62 extends.
  • the cap, or frame, 56 may have a complementary, or compatible ledge 64 about its perimeter, the ledge 64 supporting a downwardly-oriented shoulder 66.
  • the ledge 64 of the cap 56 may have the same height as the anchor 62 of the mold 50, thus facilitating the creation of a two-layer mat structure, in which the layers (e.g., 102, 104) are of roughly equal thickness. Alternately, the ledge 64 may be of a different height to create a mat structure with layers (e.g., 102, 104) of different thicknesses, as may be useful in circumstances where the second layer (e.g., 104) includes only a coloring agent and a binder or where different thicknesses are otherwise desired.
  • the cap 56 further includes a hole, or opening, 68, through which a second color or colored matrix may be introduced, as will be described beiow.
  • the anchor 62 and the ledge 64 fit together to seat the cap 56 onto the mold 50.
  • This seating may be accomplished because the inside area 58 defined by the cap 56 is equal to the area 54 defined by the moid 50 and because the height of the shoulder 66 is comparable to the height of the anchor 62.
  • the length and width of the mold 54 determine the dimensions, or footprint, of the resulting mat (10 or 20), and molds having various dimensions may be employed to meet user specifications.
  • the anchor 62 and the ledge 64 may be reversed or arranged in a variety of other orientations relative to each other, or alternate seating mechanisms may be substituted.
  • the manufacturing process is not limited to the exemplary configuration shown in FIG. 7.
  • FIGS. 8 and 9 Exemplary processes for creating dual-colored mat products (e.g., 10, 20) are illustrated in FIGS. 8 and 9, each of which employ the previously described mold 50 and some of which also employ the corresponding cap 56.
  • components of the mats 10 or 20 which include rubber components 12 (in the form of rubber granules 611, rubber buffings 613, or both), a binder 16, and a coloring agent 18.
  • the mat 10, 20 may further include fibers 14 and a catalyst 22.
  • the binder (shown as 16 in FIGS. 8 and 9) functions to hold the rubber components 12 together.
  • the binder 16 may be a curable latex or urethane binder, such as a moisture-curable polyurethane. Binders other than polyurethane (e.g., polyacrylates) may instead be used to adhere the rubber components 12. Additionally, binders that are cured by other means, such as exposure to heat, UV radiation, electron beams, or chemicals, may instead be used.
  • the coloring agent 18, 18' may be a pigment, such as an iron oxide pigment or may be some other colorant, such as a dye or polymeric colorant.
  • the coloring agent(s) 18, 18' may further include an anti-gloss agent or compound to minimize sheen or gloss.
  • Diatomaceous silica may be used as anti-gloss agent.
  • the diatomaceous silica for instance, may be sprinkled on the surface of the uncured, molded mixture (24 or 24') to reduce gloss.
  • the layers 102, 104 of the mulch mat 10 may be colored with different colored pigments to provide a dual-colored product.
  • the first and second pigments 18, 18' may be red, white, brown, green, blue, black, sandstone, or some other color. In one aspect, the first and second pigments 18, 18' are different from one another.
  • the mulch mat mixture 24, 24' may further include a catalyst 22 to promote curing of the binder 18.
  • the catalyst may be chosen based on the type of binder system being used.
  • a mold 50 is provided for making the mulch mat 10 (or 20).
  • the mold 50 (as shown in FIG. 7) has anchors 62 projecting upwardly from the peripheral lip 60.
  • the distance between the interior portions of the anchors 62 defines an inner diameter 51 , which is determinative of the dimensions of the mat product 10 (or 20).
  • the distance between the exterior, or outward-facing, portions of the anchors 62 defines an outer diameter 54.
  • a corresponding cap 56 may be used with the mold 50.
  • the cap 56 includes a shoulder 66 that is sized to seat the cap 56 on the mold 50 when the shoulder 66 is positioned on the lip 60 adjacent the anchors 62.
  • the distance between the interior-facing sides of the shoulders 66 defines the inner cap diameter 58, which is equal to, or just slightly larger than, the outer diameter 54 of the mold 50.
  • the cap 56 further includes an opening 68 through which a second layer may be introduced.
  • the opening 68 may be substantially equal in area to the inside area of the mold 50, so that the second layer (e.g., 104) may be easily spread onto the first layer (e.g., 102). Alternately, the opening 68 may be much smaller, as represented schematically in FIGS. 8 and 9, in which case, vibration or other means may be necessary to spread the second layer 104 to a relatively uniform thickness.
  • a first mixture 24 is produced by mixing the rubber components 12, (optionally) the fibers 14, a binder 16, a first coloring agent 18, and a catalyst 22 in a mixing vessel.
  • the resultant mixture 24 is weighed and placed into the mold 50.
  • the upper surface may be manually leveled, as schematically depicted by a hand symbol 152, to form an irregular surface.
  • the mixture 24 is allowed to create an uneven and jagged surface texture on the upper surface of the first layer 102.
  • the mold-contacting side of the first layer 102 may also be somewhat irregular or uneven, further contributing to a more natural appearance.
  • the cap 56 may be positioned over the mold 50, such that the shoulders 66 of the cap 56 are aligned with the anchors 62 of the mold 50 and are positioned on the peripheral lip 60 of the mold 50.
  • a second mixture 24' is produced by combining rubber components 12, binder 16, a second colorant 18 s , and, optionally, fibers 14 and a catalyst 22.
  • the second colorant 18' may be a different color than the first colorant 18, resulting eventually in a dual-colored mat 10.
  • the rubber components 12 may be rubber buffings 613, rubber granules 611, or some combination thereof and may or may not be the same type or combination used in the first mixture 24.
  • the second mixture 24' may be applied to the first layer 102 by pouring the second mixture 24' through the opening 68 in the cap 56 to form the second layer 104.
  • the second layer 104 may again be manually spread, or may be vibrated or moved through some other means, to fully and relatively evenly cover the first layer 102.
  • the cap 56 and mold 50 are removed, and the finished dual-colored mat 10 may be prepared for packaging for storage, shipment, or sale.
  • FIG. 9 shows several alternate processes for making a realisttc-iooking dual- sided mat 10.
  • the mold 50 is used, which has an upper perimeter edge 52, an inner diameter 51 , a peripheral lip 60, anchors 62 projecting from the peripheral lip 60, and an outer diameter 54 between the exterior-facing sides of the anchors 62.
  • a mixture 24 having a first color is produced by combining the rubber components 12, (optionally) the fibers 14, the binder 16, the first coloring agent 18, and the catalyst 22.
  • the resultant mixture 24 is weighed and placed into the mold 50.
  • the upper surface may be manually leveled, as schematically depicted by a hand symbol 152, to form an irregular surface on the first layer 102.
  • the first layer 102 has an uneven and jagged surface texture on at least the exposed surface of the first layer 102, and the moid-contacting (lower) surface may be uneven or irregular as well, depending upon the degree of compaction with which the first mixture 24 is introduced into the mold 50.
  • a second mixture 24' may be prepared by combining rubber components 12, binder 16, and a second coloring agent 18', optionally with fibers 14 and a catalyst 22.
  • the rubber components 12 may or may not be the same size and/or shape as the rubber components 12 used in the first mixture 24, and the second coloring agent 18' is different from the first coloring agent 18.
  • the second mixture 24' is introduced onto the first layer 102 created by the first mixture 24, in a manner that w ⁇ l be described below.
  • a partially or fully cured first layer 102 may be extracted from the mold 50, reversed or flipped such that the upper surface faces downward, and returned to the mold 50.
  • the previously described cap, or frame, 56 may then be seated on the mold 50.
  • the second mixture 24' may then be introduced through the opening 68 in the cap 56 to form a second layer 104 in contact with the first layer 102.
  • the cap 56 is removed, and the finished dual-colored mat 10' may be extracted from the mold 50.
  • the resulting mat 10' has an irregular, or uneven, surface on each side, which may be desirable when both of the layers 102, 104 are configured to resemble shredded or chipped wood mulch or cut grass.
  • the first layer 102 may be produced (and at least partially cured) before being removed from the mold SO.
  • the second mixture 24' may be introduced into the mold 60 and, optionally, manually smoothed (152), according to the process used to produce the first layer 102.
  • the first layer 102 may then be placed over the uncured second layer 104, such that the curing of the second layer 104 serves to bond the first and second layers 102, 104.
  • the resulting mat 10 resembles that manufactured according to the process illustrated in FIG.
  • the upper surface of the first layer 102 may possess a more uneven or jagged texture, as compared to the lower surface of the mat 10 (formed by the mold-contacting side of the second layer 104),
  • the degree of irregularity depends upon the amount of compaction and the volume of the second mixture 24'. Accordingly, while this method may work sufficiently to produce dual-sided mats 10 in which each layer is comprised primarily of rubber buffings 613 and, therefore, resembles shredded wood or grass clippings, the method may be better suited for a mat 10 in which at ieast one layer (e.g., 104) is comprised primarily of rubber granules 611, resulting in the appearance of pebbles or stones.
  • yet another approach includes the formation and extraction of the first layer 102 from the moid 50 and the subsequent formation and extraction of the second layer 104 from the mold 50.
  • the first layer 102 and the second layer 104 may then be joined to one another by chemical reaction or by application of heat, compression, adhesive, or combinations thereof.
  • the resulting mat 10' may include outermost surfaces having an irregular, or random, surface texture associated with shredded or chipped wood mulch or cut grass.
  • the mixtures 24, 24 1 may contain, by weight,: from about 75% to about 88% rubber components 12; from about 0 % to about 2% fiber 14; from about 10% to about 15% binder 16; from about 2% to about 5% coloring agent 18 or 18' (based on the total weight of the binder 16); from about 0.01 % to about 0.03% catalyst 22 (based on the total weight of the binder 16); and a negligible percent of UV light stabilizers and anti-oxidants.
  • the fertilizer may be organic, inorganic, or a combination of organic and inorganic components. Moreover, the fertilizer may be granular, a powder, a liquid, a slow-release fertilizer, and combinations of these and other fertilizer types. Further, the fertilizer may be added during the mat formation process (i.e., by incorporating into one or both mixtures 24, 24') or after the mat formation process (i.e., by sprinkling onto one or both layers 102, 104). The fertilizer may also be added to the mat 10 after use for a period of time to replenish the fertilizing properties of the mat 10. When used, the fertilizer may be added into one or both mixtures (24, 24') or on one or both layers (102, 104) in an amount equivalent to from about 1% to about 10% of the weight of the mat 10.
  • FlG. 10 shows the mulch mat 20 to which fertilizer granules 150 have been applied.
  • the fertilizer 150 activates, such as by becoming a liquid 154, and passes through the mat 20 to nourish the tree roots 58.
  • the mat 20 is sufficiently porous to permit the liquid 154 to pass through to the tree roots, but is sufficiently dense to prevent weeds, grass, and other undesired plant life from growing through the mat 20.
  • fertilizer 150 may be embedded in various portions of the mulch mat 20.
  • the fertilizer 150 may be in the form of a liquid that is incorporated into the mixture 24 (and/or 24') to form at least one layer of the mat 20.
  • the user may replenish the fertilizer 150 by sprinkling or spraying new fertilizer onto the upper surface of the mat, from which the newly applied fertilizer will leach or seep into the underlying roots, as described above.
  • the mat may be used around foliage other than trees (such as shrubs), or around posts or poles (such as mailbox posts, light poles, and other inanimate objects) to protect wooden or painted surfaces. Obviously, in the event that the mat is to be used around a non-living object, a fertilizer compound is unnecessary.
  • the mulch mat 10 in use, appears as a natural mulch-covered area.
  • the mulch mats 10, 20 are sufficiently durable to withstand various weather conditions and last many times longer than natural mulch, which tends to fade, decompose, and become scattered, due to wind, rain, and foot traffic.
  • the mulch mat 10 provides protection to trees and plants, preventing weed or grass growth adjacent to the trees or plants and preventing incidental damage from mowers or trimmers.
  • the fertilizer-treated mulch mats 10 (or 20) beneficially nurture trees or plants, as fertilizer leaches through the mat's lower surface and into the root system of the trees or plants.
  • edging systems or mats of the composition according to the present disclosure can be used over ground to delineate lawn edges or outdoor equipment storage areas. Moreover, due to their dual colors, the products save storage and sales space; i.e., one multicolored edging systems or mats is attractive to different consumers having different landscaping needs.

Abstract

The present mulch mats exhibit a realistic appearance and have different colors and/or textures on opposite sides. The present elastomeric mulch mats are thus reversible, and each side includes rubber components, a curable binder holding the components together, and a coloring agent. The rubber components may be rubber buffings and/or rubber granules, for example. The mat features a perimeter edge, a lower surface, and an upper surface opposite the lower surface, the upper and lower surfaces having different colors. The first and second colors in this aspect may be red, white, brown, green, blue, sandstone, black, or some other color, the first color being different from the second color. The first and second colors are derived from respective coloring pigments.

Description

DUAL-COLORED MULCH MAT WITH REALISTIC APPEARANCE
TECHNICAL FIELD
[0001] The present disclosure relates to dual-colored, decorative ground cover useful for the protection of trees and plants and for covering other outdoor areas (such as walkways). More particularly, the disclosure is directed to reversible rubber mat products that provide a realistic appearance characteristic of natural mulch and that exhibit different colors on opposite sides. Aiso provided herein are natural-looking rubber mat products that may include fertilizer compounds, which nurture the plants surrounded by the mat products. Processes for producing such dual-colored mat products are also provided.
BACKGROUND
[0002] To beautify lawns, gardens, and other outdoor grounds, natural mulching systems — such as natural bark, wood products, peat, pine needles, and the like — are commonly used for mulching around trees, plants, and other items, in addition to their aesthetic function, these natural mulching systems protect the root systems of the surrounded plant life from sometimes harsh environmental conditions and also inhibit weed and grass growth in the areas that have been mulched. As a result, the need for mowing or trimming in close proximity to the surrounded plant life is minimized, thereby reducing the risk that the plant life may be damaged by these activities. [0003] Natural mulching systems have several attendant disadvantages, however. First, because the materials are natural, they tend to degrade (i.e., deteriorate or fade) over time due to exposure to the elements. Natural mulching elements may further be eroded by hard rains, routine watering, or wind, for example, leaving the ground thereunder subject to erosion and other environmental conditions. Consequently, the mulch systems require on-going maintenance and replenishment to ensure an adequate level of protection and to preserve a groomed appearance. Such continuing care may be expensive and cumbersome to maintain, leaving some areas exposed for some period of time.
[0004] Another disadvantage of some mulching systems may be the tendency of the mulching systems themselves to absorb water, thereby preventing water from seeping through the mulching system to the underlying roots. Afternateiy, or in addition, some mulching systems exhibit a tendency to draw water or moisture away from the underlying roots by capillary action. In each instance, the risk of damage to the plants may be increased, if such conditions exist for a long period.
[0005] Yet another shortcoming of natural mulching systems may be that such systems provide few, if any, nutrients to the underlying roots of plants that they surround. For example, a gardener or groundskeeper may have to apply fertilizer before the mulching system is installed or with some frequency after installation. Such efforts may be ineffective or labor-intensive, especially if the mulching system is applied over an impermeable landscape sheet. [0006] To address some of these problems, artificial mulching systems have been introduced, in which rubber or other synthetic materials are chipped or ground to a desired size and/or shape. In some instances, loose rubber chips or granules may be arranged around a desired area (such as a flower bed), in much the same manner as conventional natural mulch. In other instances, the rubber chips or granules are secured with a binder composition to form a mulch mat, as described, for example, in US Patent No. 5,396,731 to Byrne. The production process for manufacturing these and similar rubber mats, however, may sometimes lead to an unnatural appearance, either because the binder causes the finished mat to appear shiny or because the mat surfaces are smoothed to create a mat of a substantially uniform thickness.
[0007] Another drawback of both natural and artificial mulch systems is that the consumer may only purchase mulch or a mulch mat of a single color. If the consumer desires a different color (or if the color fades, as may happen with natural mulch), then a subsequent purchase and reinstallation are required, in the case of natural mulch, consumers have the option of purchasing and applying mulch dye to their faded mulch, but such applications may be costly, messy, and burdensome.
[0008] To satisfy consumer interest in mulch products of different colors, many retail stores are compelled to allot additional floor or shelf space for similar products of different colors. Where additional shelf or floor space is unavailable, the store may be forced to stock the one or two colors that previously have been most popular. As a result, the retailer may have to accommodate special orders from customers who want a product of a color different from the one or two the retailer may have elected to stock.
[0009] Accordingly, the consumer and retailer would each benefit from the production of a realistic-appearing artificial mulch pad, which includes opposing sides of different colors; which minimizes the floor or shelf space necessary to display the product due to its reversibility; and which facilitates an easy transition from one appearance to another, due to its lightweight construction.
SUMMARY
[0010] The present disclosure is directed in general to dual-colored mats made from rubber, and, particularly, from recycled rubber. The mats may be used to create natural but manicured edges around trees, shrubbery, flower beds, posts, poles and the like to define lawn boundaries and to inhibit grass and weed growth in the covered areas. The mats may also be used to create larger manicured edges or areas for walkways or for situating water hose storage carts, outdoor garden supply sheds, playground equipment and the like in order to render mowing or trimming around or under such items unnecessary.
[0011] In one aspect, the present mulch mats exhibit a realistic appearance and have different colors on opposite sides. The present efastomeric mulch mats are thus reversible, and each side includes rubber components, a binder holding the components together, and a coloring agent. The rubber components may be rubber buffings and/or rubber granules, for example. The mat features a perimeter edge, a lower surface, and an upper surface opposite the lower surface, the upper and lower surfaces having different colors. The first and second colors in this aspect may be red, white, brown, green, blue, sandstone, black, or some other color, the first color being different from the second color. The first and second colors are derived from respective coloring pigments.
[0012] To simulate the appearance of natural mulch, the rubber buffings may be randomly oriented within the mat, resulting in the angular positioning of the rubber buffings relative to each other and in the creation of uneven, or jagged, surfaces. The thickness of the mat, as measured from the lower surface to the upper surface, varies from point to point, due to the irregular texture produced by the randomly projecting rubber buffings. The rough texture and variable thickness produce an appearance more characteristic of natural mulch.
[0013] In another aspect, the mulch mats may exhibit different textures on opposite sides, in addition to, or instead of, different colors. For example, one side may include rubber buffings, binder, and a first colorant to resemble shredded wood mulch or pine needles, while the opposite side may include rounded rubber granules, binder, and a second colorant to resemble small pebbles. In keeping with this theme, the first side may be brown or reddish in color, and the second side may be gray. [0014] According to other aspects, the mulch mat may include rubber buffings, rubber granules, fibers, an anti-gloss agent, a fertilizer compound, and various combinations of the above. In those mats where a fertilizer compound is present, the fertilizer may be in granular form. The fertilizer may be primarily located on a single surface of the mat, may be localized on both outer surfaces of the mat, or may be intimately mixed with the rubber components within the mat.
[0015] In the production of such elastomeric mats, rubber components (i.e., buffings or granules) are combined with at least a binder and a first coloring agent (e.g., a pigment) to create a first matrix that is subsequently shaped and cured in a mold to form a first layer of the mat. A second rubber matrix is similarly produced, using at least rubber components, a binder, and a second coloring agent having a color different from that of the first coloring agent. The second rubber matrix may be introduced onto the first layer, via a cap placed over the mold, or may be molded separately and then secured to the first layer. In some aspects, the rubber matrices are roughly distributed (e.g., manually) to preserve an uneven texture and, thus, a more natural appearance. Catalysts may be used to promote curing.
[0016] The dual-colored mats may have a variety of color combinations; for instance, brown on one of their sides and red on the opposite side. Accordingly, a home improvement store, garden store or the like is able to offer a choice of at least two colored products to consumers while using only one section of limited floor or shelf space. Whereas one consumer may want a brown mat and another consumer may want a red mat, both consumers can each purchase one of the brown-red mats and simply place the desired color facing up to create their respective mulch-like areas. Moreover, where the store previously had offered only a choice of brown and red mats — each occupying its own section of floor or shelf space — the store can now offer another coior combination (such as mats having green on one side and black on the other), thus doubling consumer choices, in this example to four colors, using the same two sections of floor or shelf space.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] A full and detailed disclosure is set forth in the accompanying Detailed
Description, which makes references to the appended drawings, in which:
[0018] FIG. 1 is a perspective view of a flexible mulch mat shown in an intended use, according to one aspect of the disclosure;
[0019] FIG. 2 is a top plan view of the flexible mulch mat of FIG. 1;
[0020] FIG. 3A is a perspective view of a mulch mat, according to one aspect of the disclosure;
[0021] FIG. 3B is a schematic cross-section of the mat of FIG. 3A; [0022] FIG. 4A is a perspective view of a mulch mat, according to another aspect of the disclosure;
[0023] FIG. 4B is a schematic cross-section of the mat of FIG. 4A;
[0024] FIG. 5A is a perspective view of yet another mulch mat, according to yet another aspect of the disclosure;
[0025] FIG. 5B is a perspective view of the mat of FIG. 5A, as installed proximate a building;
[0026] FiG. 6 is a schematic view of a manufacturing line showing a process of forming the rubber components of the present mulch mats;
[0027] FIG. 7 provides plan and eievational views of a mold used in the manufacturing lines of FIGS. 8 and 9, according to other aspects of the disclosure;
[0028] FIG. 8 is a schematic view of a manufacturing line showing one process of forming the mulch mats of the present disclosure;
[0029] FIG. 9 is a schematic view of another manufacturing line showing additional processes of forming the mulch mats of the present disclosure; and [0030] FIG. 10 is an eievational view of a cross-section of the mulch mat of FIG. SA.
DETAILED DESCRIPTION
[0031] Reference is now made to the drawings for illustration of various components of the present muich mats and various processes used in the manufacture thereof. While the particular descriptions used for certain aspects or embodiments may refer to "rubber" or "recycled rubber" components, it should be understood that elastomeric materials other than rubber may be used, that the word "rubber" encompasses synthetic and natural rubbers, and that virgin rubber may be substituted for, or used in conjunction with, recycled rubber. It should also be understood that post-consumer products other than tires may also, or instead, be used to create the rubber components referenced herein.
[0032] The term "dual-coiored", as used herein, refers to products that exhibit different colors on opposite sides thereof. The term "reversible" refers to a characteristic of the present products, attributable to their dual colors, in which either side of the products may be displayed.
[0033] Generally, the present muich mats (alternately, "pads", "skirts", or "rings") may comprise rubber buffings (or shavings) and/or rubber granules that are adhered together by a binder and that have opposite sides colored with different pigments. The rubber buffings and/or rubber granules may be obtained by chipping, cutting, or chopping used tires or other post-industrial rubber, or synthetic materials, as shown in FIG. 6, into rubber components 12, which are made to appear as wood chips, wood shreds, wood nuggets, pebbles, stones, pine needles, or other natural materials. Such process will be described below, in reference to FIGS. 6-9.
[0034] The mulch mat may be shaped as a ring, or skirt, which encircles trees, shrubbery, posts, poles, and the like (as shown in FIG. 1), or the mulch mat may be shaped as a longitudinal pane! (e.g., as a rectangle) that may be used to cover larger outdoor areas (as shown in FIGS. SA and 5B). When the muich mat is configured as a tree ring (that is, as a surround for trees or plants), the mulch mat (10) features a hole (30) therethrough and a slit (33) that extends from the perimeter edge to the hole (30) to permit the mulch mat to be fitted around a plant (55) or other object.
[0035] Specifically, FIG. 1 iilustrates a representative use of a dual-colored mulch mat, according to the present disclosure, in which a muich mat 10 is placed around a tree 55 or other piant to function as a tree ring or skirt. The mulch mat 10 may be generally circular in shape and may include a centrally located hole, or aperture, 30 that may be fitted around a tree trunk 57. A slit 33 permits the mulch mat 10 to be positioned properly around the trunk 57. Optionally, the mulch mat 10 may include fertilizer disposed about the rubber components comprising the mat 10, as will be discussed in greater detail herein. The mulch mat 10 provides a protective border around the tree 55, preventing grass 59 from growing too close to the trunk 57 and thereby reducing the likelihood of the tree 55 being damaged from mowers, flexible line trimmers, edgers, and the like. The mulch mat 10 may have a thickness of between about 1 inch and about 4 inches.
[0036] In some configurations, the mulch mat 10 includes opposite sides, or layers, 102, 104 of different colors, which may be produced by combining the respective rubber components and binder with different coloring agents, such as pigments. The first and second layers may be one of brown, red, white, green, black, sandstone, blue, or some other color, the first and second layers being of different colors to maximize consumer options. As desired, the consumer may reverse, or flip, the mulch mat 10 to display the color and/or texture associated with the previously ground-contacting side (for instance, using FIG. 1 as an example, layer 102 may be placed in contact with the ground and layer 104 may be displayed). Such reversibility provides the consumer with greater flexibility in producing an aesthetically pleasing appearance.
[0037] FIG. 2 shows the dual-colored mulch mat 10 from one surface (for example, a surface having the appearance of shredded, natural mulch). Notably, although the mulch mat 10 is generally circular in shape, this surface of the mulch mat 10 features an irregular (i.e., non-uniform) texture and perimeter. Such perimeter results from the random and angular orientation of the rubber components, resulting in an irregular arrangement and an irregular spacing between the rubber components with some of the rubber components extending beyond the perimeter edge. Further, this irregular spacing leads to voids between the rubber components, thereby creating passageways for water to flow through the mulch mat 10 and for moisture to evaporate upward from beneath the mulch mat 10. While the mat 10 is shown in a generally circular shape, other shapes having curved or straight sides may also be manufactured to meet user preferences (for example, long rectilinear panels that may be used to cover larger areas, as shown in FIGS. 5A and 5B).
[0038] The hole, or aperture, 30 may be centrally located within the mulch mat 10, though other placements may be possible as needs dictate. As shown in FIGS. 1 and 2, the hole, or aperture, 30 may be circular in shape. However, the hole 30 may be formed or cut into any suitable or desired shape, such as a square, for instance, in the event that the mulch mat is to be placed around a square-shaped post, such as those used to support a mailbox. In the event that the hole or aperture 30 is too small to fit around the trunk of the tree or plant to be protected, the mulch mat 10 may be cut by the user to remove an additional portion of the mulch mat 10. The mulch mat 10 is sufficiently pliable to permit cutting.
[0039] The slit 33 extends from the hole 30 to the perimeter edge, such that the mulch mat 10 may be fitted around a tree trunk, as shown in FIG. 1 , or some other object. According to one practice, the slit 33 may be cut from one surface of the mulch mat 10, using any suitable means, such as a heated wire cutter. By stopping short of the opposite surface, uncut areas remain, which facilitate handling before installation. In addition, the tearing of the mulch mat 10 along the slit 33 results in an uneven appearance along the opposite surface of the mulch mat 10, further enhancing its resemblance to natural mulch. Due to the irregular surface contours of the mulch mat 10, the slit 33 is rejoinable to impart a seamless (and more realistic) appearance to the mat 10.
[0040] According to another aspect of the present disclosure, the pre-formed slit 33 may have a tortuous or serpentine shape (not shown), which is relockable by virtue of interlocking members formed when the mulch mat 10 is torn along the slit 33. As described above, the uneven edges along the upper surface of the mat 10, when locked together around a tree or plant, produce the visual appearance of a continuous natural surface.
[0041] FIG. 3A provides a perspective view of the irregular mass of rubber components - and, specifically, rubber buffings - that produce one configuration of the present mulch mats 10. A portion of the rubber components project from layer 102, resulting in a non-uniform, rough texture and a realistic appearance. As shown, the rubber components are similarly randomly oriented in the layer 104. The angular orientation of the rubber buffings within the mat 10 forms an interlocking matrix that enhances the structural integrity of the mat 10. The use of rubber components of different sizes further contributes to the random contours of the mat and to the creation of non-linear channels throughout the body of the mat for water and moisture transport.
[0042] A schematic cross-section of the dual-colored mulch mat 10 of FIGS. 2 and 3A is shown in FIG. 3B. The mat 10 includes rubber components (primarily buffings, in this example), which are held together with a binder material and which are colored, in layer 102, with a first pigment and, in layer 104, with a second pigment. In one possible configuration, the first pigment may be brown, and the second pigment red to create the appearance of two different mulch products. In another possible configuration, the first pigment may be brown to resemble mulch and the second pigment green to resemble freshly mown grass. These configurations are provided for illustration only and not as limitations of many other combinations. Additionally, fertilizer granules (not shown) may be disposed about the rubber components, either throughout the mat layers or disposed proximate to one surface of the mat.
[0043] The mulch mat 10 may be described as occupying a plane defining an x-axis and a y-axis. The rubber buffings are randomly oriented and occupy various angular positions relative to the central planar surface (that is, the area where layer 102 and layer 104 meet). Said differently, the rubber buffings may be affixed in an irregular arrangement, in which the buffings extend, or project, at a variety of angles (i.e., in the "z"-direction) relative to the central planar surface (i.e., the "x-y" plane). As a result of this random orientation, the thickness of the mat varies from point to point
[0044] In addition to, or instead of, different colors on opposite sides, the mulch mats 10 may feature different textures on opposite sides. As shown in FIGS. 4A and 4B, the mulch mat 10 may have a first layer 102 made of rubber buffings colored with a first color to resemble shredded wood mulch, pine needles, or cut grass and a second layer 106 made of rubber granules colored with a second, different color to resemble small pebbles. Representative colors for such a construction include brown, red, or black for the mulch-resembling layer (or green to resemble cut grass), and gray, black, or brown for the pebble-resembϋng layer.
[0045] Instead of a circular mat - such as the mats 10 - the perimeter edges may define a rectangular, or other polygonal, shape, suitable for covering a large area. Such a mat may be Tollable for easy handling and may be useful in creating a walkway, a patio, or an area for storage of water hoses, outdoor equipment, or outdoor sheds. In yet another variation, the mulch mat or pad may have an irregular shape bounded by straight edges, curved edges, or a combination of straight and curved edges.
[0046] Turning now to FIGS. 5A and 5B, a lawn and garden mulch mat 20 is shown, which is constructed of the same materials as those used for the mulch mats 10. Like the mulch mat 10, the mulch mat 20 is a dual-colored ground cover, in which opposite sides, or layers, 202, 204, exhibit different colors and/or textures. For a mulch-like appearance, one of the layers (202 or 204) may be comprised of rubber buffings. For an alternate appearance, one of the layers (202 or 204) may include rubber components of a different shape (e.g., rounded granules) and/or color to resemble small pebbles, stones, or wood chips. Thus, the various combinations of texture and color in a rectangular shape provide the consumer with more choices in the selection of a lawn and garden mat 20.
[0047] Such mats 20 may have a square shape (for example, of about 18 square inches, although sizes up to 40 square inches may instead be used) or a rectangular shape, in which the width of the mat 20 may be from about 18 inches to about 36 inches and the length of the mat 20 may be from about 24 inches to about 48 inches, the width and length being independently selected from within these ranges.
[0048] Any combination of colors may be used for the iayers 202, 204. In one aspect, different colors are used for layers 202, 204. As a representative example, the layer 202 may be brown to resemble shredded wood mulch and the layer 204 may be red to resemble shredded cedar wood mulch. In another aspect, different textures (arising from the use of different sized and/or shaped rubber components) may be used. As a representative, non-limiting example, the layer 202 may include rubber buffings and be brown to resemble pine needles and the layer 204 may include rubber granules and also be brown to resemble small pebbles. In yet another aspect, different colors and textures may be used. As a representative, non-iimiting example, the layer 202 may have rubber buffings and a green pigment to resemble cut grass, while the layer 204 may include rounded rubber chunks and a gray pigment to resemble small river rocks.
[0049] FIG. 5B shows that the mat 20 may be used to park or store lawn and garden equipment, such as a wheelbarrow 701. Accordingly, because the mat 20 is configured to prevent grass or weed growth in the covered areas, the need for mowing or trimming grass and weeds around the equipment 701 is eliminated. [0050] Moreover, by virtue of the substantially straight edges or sides of the mats 20, a plurality of the mats 20 may be abutted against each other to form a relatively large area, such as a patio-type area, in which the mats 20 are adjacent along a seam 22 without any significant gaps between neighboring mats 20 (as shown in FIG. 5A). Such a large assembly of the mats 20 may be useful in any number of locations, including use as a patio, an underlayment for a bench-type swing, a base for an outdoor shed or equipment storage area, or a ground cover beneath a deck, where it is desirable to inhibit weed growth but where mulch installation and maintenance is difficult.
[0051] The skilled artisan may instantly appreciate that any or all of the sides of the mats 10, 20 may be irregularly shaped (or cut to an irregular shape) to mimic natural stones and pavers or to conform to the shape of existing landscaping or structural elements, such as ponds, stones, driveways, and the like.
[0052] As mentioned above, the mulch mat 10 (or 20) may include rubber shavings or buffings 613 and may also include rubber granules 611 (the production of which is shown in FIG. 6), generically and, optionally, collectively referred to herein as the rubber components 12. The rubber buffings 613 and rubber granules 611 may be combined, in various proportions, in the separate layers 102, 104 (or 202, 204) of the mulch mats 10 (20), or may be segregated to one of the layers 102, 104 (202, 204). Alternately, the mulch mat 10 (20) may include two layers 102, 104 (202, 204) of a single type of rubber component, it should be understood that the rubber components 12 (whether granules 611 or buffings 613) may vary in size within a given layer or a given mat construction, if desired.
[0053] Turning now to FIG. 6, the rubber components 12 may be obtained from used tires 610, which are processed to produce rubber shavings or buffings 613 and/or rubber granules 611.
[0054] The rubber components may be derived from used tires or retread pieces, although other rubber sources (including virgin sources) may be used instead of, or in conjunction with, tires. The shavings or granules may be made of any of various types of rubber, including acrylonitrile-butadiene rubber (NBR), styrene-butadiene rubber (SBR), carboxylated NBR, chlorinated rubber, silicone containing rubber, ethylene- propylene-diene monomer (EPDM) and the like. Alternately, the buffings 613 or granules 611 may be made of an elastomer material other than rubber.
[0055] When the used tires 610 or retread pieces are ground in a granulator 615, steel or other fiber components 14 are removed, leaving rubber granules 611. Obviously, other rubber or elastomeric sources may not include fiber or other reinforcing constituents. The resulting rubber granules 611 are generally in the range of about 1/8 inch to about 3A inch in major dimension. The granulator 615 may be adjusted to produce granules of different dimensions, and granules having different dimensions may be used in the same mulch mat. [0056] To create a surface (or layer) having the appearance of shredded or chipped wood mulch, pine needles, or grass clippings, the majority of the rubber components 12 of the given layer of the mulch mat 10 may be rubber shavings or buffings, which provide relatively more strength and flexibility to the mat 10. To produce such buffings, or shavings, 613, a buffing machine 617 is rotated about the tire 610 (or vice versa) to shed the buffings 613. The rubber buffings, or shavings, are characterized as having a length greater than their width (e.g., about % inch to about 3 inches in length and about 1/8 inch to about 1 inch in width). According to one aspect provided herein, the buffings 613 and/or granules 611 are of non-uniform size and shape to enhance the natural appearance of the mulch mat 10.
[0057] If rayon, nyion, polyaramid, or other such materials were used to reinforce the tires 610, the discrete fibers 14 of such materials may also be the byproduct of shredding, mulching, granulating, or buffing the tires 610. Such fibers may have a length of about 1 inch. Optionally, these fibers 14 may be included with the rubber components 12 in the manufacturing process. As yet another option, virgin fibers 14 may also, or instead, be used in the mulch mat 10.
[0058] FIG. 7 illustrates a mold 50 and a complementary cap, or frame, 56 that may be used in the manufacture of the present mat products (e.g., 10, 20). In one aspect, the mold 50 may have a height (as indicated by a top edge 52) that is about half the desired thickness of the finished mat product and that ranges from about 0.5 inches to about 2 inches. The mold 50 includes a peripheral lip 60 from which a projection, or anchor, 62 extends. The cap, or frame, 56 may have a complementary, or compatible ledge 64 about its perimeter, the ledge 64 supporting a downwardly-oriented shoulder 66. The ledge 64 of the cap 56 may have the same height as the anchor 62 of the mold 50, thus facilitating the creation of a two-layer mat structure, in which the layers (e.g., 102, 104) are of roughly equal thickness. Alternately, the ledge 64 may be of a different height to create a mat structure with layers (e.g., 102, 104) of different thicknesses, as may be useful in circumstances where the second layer (e.g., 104) includes only a coloring agent and a binder or where different thicknesses are otherwise desired. The cap 56 further includes a hole, or opening, 68, through which a second color or colored matrix may be introduced, as will be described beiow.
[0059] As shown, the anchor 62 and the ledge 64 fit together to seat the cap 56 onto the mold 50. This seating may be accomplished because the inside area 58 defined by the cap 56 is equal to the area 54 defined by the moid 50 and because the height of the shoulder 66 is comparable to the height of the anchor 62. Clearly, the length and width of the mold 54 determine the dimensions, or footprint, of the resulting mat (10 or 20), and molds having various dimensions may be employed to meet user specifications. If desired, the anchor 62 and the ledge 64 may be reversed or arranged in a variety of other orientations relative to each other, or alternate seating mechanisms may be substituted. Thus, the manufacturing process is not limited to the exemplary configuration shown in FIG. 7. [0060] Exemplary processes for creating dual-colored mat products (e.g., 10, 20) are illustrated in FIGS. 8 and 9, each of which employ the previously described mold 50 and some of which also employ the corresponding cap 56. Common to all exemplary processes are components of the mats 10 or 20, which include rubber components 12 (in the form of rubber granules 611, rubber buffings 613, or both), a binder 16, and a coloring agent 18. Optionally, the mat 10, 20 may further include fibers 14 and a catalyst 22.
[0061] The binder (shown as 16 in FIGS. 8 and 9) functions to hold the rubber components 12 together. The binder 16 may be a curable latex or urethane binder, such as a moisture-curable polyurethane. Binders other than polyurethane (e.g., polyacrylates) may instead be used to adhere the rubber components 12. Additionally, binders that are cured by other means, such as exposure to heat, UV radiation, electron beams, or chemicals, may instead be used.
[0062] Although functional, the simple combination of rubber components and binder fails to produce mats having a natural aesthetic appearance, e.g., an indigenous mulch- like appearance. First, rubber tire particles are typically coal black, while the binder coating them typically is clear or yellowish in appearance. As a result, such binder/rubber mix, when cured, may have an undesirable color. Further, the presence of the binder may generate an unrealistic sheen or gloss. [0063] Thus, to provide a natural appearance to the mulch mat 10 (or 20), coloring agents 18 and 18' may be incorporated into the layers 102, 104 of the mulch mat 10 (20), preferably after having been combined with the binder 16. The coloring agent 18, 18' may be a pigment, such as an iron oxide pigment or may be some other colorant, such as a dye or polymeric colorant. The coloring agent(s) 18, 18' may further include an anti-gloss agent or compound to minimize sheen or gloss. Diatomaceous silica may be used as anti-gloss agent. The diatomaceous silica, for instance, may be sprinkled on the surface of the uncured, molded mixture (24 or 24') to reduce gloss.
[0064] As discussed previously, the layers 102, 104 of the mulch mat 10 may be colored with different colored pigments to provide a dual-colored product. The first and second pigments 18, 18' may be red, white, brown, green, blue, black, sandstone, or some other color. In one aspect, the first and second pigments 18, 18' are different from one another.
[0065] An almost limitless variety of colors (including shades and tints) and color combinations may be incorporated into the present mat products, which are not to be limited to the previously recited colors. Among many possible variations, the following may be most common: red/brown, brown/green, brown/black, red/green, and red/black. Also, although natural colors and color combinations (that is, those that mimic wood, stones, grass, and the like) are expected in most cases, it is conceivable that some consumers may desire unusual colors (e.g., purple or pink) to compliment a particular motif or to decorate for a special occasion. Accordingly, the selection of colors for the layers (102, 104) of the mat (10) may be limited only by consumer imagination.
[0066] As described with reference to FIGS. 8 and 9, the mulch mat mixture 24, 24' may further include a catalyst 22 to promote curing of the binder 18. The catalyst may be chosen based on the type of binder system being used.
[0067] The skilled artisan will appreciate that these sources and brands are provided by way of example only and that any suitable binder, colorant (pigment), anti-gloss additive, catalyst, and the like may be used.
[0068] Turning now to FIG. 8, a mold 50 is provided for making the mulch mat 10 (or 20). The mold 50 (as shown in FIG. 7) has anchors 62 projecting upwardly from the peripheral lip 60. The distance between the interior portions of the anchors 62 defines an inner diameter 51 , which is determinative of the dimensions of the mat product 10 (or 20). The distance between the exterior, or outward-facing, portions of the anchors 62 defines an outer diameter 54.
[0069] As previously discussed, a corresponding cap 56 may be used with the mold 50. The cap 56 includes a shoulder 66 that is sized to seat the cap 56 on the mold 50 when the shoulder 66 is positioned on the lip 60 adjacent the anchors 62. The distance between the interior-facing sides of the shoulders 66 defines the inner cap diameter 58, which is equal to, or just slightly larger than, the outer diameter 54 of the mold 50. The cap 56 further includes an opening 68 through which a second layer may be introduced. The opening 68 may be substantially equal in area to the inside area of the mold 50, so that the second layer (e.g., 104) may be easily spread onto the first layer (e.g., 102). Alternately, the opening 68 may be much smaller, as represented schematically in FIGS. 8 and 9, in which case, vibration or other means may be necessary to spread the second layer 104 to a relatively uniform thickness.
[0070] A first mixture 24 is produced by mixing the rubber components 12, (optionally) the fibers 14, a binder 16, a first coloring agent 18, and a catalyst 22 in a mixing vessel. The resultant mixture 24 is weighed and placed into the mold 50. If necessary, the upper surface may be manually leveled, as schematically depicted by a hand symbol 152, to form an irregular surface. As shown, the mixture 24 is allowed to create an uneven and jagged surface texture on the upper surface of the first layer 102. Depending on the degree of compaction used to press the mixture 24 into the mold 50, the mold-contacting side of the first layer 102 may also be somewhat irregular or uneven, further contributing to a more natural appearance. Once the first layer 102 (having a first color derived from the first pigment 18) is created within the mold 50, the cap 56 may be positioned over the mold 50, such that the shoulders 66 of the cap 56 are aligned with the anchors 62 of the mold 50 and are positioned on the peripheral lip 60 of the mold 50.
[0071] In a second mixing operation, a second mixture 24' is produced by combining rubber components 12, binder 16, a second colorant 18s, and, optionally, fibers 14 and a catalyst 22. The second colorant 18' may be a different color than the first colorant 18, resulting eventually in a dual-colored mat 10. The rubber components 12 may be rubber buffings 613, rubber granules 611, or some combination thereof and may or may not be the same type or combination used in the first mixture 24.
[0072] The second mixture 24' may be applied to the first layer 102 by pouring the second mixture 24' through the opening 68 in the cap 56 to form the second layer 104. The second layer 104 may again be manually spread, or may be vibrated or moved through some other means, to fully and relatively evenly cover the first layer 102. After curing, the cap 56 and mold 50 are removed, and the finished dual-colored mat 10 may be prepared for packaging for storage, shipment, or sale.
[0073] FIG. 9 shows several alternate processes for making a realisttc-iooking dual- sided mat 10. Again, the mold 50 is used, which has an upper perimeter edge 52, an inner diameter 51 , a peripheral lip 60, anchors 62 projecting from the peripheral lip 60, and an outer diameter 54 between the exterior-facing sides of the anchors 62. As before, a mixture 24 having a first color is produced by combining the rubber components 12, (optionally) the fibers 14, the binder 16, the first coloring agent 18, and the catalyst 22. The resultant mixture 24 is weighed and placed into the mold 50. if necessary, the upper surface may be manually leveled, as schematically depicted by a hand symbol 152, to form an irregular surface on the first layer 102. The first layer 102 has an uneven and jagged surface texture on at least the exposed surface of the first layer 102, and the moid-contacting (lower) surface may be uneven or irregular as well, depending upon the degree of compaction with which the first mixture 24 is introduced into the mold 50.
[0074] Subsequentiy or simultaneously, a second mixture 24' may be prepared by combining rubber components 12, binder 16, and a second coloring agent 18', optionally with fibers 14 and a catalyst 22. As mentioned previously, the rubber components 12 may or may not be the same size and/or shape as the rubber components 12 used in the first mixture 24, and the second coloring agent 18' is different from the first coloring agent 18. The second mixture 24' is introduced onto the first layer 102 created by the first mixture 24, in a manner that wϋl be described below.
[0075] According to a first approach, a partially or fully cured first layer 102 may be extracted from the mold 50, reversed or flipped such that the upper surface faces downward, and returned to the mold 50. The previously described cap, or frame, 56 may then be seated on the mold 50.
[0076] The second mixture 24' may then be introduced through the opening 68 in the cap 56 to form a second layer 104 in contact with the first layer 102. After the second layer 104 has been leveled (e.g., manuaily, as indicated by hand symbol 152, or by vibration or some other method) and cured, the cap 56 is removed, and the finished dual-colored mat 10' may be extracted from the mold 50. The resulting mat 10' has an irregular, or uneven, surface on each side, which may be desirable when both of the layers 102, 104 are configured to resemble shredded or chipped wood mulch or cut grass.
[0077] Alternately, as illustrated in FIG. 9 by a double-line arrow, the first layer 102 may be produced (and at least partially cured) before being removed from the mold SO. Subsequently, the second mixture 24' may be introduced into the mold 60 and, optionally, manually smoothed (152), according to the process used to produce the first layer 102. The first layer 102 may then be placed over the uncured second layer 104, such that the curing of the second layer 104 serves to bond the first and second layers 102, 104. The resulting mat 10 resembles that manufactured according to the process illustrated in FIG. 8, in which the upper surface of the first layer 102 may possess a more uneven or jagged texture, as compared to the lower surface of the mat 10 (formed by the mold-contacting side of the second layer 104), The degree of irregularity, as previously mentioned, depends upon the amount of compaction and the volume of the second mixture 24'. Accordingly, while this method may work sufficiently to produce dual-sided mats 10 in which each layer is comprised primarily of rubber buffings 613 and, therefore, resembles shredded wood or grass clippings, the method may be better suited for a mat 10 in which at ieast one layer (e.g., 104) is comprised primarily of rubber granules 611, resulting in the appearance of pebbles or stones.
[0078] Finally, yet another approach (indicated with a dashed arrow in FIG. 9) includes the formation and extraction of the first layer 102 from the moid 50 and the subsequent formation and extraction of the second layer 104 from the mold 50. The first layer 102 and the second layer 104 may then be joined to one another by chemical reaction or by application of heat, compression, adhesive, or combinations thereof. The resulting mat 10' may include outermost surfaces having an irregular, or random, surface texture associated with shredded or chipped wood mulch or cut grass.
[0079] By way of example, the mixtures 24, 241 may contain, by weight,: from about 75% to about 88% rubber components 12; from about 0 % to about 2% fiber 14; from about 10% to about 15% binder 16; from about 2% to about 5% coloring agent 18 or 18' (based on the total weight of the binder 16); from about 0.01 % to about 0.03% catalyst 22 (based on the total weight of the binder 16); and a negligible percent of UV light stabilizers and anti-oxidants.
[0080] in some instances, it may be desirable to incorporate a fertilizer compound into the mulch mat 10. The fertilizer may be organic, inorganic, or a combination of organic and inorganic components. Moreover, the fertilizer may be granular, a powder, a liquid, a slow-release fertilizer, and combinations of these and other fertilizer types. Further, the fertilizer may be added during the mat formation process (i.e., by incorporating into one or both mixtures 24, 24') or after the mat formation process (i.e., by sprinkling onto one or both layers 102, 104). The fertilizer may also be added to the mat 10 after use for a period of time to replenish the fertilizing properties of the mat 10. When used, the fertilizer may be added into one or both mixtures (24, 24') or on one or both layers (102, 104) in an amount equivalent to from about 1% to about 10% of the weight of the mat 10.
[0081] FlG. 10 shows the mulch mat 20 to which fertilizer granules 150 have been applied. As rain or water 162 contacts the fertilizer 150, the fertilizer 150 activates, such as by becoming a liquid 154, and passes through the mat 20 to nourish the tree roots 58. Also as shown, the mat 20 is sufficiently porous to permit the liquid 154 to pass through to the tree roots, but is sufficiently dense to prevent weeds, grass, and other undesired plant life from growing through the mat 20. It will be appreciated that, although fertilizer 150 is depicted as granules on the upper surface of the mat 20, the fertilizer 150 may be embedded in various portions of the mulch mat 20. Alternately or additionally, the fertilizer 150 may be in the form of a liquid that is incorporated into the mixture 24 (and/or 24') to form at least one layer of the mat 20.
[0082] Once the fertilizer 150 is depleted, perhaps after a season of use, the user may replenish the fertilizer 150 by sprinkling or spraying new fertilizer onto the upper surface of the mat, from which the newly applied fertilizer will leach or seep into the underlying roots, as described above.
[0083] Although reference has been made to the use of the present mulch mats around trees, it should be understood that the mat may be used around foliage other than trees (such as shrubs), or around posts or poles (such as mailbox posts, light poles, and other inanimate objects) to protect wooden or painted surfaces. Obviously, in the event that the mat is to be used around a non-living object, a fertilizer compound is unnecessary.
[0084] in use, the mulch mat 10 (or 20) appears as a natural mulch-covered area. The mulch mats 10, 20 are sufficiently durable to withstand various weather conditions and last many times longer than natural mulch, which tends to fade, decompose, and become scattered, due to wind, rain, and foot traffic. The mulch mat 10 provides protection to trees and plants, preventing weed or grass growth adjacent to the trees or plants and preventing incidental damage from mowers or trimmers. Additionally, the fertilizer-treated mulch mats 10 (or 20) beneficially nurture trees or plants, as fertilizer leaches through the mat's lower surface and into the root system of the trees or plants.
[0085] Accordingly, edging systems or mats of the composition according to the present disclosure can be used over ground to delineate lawn edges or outdoor equipment storage areas. Moreover, due to their dual colors, the products save storage and sales space; i.e., one multicolored edging systems or mats is attractive to different consumers having different landscaping needs.
[0086] It will thus be appreciated that those skilled in the art will be able to devise various arrangements, which, although not explicitly described or shown, embody the principles of the invention and are included within its spirit and scope. Furthermore, all examples and conditional language recited herein are principally intended for pedagogical purposes to aid the reader in understanding the principles of the inventions and the concepts contributed by the inventor(s) to furthering the art and are to be construed as being without limitation to such specifically recited examples and conditions.
[0087] Moreover, all statements herein reciting principles, aspects, and embodiments of the inventive products and processes, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents and equivalents developed in the future, i.e., any elements that perform the same function, regardless of structure.
[0088] This description of the exemplary embodiments is intended to be read in connection with the figures of the accompanying drawings, which are to be considered part of the entire description of the invention. In the description, relative terms such as lower", "upper", "horizontal", "vertical", "above", "below", "up", "down", "top" and "bottom", as well as derivatives thereof (e.g., "horizontally", "downwardly", etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation, unless otherwise indicated. Terms concerning attachment, coupling, bonding, and the like, such as "bonded", "connected", "attached", or "interconnected", refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, unless expressly described otherwise.
[0089] The foregoing description provides a teaching of the subject matter of the appended claims, including the best mode known at the time of filing, but is in no way intended to preclude foreseeable variations contemplated by those of skill in the art.

Claims

We claim:
1. A dual-colored elastomeric mat comprising: a first side being configured for contacting ground, the first side comprising a cured matrix of a first plurality of rubber components, a curable binder, and a first coloring agent, the cured binder holding the rubber components together; a second side opposite the first side and being configured for alternative contact with the ground, the second side comprising a cured matrix of a second plurality of rubber components, a curable binder, and a second coloring agent, the cured binder holding the rubber components together and the second side to the first side, and the second coloring agent being a different color than the first coloring agent; and wherein a portion of the rubber components are randomly and angularly oriented within the mat to impart a non-uniform thickness to the mat and a nonuniform texture to at least one of the first side and the second side of the mat.
2. The mat of Claim 1 , wherein the rubber components are selected from the group consisting of rubber buffings, rubber granules, and combinations thereof.
3. The mat of Claim 2, wherein the first side comprises rubber buffings and the second side comprises rubber granules.
4. The mat of Claim 1 , wherein the cured matrix of one of the first side and the second side comprises fibers.
5. The mat of Claim 1 , further comprising an anti-gioss agent.
6. The mat of Claim 1 , wherein the mat comprises a perimeter edge, the perimeter edge defining a substantially circular shape.
7. The mat of Claim 5, wherein the randomly and angularly oriented buffings extend beyond the perimeter edge of the upper surface of the mat to create a nonuniform perimeter.
8. The mat of Claim 1 , wherein the mat comprises a rectangular shape.
9. The mat of Claim 1 , further comprising a fertilizer compound.
10. The mat of Claim 8, wherein the fertilizer compound is in granular form.
11. The mat of Claim 8, wherein the fertilizer compound is primarily located on one side of the mat.
12. The mat of Claim 8, wherein the fertilizer compound is intimately mixed within the mat.
13. A method of manufacturing a dual-colored rubber mat, the method comprising: providing a mold; introducing a first colored matrix comprised of rubber components, a binder, and a first coloring agent into the mold and curing the first matrix to form a first layer; creating a second colored matrix of rubber components, a binder, and a second coloring agent; introducing the second colored matrix in contact with one side of the first layer; curing the second colored matrix to form a second layer; and securing the second layer to the first layer to form a dual-colored mat; wherein a portion of the rubber components are randomly and angularly oriented within the mat to impart a non-uniform thickness to the mat and a nonuniform texture to at least one of the first side and the second side of the mat.
14. The method of Claim 13, wherein the mold includes a peripheral lip and a projection, the projection depending from the peripheral lip.
15. The method of Claim 14, further comprising joining the mold with a cap, the cap defining an opening therethrough for the passage of the second colored matrix onto the first layer.
16. The method of Claim 15, wherein the cap includes a ledge defining a shoulder, the ledge being compiementarily shaped with the projection of the mold, to seat the cap and the mold together.
17. The method of Claim 13, wherein the rubber components are selected from the group consisting of rubber buffings, rubber granules, and combinations thereof.
18. The method of Claim 17, wherein the first colored matrix includes a first type of rubber components and the second colored matrix includes a second type of rubber components.
19. The method of Claim 13, further comprising mixing a catalyst into the first colored matrix.
20. The method of Claim 13, further comprising mixing fibers into the first colored matrix.
21. The method of Claim 13, wherein the first layer comprises an upper side and a lower side, the lower side being opposite the upper side and being in contact with the mold, the method further comprising reversing the first layer before the introduction of the second matrix, such that the second matrix is introduced onto the lower side of the first layer.
22. The method of Claim 13, wherein the securing of the second layer to the first layer to form a dual-cofored mat occurs simultaneously with the curing of the second colored matrix to form a second layer.
23. The method of Claim 13, wherein the securing of the second layer to the first layer to form a dual-colored mat occurs as a result of a chemical reaction.
24. The method of Claim 13, wherein the securing of the second layer to the first layer to form a dual-colored mat occurs with an application selected from the group consisting of heat, compression, adhesive, and combinations thereof.
PCT/US2008/083114 2008-11-11 2008-11-11 Dual-colored mulch mat with realistic appearance WO2010056234A1 (en)

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WO2017044920A1 (en) 2015-09-11 2017-03-16 Iorio Paul Anthony Tree frame and grate system and method to improve growth of vegetation in an urban environment
US11124959B2 (en) 2015-08-11 2021-09-21 Mmt, Inc. Stormwater biofiltration system and method

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US11124959B2 (en) 2015-08-11 2021-09-21 Mmt, Inc. Stormwater biofiltration system and method
WO2017044920A1 (en) 2015-09-11 2017-03-16 Iorio Paul Anthony Tree frame and grate system and method to improve growth of vegetation in an urban environment
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