Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
MAT WASHING SYSTEM
FIELD OF THE INVENTION
The present invention is generally directed to an industrial washing system
for washing large flat
objects, more specifically for non-contact washing of large mats also referred
to as road or access mats.
BACKGROUND OF THE INVENTION
In order to facilitate transport and movement of heavy vehicles in
construction areas and remote
mining or oil and gas worksites, it is often desirable to have access roads or
worksites covered with road
mats also referred to as access mats. These allow vehicles to circulate on
very difficult unpaved roads by
reducing or even completely eliminating the risk of getting bogged down in
mud. These mats arc laid right
over access roads to help the circulation of heavy equipment such as trucks,
cranes and other heavy
machinery. However, over time, the mats get covered in dirt and must be washed
prior to being moved to
another work site or being re-used. Manual washing of these mats is extremely
time consuming and is a
very inefficient process. The sheer number of mats to be washed is a barrier
to washing such mats purely
by human activity as it would become economically undesirable to do so.
Known devices for washing swamp mats, such as the one disclosed in US patent
number 8,273,186,
have a conveying system to transport the mats through the device on rollers. A
multiplicity of powered
conveyor rollers expose the system to the possibility of breakdowns as the
dirt, dust may accumulate on the
rollers and diminish their ability to operate optimally which can possibly
results in delays and cost overruns.
Because the mats are made of horizontal and vertical boards, the boards may
tend to jam in the slots between
the rollers of the conveyor system.
Northern Mats' Canadian Patent CA 2,871,376 discloses a system for washing a
large flat object
having a length and a width, wherein the length is of greater dimension than
said width, said
system comprising: a frame having a first and second end; a transport system
adapted to vertically
transport said large flat object suspended thereon; said transport system
defining a horizontal axis along
the device and adapted to transport said object from the first end of the
frame to the second end of the
frame; and at least one brushing means for brushing and removing particles
lodged on said object; said at
least one brushing means located along the transport system between the first
and second end of the
frame and adapted to frictionally engage said object when in operation. A
drawback that was noted
during operation of the system was that in order to wash the entire surface of
the mats, the mat would go
through a first wash cycle
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and then be unloaded from the transport system and then undergo a second wash
in order to ensure complete
washing of the exposed surfaces of the objects or mats.
In light of the prior art, there is clearly still a need for a mat washing
system which overcomes the
drawbacks of the prior art. Generally speaking, two issues that the inventors
targeted in their design of a
novel system were those of reliability and efficiency of the mat washing
operation. The present invention
is directed to an industrial washing device, more specifically to a device for
washing mats, where the
washing operation is controlled for the most part by a computerized control
system.
Consequently, there still remains a need for a reliable device which provides
a method of washing
mats which overcomes certain drawbacks of prior art devices.
SUMMARY OF THE INVENTION
Accordingly, the present invention is generally directed to an industrial
washing system, more
specifically to a system for washing mats. According to one aspect of the
present invention, there is
provided a system for washing a large flat object having a length greater than
a width, the width defining a
cross-section, said system comprising:
a frame defining a longitudinal path and comprising
- a first end;
- a second end; and
- a wash chamber positioned between said first and second ends;
a transport system secured to the frame and adapted to transport said object
positioned
thereon; said transport system comprising:
- a plurality of idle rollers located along said longitudinal path and adapted
to
support said object as it travels along the longitudinal path; and
- a drive system to provide mechanical transport motion to said object along
the
longitudinal path from said first end of the frame to said second end of the
frame,
said drive system being positioned outside the wash chamber; and
- first end comprising a loading mechanism to position the
object on at least one of
the plurality of rollers, and said second end comprising an unloading
mechanism
to remove the object from at least one of the plurality of rollers;
said wash chamber comprising an entrance located proximate the first end and
an exit
located proximate the second end, and a plurality of high pressure nozzles
(water jets) positioned
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within the wash chamber and adapted to spray said object when such is within
the washing
chamber.
According to a preferred embodiment, the object is transported vertically
along its edge through
the brushless wash system. The object is meant to transit along the
longitudinal path defined by the frame
of the systems.
According to a preferred embodiment of the present invention, there is
provided a brushless system
for washing a large flat object having a length greater than a width, the
width defining a cross-section. said
system comprising:
- a frame defining a longitudinal path and comprising
- a first end;
- a second end; and
- a wash chamber positioned between said first and second ends;
- a transport system secured to the frame and adapted to transport said
object positioned thereon;
said transport system comprising:
- a plurality of idle rollers located along said longitudinal path
and adapted to support said
object as it travels along the longitudinal path;
- a drive system to provide mechanical transport motion to said object along
the
longitudinal path from said first end of the frame to said second end of the
frame, said
drive system being positioned outside the wash chamber; and
- first end comprising a loading mechanism to position the object
on at least one of the
plurality of rollers, and said second end comprising an unloading mechanism to
remove
thc object from at least one of the plurality of rollers;
said wash chamber comprising an entrance located proximate the first end and
an exit located
proximate the second end, and a series of high pressure nozzles (water jets)
positioned within the
wash chamber and adapted to spray the entire surface of said object when such
is within the washing
chamber.
According to another preferred embodiment of the present invention, there is
provided a brushless
system for washing a large flat object having a length greater than a width,
the width defining a cross-
section, said system comprising:
- a frame defining a longitudinal path and comprising
- a first end;
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- a second end; and
- a wash chamber positioned between said first and second ends,
- a transport system secured to the frame and adapted to vertically
transport said object positioned
thereon; said transport system comprising:
- a plurality of idle rollers located along said longitudinal path
and adapted to support said
object as it travels along the longitudinal path;
- a drive system to provide mechanical transport motion to said object along
the
longitudinal path from said first end of the frame to said second end of the
frame, said
drive system being positioned outside the wash chamber; and
- first end comprising a loading mechanism to position the object
on at least one of the
plurality of rollers, and said second end comprising an unloading mechanism to
remove
the object from at least one of the plurality of rollers;
said wash chamber comprising an entrance located proximate the first end and
an exit located
proximate the second end, and a series of high pressure nozzles (water jets)
positioned within the
wash chamber and adapted to spray the entire surface of said object when such
transits through the
washing chamber;
wherein the entire cross-section (to be understood as being the width of the
object) of said object
is untouched by the system at at least one point during its transit through
the wash chamber.
Preferably, the large flat object is positioned on its side along an edge
thereof.
Preferably also, the drive system comprises a pair of opposing drive rollers
adapted to frictionally
engage said object and drive the object into the wash chamber. Preferably, the
drive system comprises a
second pair of opposing drive rollers adapted to frictionally engage said
object after a portion thereof exits
the wash chamber and pull the object out of the wash chamber. Preferably also,
the pair of drive rollers arc
mounted on the frame proximate the entrance of the wash chamber. Preferably,
at least one of the rollers
of the pair of drive rollers is pivotally mounted on the frame to allow
movement between a first position
which allows room for insertion of the object onto the transport system and a
second position where the
two rollers are in frictional contact with the object.
Preferably, a second series of high pressure jets located within the wash
chamber in a position after
the series of high pressure water jets. Preferably, a third series of high
pressure jets located within the wash
chamber in a position after the second series of high pressure water jets.
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According to another preferred embodiment of the present invention, the
loading support further
comprises hydraulic cylinders to move said loading support from a horizontal
position to a substantially
vertical position.
According to another preferred embodiment of the present invention, there is
an unloading support
located at the second end of the frame to receive the washed object.
Preferably, the unloading support
further comprises an index with a horizontally moving clamp. According to a
preferred embodiment, the
unloading support comprises a frame pivotally movable about an axis to move
from a substantially vertical
position to a substantially horizontal position.
According to another preferred embodiment of the present invention, at least
one water collecting
means to collect water used in washing the object. Preferably, the water
collecting means is a trough located
underneath the path of the object being washed and adapted to receive and
collect the water dripping off
the object. Preferably, the water collecting means further comprises a channel
adapted to direct the
collected water to a settling tank.
According to another preferred embodiment of the present invention, there is
at least one water
treatment means for treating the water collected by the collecting means.
According to another preferred embodiment of the present invention, the system
further comprises
a closed loop water recirculation system.
According to another preferred embodiment of the present invention, the system
comprises a
chemical spraying assembly to chemically treat the object after the washing
operation, wherein said
chemical spraying assembly is located proximate the exit of the wash chamber.
Preferably, the system
comprises a chemical recovery means separate from the water collecting means.
According to another preferred embodiment of the present invention, the
separate chemical
recovery means comprises a channel adapted to receive chemical containing
fluid dripping off the object.
Preferably, the separate chemical recovery means further comprise a chemical
recovery vessel in fluid
connection with said channel adapted to receive liquid dripping off the
object.
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Preferably, the system further comprises a tank supplying water used in the
washing process which
tank comprises a filtration system to remove suspended solids present in water
prior to the water exiting
the tank. Preferably, the filtration system comprises a geotextile fabric.
According to another aspect of the present invention, there is provided a
method for contact-free
washing of a mat, said method comprising:
providing a mat washing system as described above;
providing a mat;
loading said mat onto the mat washing system;
securing said mat onto the transport system by frictionally engaging opposing
drive rollers to a
portion of the mat;
transporting the mat through the wash chamber;
striking the entire surface area of the mat with high pressure fluid; and
retrieving the mat from the wash chamber.
BRIEF DESCRIPTION OF THE FIGURES
The present invention may be better understood in consideration of the
following description of
various embodiments of the invention in connection with the accompanying
drawings, in which:
Figure 1 is a perspective view of the mat washing system according to a
preferred embodiment of
the present invention;
Figure 2 is a close up perspective view of the loading section of the mat
washing system according
to a preferred embodiment of the present invention;
Figure 3 is a close up perspective view of the loading section of the mat
washing system according
to a preferred embodiment of the present invention where the mat table is
tilted up prior to the loading of a
mat onto the idle rollers;
Figure 4 is a side perspective view of the loading mechanism of the mat
washing system according
to a preferred embodiment of the present invention;
Figure 5 is a side perspective view showing a mat being removed from the
stack;
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Figure 6 is a top perspective view showing the drive rollers in an open
position to allow the
placement of a mat on the idle rollers;
Figure 7 is a top perspective view showing the drive rollers in a closed
position after placement of
a mat on the idle rollers;
Figure 8 is a front perspective view of a mat being positioned on the idler
rollers of a system
according to a preferred embodiment of the present invention;
Figure 9 is a side perspective view showing the drive rollers pinching a mat
prior to the mat
entering the wash station;
Figure 10 is a top perspective view showing the wash chamber according to a
preferred
embodiment of the present invention with the covers removed;
Figure 11 is a perspective view of the mat washing system according to a
preferred embodiment
of the present invention with the infeed and outfeed tables removed and ready
to be transported; and
Figure 12 is a perspective view of the mat washing system according to a
preferred embodiment
of the present invention in ready mode along with the water receiving tanks.
DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION
The system for washing large flat objects, according to a preferred embodiment
of the present
invention, is adapted to be moved from site to site as needed by loading it
onto a custom-made trailer. The
trailer follows highway transportation rules and is designed (weight) to be
transported during a 75% Road
Ban. Known devices from other companies are understood to be stationary
systems once installed.
Preferably the system further comprises a loading support located at the first
end of the frame, said
loading support adapted to receive a plurality of objects to be washed. More
preferably, the loading support
further comprises an index to separate and lift the object from said support.
Preferably also, the loading
support is adapted to move from a horizontal position to a vertical position.
Preferably, the loading support
further comprises hydraulic cylinders to move said loading support from a
horizontal position to a vertical
position.
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The system for washing large flat objects, according to a preferred embodiment
of the present
invention has a single vertical transport system. Known devices have several
separate horizontal conveying
systems that may work together to pass the mats to each other from the front
end of the device to the back
end.
According to yet another aspect of the invention, the mat washing device can
be completely
automated utilizing a programmable logic controller (PLC). The PLC allows for
the mat washing machine
to operate completely on its own once the mats are placed horizontally on the
infeed stacker. This is an
advantage over known devices as none have integrated complete automation
capabilities.
A programmable logic control system (PLC) signals the loading mechanism (40)
to pick up a mat
from the loading station (or inked station) (4) and place it onto idle rollers
(22). The mat is then frictionally
clamped between a pair of drive rollers (24a, 24b) set on either side of the
mat and adapted to push the mat
into the wash chamber (30).
Known systems require additional transporting system to load and unload mats.
According to a
preferred embodiment of the present invention, the device for washing large
flat objects has loading and
unloading capabilities which may be integral to the entire system and designed
to automatically work with
the entire system. There are no add-ons required. The loading & unloading
system is novel to the industry
as the loading portion takes a mat from a horizontal position to a vertical to
wash it and reverses clean mats
to unload them from the system. In a preferred embodiment, the loading and
unloading systems each
comprise two main parts: a table and a loader (unloader). The table is adapted
to receive a plurality of mats
and is tillable to allow the mats resting thereon to be positioned at an angle
therefore allowing the loader to
grab one mat at a time and deposit the mat in a vertical position (on its side
edge) onto idle rollers located
on the wash system. The loader (unloader) comprises a system of hydraulic
clamps adapted to grasp the
mat from its edges and move it onto the idle rollers. The design is such that
the bottom part of the clamp
portion can be inserted between two idle rollers and therefore allow to
position the mat onto the idle rollers
without dropping it or violently slamming it onto the rollers. This is
desirable as it allows for a longer
useful lifetime of the rollers and to a certain extent, the mats as well.
Figure 1 shows an overview of the mat washing system (1) according to a
preferred embodiment
of the present invention, the main sections of the system are as follows: the
first end (2), the second end
(3); the loading section (4); the unloading section (5); outriggers (11); wash
chamber (30); drive rollers
(24a, 24b and 26a, 26b); frame (10) and idle rollers (22).
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Figure 2 is a closc-up view of the mat washing system (1) with the tanks
removed from view. Mats
are brought in with a forklift or loader dropping a stack of 4 on the infeed
table (41). The infeed table
comprises a base (42), a top (43) and means of lifting and tilting the top
(43) such as hydraulic pistons (44).
Figure 3 shows that the top (43) of the inked table is lifted and tilted to
move the stack of mats closer to
the loading mechanism (40)
Figure 4 shows an isolated view of the clamps (50) and the loading mechanism
(40). The loading
mechanism is an articulated frame comprising a base (45), a middle section
(46) and a clamp section (50)
comprising a pair of clamps (51, 51a) adapted to grasp the mat off of the
infeed table (41) and position it
onto at least one idle roller (22). The clamps (51, 51a) grasp the mat by its
edges while the top (43) of the
loading table (41) is tilted through the action of hydraulic pistons (44) and
lifts a single mat off of the stack
of mats resting on the table (41). The articulation of the loading mechanism
(40) is accomplished through
the use of pivot points (47) between the base of the loading mechanism and the
middle section (48) as well
as a pair of hydraulic pistons connecting the said base and middle section. To
combined action of the pivot
points and of the hydraulic pistons work in concert to accomplish the pivot
motion. Similarly, the same
concept is applied between the middle section (46) and the clamp section (50).
Pivot points (57) between
the middle section (46) of the loading mechanism and the clamp section (50) as
well as a pair of hydraulic
pistons (58) connecting the middle section (46) and the clamp section (50)
allow for the clamps to pivot
and provide a greater range of motion to the loading mechanism. The clamps (51
and 51a) comprise two
pairs of hydraulic pistons (52 and 54) each pair located at one end of the
clamp frame (55). The clamps
further comprise a gripper portion (62, 62a and 64, Ma) at each end of the
clamp frame and slidable along
the length thereof through the actuation of the hydraulic pistons (52, 52a and
54, 54a).
Similarly, the unloading system (60) comprises an articulated frame comprising
a base, and middle
section and a clamp system. The base section is preferably connected and/or
mounted to the frame (10) of
the system. The middle section consists of a pivotally movable sturdy frame
connected to the base and
having a range of motion sufficient to "lean in" towards the table of the
outfeed station (5) to deposit the
washed mat thereon.
Figure 5 shows the loading mechanism (40) pulls one mat at a time from the
stack, straightens and
places them in-between the drive (feed) rollers (24a, 24b) in an "open"
position as better illustrated in
Figure 6. In this preferred embodiment, the pair of feed rollers is in an
"open" configuration to allow the
mat to be placed in a position where, once the pair of rollers are in a
"closed" configuration, each one of
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the feed rollers will be in frictional contact with opposite sides of the mat
and will be capable of providing
niotion to the mat to enter into the wash chamber. The feed rollers "push" the
mat into the wash chamber
(30) and this is assisted by the idle rollers (22) on which the mat is
positioned. Once through the wash
chamber (30), a second pair of drive rollers (26a, 26b) will assist the first
pair of drive rollers (24a, 24b) by
"pulling" the mat.
Once in position to be loaded onto the idle rollers (22), the mat is then
straightened to a vertical
position and lowered onto the idle rollers. The mat is then held in place by
the drive rollers (24a, 24b) in a
closed position while resting onto idle rollers (22) and then released from
the infeed loading clamps (51,
51a), see Figures 7 and 8. The mat is now ready to be driven thru the wash
chamber (30) where it will be
grabbed by a second set of drive rollers (26a, 26b) that will pull it thru to
the outfeed station (titt) as best
illustrated in Figure 9. In this embodiment, the unloading station (outfeed
station) (5) is identical to the
infeed station (4) just running operations in reverse ending with a stack of
clean mats on the outfeed table
waiting for a forklift or loader to pick them up. The outfeed and infeed
stations need not be identical hut it
may be desirable to have them be in order to optimize the speed of mat
processing through the system.
Preferably, infeed system (4) and outfeed system (5) are coordinated to allow
the last mat to be washed
while the infeed system is being reloaded.
According to an alternative embodiment of the present invention, the wash
chamber does not
contain any idle rollers. The absence of idle rollers within the chamber is
compensated by proximity of the
last roller to the entrance of the wash chamber and the proximity of the first
roller outside the wash chamber
as well as the drive rollers which exert sufficient pressure on the mat to
maintain it straight as it enters and
exits the wash chamber and is then supported on the rollers located at the
exit of the chamber. This
embodiment provides the ideal set-up as it maximizes the distance during which
the cross-section of a mat
is completely untouched by the system as it passes therethrough. The non-
contact with the system ensures
that, contrary to every other mat washer disclosed in the prior art, the
present invention will allow a
complete washing of a mat in one pass through. This point cannot be
sufficiently emphasized as speed is
an issue and cross-contamination (from dirty mats) are critical in the
industry.
Figure 10 shows the inside of the wash chamber (30). The mat passes thru from
right to left. The
first series of nozzles arc mounted on two towers (33, 33a and 34, 34a) on
each side of the center of the
wash chamber and each one of them containing a plurality of nozzles (35).
Preferably, the two towers
consist of staggered rows of rotary turbo nozzles (48 nozzles) that run at
high pressure (2000 to 2500 psi)
and a flow of about 3 gpm each. These are run by 4 separate pumps (not shown)
that allow the operator to
Date Recue/Date Received 2021-02-16
reduce or increase pressure individually as mats can be cleaner on one side
than the other and grooves can
be much harder to remove mud (and/or ice) from than faces. The second series
of nozzles consists of a
tower (36) of fan nozzles (37) (46 nozzles) located on either side of the
center of the wash chamber (30)
and running at a lower pressure (1000 to 1500 psi). These fan nozzles (37) are
angled to flush all dirt and
dirty water away from the clean mat as it makes it way to the exit of the wash
chamber. Preferably, there
are fan nozzles which aim water at the top edge of the mat, along the edge and
top surface of the mat (as
well as the edge and bottom surface), all along both the top and bottom
surface of the mat and finally, on
the bottom edge of the mat as well as the edge where the top of the mat and
the edge of the mat meet (as
well as the edge and the bottom of the mat meet). This ensures a thorough
rinse of the mat and effective
non-contact removal of dirt and debris from each mat. Finally, a pair of
nozzle towers (38, 38a) contain a
plurality of nozzles (39) to spray sanitizing bleach on the mats just before
they exit the wash chamber. The
combination of the various spray nozzle sequences allows a road mat to be
washed without the use of
brushes which can break down, wear down and/or damage the mats. This approach
has not been seen in
the industry as the school of thought emphasizes or focusses on contact
cleaning and which type of brush
to use and how to best set up a machine in order to obtain an optimal wash.
According to a preferred embodiment, there is rubberized canvas which
surrounds the wash
chamber (30) and which directs water into a water collecting means which is
preferably a trough. The
rubberized canvas surround is easily removable for cleaning any debris that
collects on mechanical systems
and collectors. Other options and material can be considered without departing
from the purpose of such
which is to maintain the water, dirt and debris i.vithin the wash chamber and
have such drip into the through
located right under said chamber.
Figure 11 shows the mat washer system (1) ready for transport. The top of the
wash station (30)
folds down, the outrigger legs (11) collapse and fold in and the
infeed/outfeed tables unpin and remove.
Figure 12 shows the mat washing system (1) according to a preferred embodiment
of the present
invention in ready-mode along with two water-receiving (or recovery) tanks
(100 and 101) located
underneath the frame of the system.
According to a preferred embodiment of the present invention, the device for
washing large flat
objects recycles the water used in the washing of the mats and can be operated
in remote areas without
reliance on a fixed & unlimited water source or utility. This feature is not
known to be part of known mat
washing devices and limits their use in locations where large volume of water.
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According to a preferred embodiment, the system further comprising at least
one water collecting
means to collect water used in washing the object. Preferably, the water
collecting means is a trough located
underneath the path of the object being washed and adapted to receive and
collect the water dripping off
the object. More preferably, the water collecting means further comprises a
channel adapted to direct the
collected water to a settling tank. According to a preferred embodiment, the
system further comprises at
least one water treatment means for treating the water collected by the
collecting means.
The system to wash large flat objects according to a preferred embodiment of
the present invention
comprises a transport system; a washing section; a water supply and
recirculation system; an object loading
section and an object unloading section. Preferably, there is a section or a
controller room where the system
operation and monitoring is carried out. The water supply and recirculation
system comprises a water tank
capable of storing and providing water that has been trucked in for operations
in a remote area. The water
system further comprises a large channel located underneath the transport
system in a position to recover
water used in the process to wash the objects. The water captured in the
channel is directed to a settling
tank, in a preferred embodiment there are 6 settling chambers in total, where
the dirt and other particulates
arc settled out and the water is further directed to a second settling tank
which allows for further settling
and clarifying of the water prior to it being filtered (optionally) and
reintroduced in thc water tank.
According to a preferred embodiment, the system is mounted on a tractor
trailer.
According to another preferred embodiment, the system further comprises a
closed loop water
recirculation system. Preferably, the system further comprises a chemical
spraying assembly to chemically
treat the object to be washed, wherein said chemical spraying assembly is
located after the washing
chamber. More preferably, the system further comprises a separate chemical
recovery system. Even more
preferably, the separate chemical recovery system comprises a channel adapted
to receive liquid dripping
off the object. Preferably also, the separate chemical recovery system further
comprises a chemical recovery
vessel in fluid connection with said channel adapted to receive liquid
dripping off the object.
According to a preferred embodiment, the system further comprising a tank
supplying water and
more preferably the water used in the washing process is recirculated into the
tank which comprises a
filtration system to remove suspended solids present in water prior to the
water exiting the tank. Preferably.
the filtration system is made up of a geotextile fabric.
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In order to be of optimal efficiency, the system for washing large flat
objects, according to a
preferred embodiment of the present invention must adhere to transportation
guidelines, it does so by having
one height for transportation and one height for operation. In some cases, the
operation height exceeds the
transportation guidelines, therefore it is preferably that the that the system
(or at least a portion thereof) be
collapsible to meet such guidelines.
The person skilled in the art would understand that any attempt to circumvent
the scope of the
invention by adding a "contacting step" during the washing stage in order to
overcome the non-contact as
disclosed herein should be considered as an obvious variation of the present
invention if such is done not
in the spirit of washing mats in an efficient way but for the purpose of
avoiding infringement.
The terms and descriptions used herein are set forth by way of illustration
only and arc not meant
as limitations unless otherwise specifically indicated. Those skilled in the
art will recognize that many
variations are possible within the scope of the invention as defined in the
following claims, and their
equivalents, in which all terms arc to be understood in their broadest
possible sense unless otherwise
specifically indicated. While the system shown and described in detail herein
is fully capable of attaining
the above-described aspects of the invention, the person skilled in the art
will understand that it is but a
preferred embodiment of the present invention and the invention is not to be
limited to that singular
embodiment.
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