AU1357100A - universal mat with removable strips - Google Patents

Description

P/00/01i1 Regulation 3.2

AUSTRALIA

Patents Act 1990

S.

S

S

S**

*Sb.*S St..

A.

S

SS S

S.

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT Invention Title: "UNIVERSAL MAT WITH REMOVABLE STRIPS" The following statement is a full description of this invention, including the best method of performing it known to me/us:.

UNIVERSAL MAT WITH REMOVABLE STRIPS FIELD OF THE INVENTION The present invention relates to floor mats.

REVIEW OF THE RELATED TECHNOLOGY In the past, floor.mats were made for specific purposes. Mats were made for entrance ways, commercial kitchen fatigue mats, oil resistance, snow and water removal, etc. Most.of.the above uses required specific mat constructions to perform whatever use was required. Sometime it took more than one supplier to provide all of the requirements. If one mat supplier tried to cover the field, the investment in machinery, people, and skills made it very expensive to react .to the demand. Warehousing alone was expensive in order to-have the specific purpose product on .15 demand.

Known floor mats, for example as shown in.U.S. -o s

S

S.

patents 3,703,059 and 4,796,399 to Kessler et al, include a framework formed of crossing ribs attached to one another at the crossing points. The ribs are usually made of plastic and 20 are either welded together or are integrally molded in one piece. The ribs cross at right angles, with -the lower tier of ribs resting on the floor.

Mats. of the type shown in Kessler USP '399 have included carpet strips held between pa.rs of adjacent upper ribs. The carpet strips are typically formed with a thermoplastic backing from which bundles of fibers extend.

The plastic backing of the strip is-adhered to the top sides of the lower ribs where it passes over them, or is attached by clips.

These mats have many advantages for use where people's shoes.maybe quite muddy or wet, and also provide anti-fatigue support. The areas between the carpet strips let water drain down into the space between the lower tier of ribs on the floor, keeping the carpeting relatively dry and avoiding puddling on the carpet itself. The mats are low in cost as compared to carpeting.

It would be a tremendous advantage if a mat could be provided which could be stocked in an intermediate condition and then finished when the requirements from the field were requested. But-this is not possible with the previously known 15 mats in which the carpet strips are substantially permanently fixed, i.e. are either not removable at all without destroying S the mat or are removable only with considerable difficulty.

This means that the carpet strips cannot be taken out easily for cleaning or replacement, and they cannot be placed in 20 arbitrary patterns of color or type to match particular applications,. and they cannot be replaced by other types of strips, e.g. abrasive strips, slit tire casing strips, hardwood flooring strips, decorative vinyl or other types of flooring strips, etc, depending on the purchaser's requirements or wishes.

SUMMARY OF THE INVENTION Accordingly, the present invention has an object, among others, to overcome deficiencies in the prior art such as noted above.

The present invention thus provides a backing framework for a floor mat having anti-fatigue properties and also having slots in which various types of strips can be fastened, making the strips .removable and replaceable.

In a first embodiment of the present invention, the edge of the carpet strip or other surfacing strip protrudes slightly and fits into side grooves which partly define the slit, which is preferably formed -between the upper surfaces of the lower ribs and an overhanging edge running alongside of the upper ribs on each side of the carpet. strip.

15 The overhanging edge or: protrusion is desirably interrupted or tooth-like, i.e. there are interruptions of the overhanging edge along the direction of the strip, although it S alternatively may be continuous. The overhanging edge, when viewed from above, has a generally crenelated or square-wave 20 shape.

S-

Preferably, the cross-sectional shape of the overhanging edge taken on a plane perpendicular to the extension of the strips, is rectangular, although it may alternatively be triangular. The preferred shape of a rectangle, optionally has its lower corner beveled on the side.

facing the strip. -Most preferably, it comprises an extension of the upper ribs of the mat running in the same direction as the strips and edges.

In a second embodiment, the carpet strip and the bottom of the slot are lined with many upstanding hook-like projections of the type which appear in hook-and-loop fastening.strips, such as the type sold under the name VELCRO, which projections adhere the bottoms of the strips to the slots. The hooks are preferably formed on the upper surface of a plastic strip and the strip is adhered (or plural strips are adhered) to the bottom.of each of the slots of the backing framework. The loop material, which can simply be cloth, forms (or is adhered to) the bottom of the carpet strip.

Thus, the carpet strips can be simply peeled out of the slots when they require replacement or cleaning. Since the hook 15 material is covered at all times during use, the hooks are not damaged and remain usable for a long t.ime.

-The invention contemplates all combinations of the features of the two embodiments discumised above, for example a combination of the overhanging edge or protrusion with the 20 hook-and-loop fastening.

The strips can be arranged in arbitrary patterns of color, texture, or material. Also, various types of inserts with loop material adhered to the bottom thereof can be used in various combinations.. For example, in place of the usual plastic/fiber bundle carpet strips, wooden strips can.be placed in all or some of the slots; this will greatly increase the attractiveness of the mat. Strips can be easily changed to suit various conditions.

The lower ribs can optionally be made thinner under the carpet strips. The backing or framework is much less stiff across the strip insertion direction and provides good anti-fatigue properties.

BRIEF DESCRIPTION OF THE DRAWING The objects, nature, and advantages of the present invention will be apparent from the following description of an embodiment taken in conjunction with drawings, wherein: Fig. 1 is an exploded perspective view of a first embodiment of the invention.

Fig. 2 is an exploded perspective view of a second embodiment of the invention.

Fig. 3 is a cross-sectional view taken on section III-III of Fig. 2.

Fig. 4 is a broken elevational view illustrating a bevel on the underside of the overhang or protrusion.

-Fig. 5 is a perspective view of a Tinnerman clip.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Fig. 1 shows a carpet strip 10 with a rigid or semirigid backing strip 12 made of plastic or rubber. The strip has two opposed edges 14 and a central area 16 with embedded carpet fibers 18.

The strip 10 slides into a slot 110 of a backing or framework 100 as indicated by the dashed lines. The edges 14 are held in side grooves defined by overhangs or protrusion portions 132 extending into the slot 110 from a pair of adjacent but separated upper ribs 130.

The framework 100 has two major structural parts, the parallel upper ribs 130 running in one direction and lower ribs .150 running in a transverse direction to the upper ribs 130, preferably at 90° from one another. The lower surfaces of the lower ribs 150 rest on the floor (not shown) and the upper surfaces of the upper ribs 130 are at the walk-on surface level. The framework 100 is preferably molded of semi-rigid plastic or rubber as one unit, but- the upper ribs go S.130 and the lower ribs 150 can also be welded or otherwise 15 fastened together from discrete elongated extruded) stock to make up the framework. The preferred stock pieces are of plastic, e.g. PVC, polyester, nylon, polyolefin, TPR, polyurethane, or any other plastic, with a rectangular crosssection, and may be.hollow round, partly curved or 2.20 square-section tubing).

In preferred embodiments, the space at the bottom of the slot 110 is reinforced with braces 137 which run between lower ribs 150, parallel to the upper ribs 130. These preferably have a.lesser cross-sectional area than the ribs 130.

The braces 137 are placed close to the protrusion portions 132 so that the edges 114 of the strip 10 are firmly held, in the vertical direction, between the braces 137 and the protrusion portions 132.

Molded-in blocks-139 may bridge between the braces 137. Extending from the floor level to the bottom of the slot 110, they provide additional support when someone walks on the carpet strip 10 after it is inserted :into the slot. 110.

Similar support may be provided by posts 135 extending to the floor level from the undersides of the upper ribs 130 where they span across a gap between two lower ribs 150.

The end opening 111 of the silot 110 is open to receive the carpet strip 10. At the other end of the mat (not shown in. Fig. 1) the lower portion of the end corresponding to opening 111 is blocked, up to the height of the top of the inserted backing strip 12, by a molded-in slot end stop wall.

15 The stop wall may optionally extend upward to the upper surface of the upper ribs 130. With the slot end stop wall, Sthe inserted end of the strip 10 cannot pass out of the slot 110 past the other side (not shown) of the mat framework 100.

This makes strip alignment during insertion easier and 20 prevents the strips from working out in at least one direction.

The embodiment of Fig. 1 has interruptions in the protrusion portions 132, so that viewed from above it appears to be crenelated on either side of the slot. These interruptions reduce friction when sliding strips into the slots 110.

The protrusion portions 132 may be of any crosssectional shape, as viewed along the length of the slot 110.

Preferably, they are rectangular as shown. Different portions may be of different shapes. One of the preferred embodiments.

is shown in Fig. 4. The protrusion portions may have any width in the horizontal direction perpendicular to the extension of the strip. Preferably they extend horizontally into the slot 110, not quite to the nearest edge of the adjacent brace 137. This leaves a small gap between the overhang or protrusion 132 and the brace 137, through which the floor may be seen when the strips 10 are absent. This gap provides clearance for downward-extending portions of a clip 30, as discussed below.

.Fig. 4 shows a portion of the mat 100 as seen 15. looking along the slot 110. The overhanging edge or protrusion 132 includes a bevel 133, and lacks the square lower corner which is shown -in Fig. 1 and is indicated in Fig.

4 by dashed lines.

Preferably, as shown in Fig. 1L the length of each 20 protrusion portion 312 is roughly equal to the spacing of the lower ribs 150, but the portions 132 nay be of any fixed length, of variable length, of random length, of lengths n .h.

S" according to a mathematical pattern, and so: on.

Preferably also the interruptions, where any protrusion portion 132 is lacking, coincide with the lower ribs 150. They may be of any length, but preferably are at least as long as the width of the lower ribs 150. Thus, the protrusions preferably are not staggered in the preferred and illustrated embodiment. The present invention contemplates any shapes, spacing, or other characteristic of the protrusion portions 132.

The crenelated protrusion portions 132 allow the carpet strip to be more easily inserted and removed. If the strip 10, and/or its edges 14, are not excessively stiff then the strip 10 can be inserted from above. If the portions of .the protrusion portion 132 are staggered, insertion may be easier. The present invention also contemplates strips with crenelated edges, whereby the strip 10 may be more easily inserted from above and then slid along the slot 110 to lock in place.

cc

C.

ccc cc cc c Cc Fig. 2 shows a second preferred embodiment of the present invention. The mat framework 100 is similar to that of Fig. 1 except that the protrusion portions 132 are preferably omitted. The upper surface of the mat, which ends up under the strip 10, is preferably bridged over between the braces 137 to form a wider surface 138 on which may be spread an adhesive A (indicated by stippling). The blocks 139, though not shown in Fig. 2, may optionally be retained. The structure may be like that of Fig. i except that a thin (e.g.

2 mm or 1/16 inch) layer bridges between the various stiffening members. The structure including the area 138 iq preferably one-piece, for example all molded at once of plastic.

The layer of adhesive A of any type for holding in place a strip of hook material 20 having hooks 23 on one side.

The underside of the strip of hook material 20 may also (or alternatively) be covered with the same adhesive A as on the surface 138 (or a different adhesive), for the purpose of permanently or semi-permanenly attaching the strip 20 over at least the central part of the surface 138, along at least a part and preferably the entire length thereof, within the slot 110. In Fig- 2 the strip 20, which is preferably flexible and formed integrally of plastic, is shown outside the slot 110 for clarity, but the present invention contemplates that the mat includes strips 20 in each slot 110. The strip 20 is preferably of a width slightly less then the width of the slot 110 so as to permit water drainage .through the mat. The strip 15 20 is, shown fastened in place in Fig. 3.

Alternatively, the upper surface of the braces 137 and blocks 139 may include hooks molded or formed directly into the preferably plastic material of the mat 100,. or hooks inserted :into the slot surface..in -the manner of toothbrush bristles. The- mat 100 may omit the lower ribs 150.

Fig. 2 also shows a carpet strip 10 which includes i: on a lower side, opposite the carpet fibers 16; a strip 13 of loop material, felt, or other stuff that the hooks 23 can grip.- The grip strip 13 is preferably fastened to the strip 10 by adhesive A. Preferably, an additional intermediate layer 11 of foam rubber or the like is fastened between- the grip scrip 13 and the carpeting 18. The intermediate layer may provide resilience, liquid absorption,, additional carpet strip height, and so on.

When laid onto the hook strip 20, the carpet strip will immediately hold firmly to the mat framework 100 because of its grip strip 13, The adhesive A or other fastening means preferably holds the one or more strips 20 to the mat 100 with strength greater than the strength of hookand-loop.fasteners, so the flexible carpet strip. 10 can be removed simplyby peeling up one end and. pulling it. Fig. 3 shows the carpet strip held in the slote i0 of the mat 100.

Fig. 3 is a cross-sectional view taken transverse to the upper ribs 130 and through the lengthof one of the lower ribs 150 (not shown in Fig. Fig. 3 alternatively represents a mat lacking the crossed-beam construction with lower ribs 150, i.e. Fig. 3 might represent a uniform crosssection of an alternate embodiment of the mat 100.

Fig. 2 shows two embodiments of a clip.30 in broken view or partial view, with one. embodiment on the left and one on the right. The optionally present clip 30 prevents 20 unintended pulling-up of the ends of the carpet strip using a hold-down crosspiece 31 which bridges over- the carpet strip 10. The best place for the clip 30 is near the end of the strip. In one embodiment both, ends..of the clip 30 include the puncturing arrow 33 shown on just the left end of the illustrated clip of Fig. 2. A mating stop or washer 35 is optionally provided to cooperate with the arrow 33. After the strip 10 is in place, the clip 30 is pressed downward until a a a.

a. a the arrows 33 penetrate the strip 10. Then the stops 35 can be forced over the arrows 33 from the underside of the mat 100. The arrows 33 may pass through che mat in the small gap between the overhang or protrusion 132 and the brace 137, or, some other space. Optionally, the arcows may also penetrate the mat.

Fig. 5 shows an slightly different embodiment of the stop 35, a "Tinnerman clip". 35', which combines the two stops into a single elongated piece with two holes. is also pressed over the arrows 33. The Tinnerman clip 35' bridges over the undersides of- the braces 137, locking the strip against the braces 137 and into the slot 110. The washers perform similarly.

Alternatively, the braces 137 may include holes for the arrows 33. Another other means of fastening the clips is within the scope of the invention.

The other embodiment of the clip 30 has two downward extensions 37 of the crosspiece 31 and two inward .extensions 39 (only one of each is shown in Fig. 2, .on: the -broken right 20 side of the clip 30; Fig. 3 shows a complete clip 30 with two downward extensions 37, one on either side. The nward extensions 39 are not visible in Fig. The inward extensions 39 optionally snap under the surface. 38 of the mat 100, or the braces 137, locking the strip 10 in place. The inward extensions 39 may also be crimped into place or formed by bending the downward extensions 37 inward after they are inserted past the undersurface of the mat 00, and over the undersides of the braces 137. The clip 30 may be of any material.

Fig. 3 shows the clip 30 its mounted position as described above. The clips 30 may be removed prior to removing the strip As long as the removable strip 10 is even moderately flexible, it will be possible to peel it out of a slot 110 for cleaning or any other reason once the clips 30 are removed.

The present invention therefore provides great flexibility in -0 uusing the mat for different functions in a variety of situations. Besides carpet, the strips 10 can include any other flexible material (or more rigid materials, especially if they are notched perpendicular to their length in the embodiment of Pig. they may includc. abrasive strips, and may alternate strips of different mate-rials. The mat may be provided in lengths of 4 to 8 ft. to adequately brush the shoe bottom dry. .Where appearance is more important, decorative strips can be used, e.g. strips wit-h slots, decorative vinyl strips, etc.; or any combination of the above strips can be used to achieve a particular objective.

The mats may also be assembled in sections.

Preferred dimensions of the mats are 32" by 12" or 24" by 24" or any size in between, which can be assembled into sizes such as 3 feet square, 4 feet square, 4 feet by 4 and 1/2 feet, or 6. feet by 3 feet.

Instead of the adhesive or adhesives A disclosed above, the various parts of the present invention may be 9 attached with fasteners rivets or staples), may be welded together ultrasonic welding), or-may be fastened by any other means.

An alternative construction contemplates reversing the hooks and loop or- felt, so that the mat or backing 3.00 Would include the loop layer and hot- che hook -layer.

Any sort of elongated- strip -retainer or means for removably holding the strips 10 in this mat IQO id within the scope.-of the.invention, and not -just i-rhe peere embodiments -of. elonga~ted -retainers including the protrusions. 132, the hook-and-loop-fastening system, and 6ornbinat'lpns of those.

-The present invent ion diff ers from previous mats in that the. strips- 10 can be. inserted 'int~o the 'slots 110 .and also removed from above the mat 100, b4y .pruouing ox' pulling- IzI 15. the embodiment- in-which -the ovethanging edge. or protrusion 132 includes a, bevel 133, the-strip,10 requires -less-force to be removed. than -Inserted: when -the bevel. -31 is 9;q the inside -lower corner, as- illustrated in::the -diawt4.. -Tho4s -Useful because, less: force can be appliecl In h lr. og.,w fingers') -than ini inserting (eg. b )ahin 9oz- a~n'stick).

(If the bevel is alternatively-on the jI~sideuprcnr (this Is, not -illustrated] then -the -stz p 3.0 will'be relativel-y more, dif ficult to remove and easier to, insert;.) Other type of strip embodiments can be inserted into slots an additional-link .strip molded for-example for scraping the bottoms of shoes, or a -slit, tire casing, and an abrasive carbide strip with grit adhered (or otherwise fastened) to the upper surface of the strip for sure footing in wet conditions. Other types of strips for various purposes are also possible, hardwood strips, decorative vinyl or linoleum strips for decorative purposes, etc.

The present invention therefore provides great flexibility in providing different mat usage functions for a variety of situations. All::carpet strips can be used for snow and water removal at an entry way location, or alternating strips of carpet pile 30 and links 20 can be provided in such an entry way, or an entry way leading from a. muddy area. Or, in a location where there is a slippery surface, abrasive strips can be used either alone or alternating with other strips, e.g. in icy areas or grocery stores, fish and meat markets where the butchers work, factories where the floor S: 15 becomes oily.

The mat of the present invention thus has alternate reception..areas where pile and carpet strips can- be slid into place where needed. The mat, may be provided in lengths of 4 to 8ft. to adequately brush the shoe bottom dry. Where 20 appearance is more important, decorative strips can be used, e.g. strips with slots, decorative vinyl stripa, etc; or any combination of the above strips can be usad to achieve a particular objective.

The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by-applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without undue experimentation and without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purposeof description and not of limitation. The means and materials for carrying out various disclosed functions may take a variety of alternative forms without departing from the invention..

-1 0 *000 .00 0 Thus :the expressions :"means to.. and "means as may be found in the specification.above and/or in the claims below, followed by a functional statement, are intended to define and cover whatever structural, physical, chemical or electrical element or structure may nowor in the future exist which carries out the recited function, whether or not precisely equivalent to the embodiment or embodiments disclosed in the specification above; and it is intended that such expressions be given their broadest ipterpretation.

00 0 0

Claims (8)

1. A floor mat formed of .rbber or.6 plastic comprising a backing (100) having a series of upper. ribs (130) on an upper surface of. the mat, the upper ribs defining slots (110) therebetween, the slots extending in .a slot direction characterized in that -the slots contain a plurality of strips (10o); and elongated strip retainers removably.holding each of the strips in a respective one of the slots, wherein a strip is retainable by pressing the strip into a slot and removable S by pullin therefrom.

2. The floor mat according o. claim- 1, wherein the elongated strip retainer includes hook material and loop material, and wherein the hook material is -fastened to one of S s. 15 -the slot and the strip,- and wherein the loop material is S fastened to another one of the slot and the strip.

3. The- floor mat according to claim 1, the elongated S strip retainer comprising an overhanging edge portion (132) of -20 one of the ribs protruding over an adacent slot.

4. The floor mat according to claim wherein the overhanging edge portion comprises a evel (1i33) on the.edge portion.

The floor mat according to claim 4, wherein the bevel is disposed along a lower inner corner of the edge portion.

6. The floor mataccording to claim 3, wherein the overhanging edge portion comprises crenelation, whereby the edge portion is interrupted. 0 *0 a

7. The floor mat according to any one of claims 1-6:, wherein the strip retainer extends continually along substantially a full length of a slot wherein the strip is retained.

8. The floor mat according to any one of claims 1-7, comprising retaining clips (30) for holding the strip into the slot. -a a a. Dated this Twenty-Fourth Day of January, 2000 R L MARKETING AND SALES INC. By their Patent Attorneys FISHER ADAMS KELLY a a a a