5-Layer Rubber Floor Mat EPDM Neoprene SBR Cloth Insert
Customer Requirements: 
Our customer is working on construction industrial, which is currently develop a specialized floor mat, which comprises five layers: EPDM 60A, closed cell sponge foam, neoprene 50A, closed cell sponge foam, and cloth inserted SBR 70A. The desired dimensions are 24” x 36” (width x length) with a height of 1.625”.
Above attached the details of the mat, also a person will stand on this mat for many hours per day, it will be stationary, no rolling. Quantities he would like between 1-5
Samples, as it comes closer to final product, and will start order with about 5,000 units once final product is created. Here are some more requirements:
- All 5 layers need to be glued together
- All edges need to be rounded/beveled
- Inner 3 layers need to be completely covered by top and bottom layers at edges/corners
- Preferably in black color.
WeProFab Preliminary Plan
Processes: First, according to the customer’s requirements, make each layer board that meets our standards. The external dimensions should be 24” × 36”. Then, from bottom to top, place the 1.625” SBR70 on the workbench, apply a layer of degreasing agent, wait for the board to dry, use the glue applicator to evenly apply the glue on the surface of the product, attach the release film, and wait for the glue to dry. During this process, apply the degreasing agent to both sides of the closed-cell sponge, wait for it to dry, and then cover the SBR70 with it. Proceed in the same manner.
Raw materials:
– EPDM 60A
– Closed cell sponge foam
– Neoprene 50A
– Cloth inserted SBR 70A
WeProFab Final Successful Plan:
Processes descriptions:
First, cut EPDM 60A, closed-cell sponge foam, neoprene 50A, closed-cell sponge foam, and cloth-inserted SBR 70A to 24” × 36”. Roughen and degrease solid rubber surfaces, and lightly treat sponge surfaces to improve adhesion. Apply a multi-substrate compatible rubber adhesive evenly on each bonding interface and air-dry to tack-free status. Laminate the layers in sequence: EPDM → closed-cell sponge → neoprene → closed-cell sponge → cloth-inserted SBR, then press and cure the adhesive, fixing total thickness at 1.625”. After curing and cooling, trim edges and inspect bond strength, dimensional accuracy, and flatness.
Critical to Quality:
Adhesive must be compatible with EPDM, CR, SBR and closed-cell foam to avoid foam erosion or delamination;
Prevent sponge collapse, bubbles or weak bonding;
Precise layer alignment and consistent thickness control to meet 24”×36”×1.625”
