C:\NRUorblDCC\AZM\4449520_1-DOC-5/07/2012 -1 MAT [001] The contents of U.S. Provisional Application No.: 61/290,398, filed December 28, 2009 and United Kingdom Patent Application No.: 0921326.5, filed 5 December 4 2009, are incorporated herein by reference in their entireties. [002] The present invention relates to a mat. [003] Conventionally, mats can be used for a number of different purposes such 10 as, for example, the mat can be provided as a floor covering for a portion of a floor surface or can be put to further use such as, for example, to allow more comfortable seating or kneeling to be achieved by a user who sits or kneels on the mat rather than directly on the floor surface. Mats can also be used in areas which may get wet from time to time such as, for example, on the floor surface adjacent a bath or sink. Furthermore in a tiled bathroom, 15 it is common to provide a bath mat that can both offer a slip-resistant, non-tiled surface on which to stand and some absorbent properties to handle inevitable water from sinks, baths or showers. [004] However, conventionally, mats tend to be relatively thin and therefore 20 provide little comfort to a person sitting or kneeling on the same on a hard floor surface. Furthermore, if the same become wet the shape and/or appearance of the same can be adversely affected. Furthermore, if the same become wet repeatedly then they can quite often absorb and retain moisture therein and never properly dry out such that the same can start to smell, and/or degrade and/or become generally unattractive for use. This tends to 25 mean that, for example, if a mat is provided for use in a bathroom, the mat can quickly become unhygienic and generally unattractive so that the same may need to be discarded relatively quickly after being first used. [005] According to the present invention, there is provided a mat comprising: 30 a cushioning layer comprising a memory foam material and extending substantially the length and breadth of the mat; C:\NRPonblDCC\AZM\4449520_ I DOC-5/712112 -2 a surface layer secured over the cushioning layer, the surface layer comprising a pile; and a slip-resistant base underlying the cushioning layer. 5 [006] Preferred embodiments of the present invention provide a mat having a structure which is such that it is comfortable in use, has various potential uses and has a longer life span. [007] Preferred embodiments of the present invention provide a comfortable, slip 10 resistant, and absorbent bath mat that is also quick-drying. [008] A person sitting, kneeling or standing on the mat may contact an external face of the mat formed by the surface layer. 15 [009] The surface layer can be of uniform colour or may carry a decorative pattern thereon. [0010] Typically, when a person applying pressure to the foam material, such as for example by sitting, kneeling or standing on the mat, gets up from the mat, the material returns 20 to at least partially to its original state. [0011] In one embodiment, the thickness of the cushioning layer is selected with respect to the particular use to which the mat is to be used. For example, a mat which is provided most typically to be stood on may not have as thick a layer of foam as a mat which is 25 provided to be sat or kneeled upon. [0012] In the preferred embodiments, the surface layer has good moisture absorbency characteristics, being formed by a series of loops of fibres which are held mutually together. Preferably, the surface layer includes a backing layer onto which the ends of the fibres of the 30 pile are bound and which is attached to the cushioning layer. The loops of fibres are found to provide very good moisture absorbency such that in the majority of cases the moisture which passes onto the mat in use may be wholly held within the surface layer.
-3 [0013] In one embodiment, the surface layer comprises polyester and polyamide. [0014] In one embodiment, the base is formed of rubber, which preferably comprises a spandex (Styrene Butadiene Rubber (SBR)) material. [0015] In one embodiment, a series of linear ribs or indents is provided at spaced intervals at least in the surface layer. The said ribs or indents can be used to improve absorbency of moisture and/or control the passage of moisture through said layer. 10 [0016] Preferably, the surface layer, cushioning layer and base are laminated together. [0017] A method of manufacturing a cushioned, absorbent mat according to a preferred embodiment of the invention comprises, in the following order, providing an 15 absorbent, quick-drying textile material in a sheet sized for use as a mat, gluing the absorbent, quick-drying woven textile material to a sheet of viscoelastic polyurethane foam material having an open cell structure, sewing the textile material to the foam material to obtain a sewed textile and foam assembly, and gluing a foam material side of the sewed textile and foam assembly to a sheet of non-slip rubber base material. 20 [0018] A preferred embodiment of the invention relates to a cushioned mat including a layer of absorbent, quick-drying woven textile material, a layer of viscoelastic polyurethane foam material having an open cell structure, the layer of foam material being glued and sewed to the layer of woven textile material to form a textile and foam assembly, 25 and a layer of rubber base material, glued to a foam material side of the textile and foam assembly. [0019] With the surface layer being formed of moisture-absorbent material, preferably in the loop structure, the moisture can be wholly or mostly absorbed by the 30 surface layer and may therefore not reach the foam. Furthermore, because the moisture may be held within this layer, it is found that the mat as a whole may dry out more quickly, -4 hence reducing the risk of smells and deterioration of the mat. [0020] The provision of the foam provides a comfortable feel to a person when standing, kneeling or sitting on the mat. $ [0021] The base affords the mat good slip resistance. [0022] Although the invention has advantageous application to bathroom mats, mats embodying the invention can be useable for a variety of applications; eg., a mat 10 embodying the invention might be used as a changing mat, play mat, pet mat, seat cushion mat, stadium seat cushion mat, picnic seat cushion mat, yoga mat, sports mat, bedroom mat, kitchen mat, computer arm rest mat, tug mat, crib mat, mattress topper, garden mat, car mat or car seat mat. 15 [0023] Features and characteristics of the present invention, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals 20 designated corresponding parts in the various figures. It is to be expressly understood, however that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. [0024] The present invention will now be described, by way of non-limiting 25 example only, with reference to the accompanying drawings, in which: [0025] Figure 1 illustrates a mat in accordance with one embodiment of the invention; 30 [0026] Figure 2 illustrates a cross section along the line AA of Figure 1; -5 [0027] Figure 3 schematically illustrates a cross-sectional view of a strand used in the manufacture of an absorbent textile layer of a bath mat in accordance with a preferred embodiment of the invention; and 5 [0028] Figure 4 schematically illustrates a cross-sectional view of a plurality of the strands of Figure 3 used to form the material of an absorbent textile layer of a bath mat in accordance with a preferred embodiment of the invention. [0029] Referring firstly to Figure 1, there is illustrated a mat in accordance with 10 one embodiment of the invention, which includes a base 2 which is formed of a slip resistant material such as, in this embodiment, that known by the trade name "spandex". This base material is in turn attached to a compressible material layer or core 4 formed of a memory foam, comprising viscoelastic polyurethane. The external face 6 of the mat, which is the surface on which a person is most likely to step, kneel or sit, is provided as a textile 15 material layer 8 which is formed of polyester and polyamide, typically in the range of 75%-85% polyester and 15% to 25% polyamide, more preferably 80% polyester and 20% polyamide. [00301 The arrangements between the different layers of the mat are shown in more 20 detail in Figure 2. [0031] Typically, the mat comprises a 80% polyester, 20% polyamide layer 8, memory foam (polyurethane foam) layer 4 and a spandex (Styrene Butadiene Rubber (SBR)) base 2. 25 [0032] The provision of the layer 8, to define the external face, means that, for example, when used adjacent a bath, when a user steps out of the bat and onto the mat, the mat absorbs moisture from the user immediately, drying the feet instantly as the textile material layer 8 is a fast absorbing structure. Normally, with regular mats, once the user 30 steps onto it and then walks off there is a trail of water droplets left, which can be uncomfortable, and even hazardous, and this is avoided in accordance with the present -6 embodiment. [0033] The provision of the compressible memory foam layer 4 with the combination of the textile layer 8 and non-slip base 2 combine to provide a luxurious 5 cushioned and absorbent feel to the mat when stood, kneeled or sat on, which sensation is not achieved by conventional mats which are formed of only a textile or fabric layer. Conventional mats typically either do not have an anti slip base, or have a sprayed on anti slip effect material which if provided does not provide any cushioning effect. 10 [0034] Figure 3 illustrates in schematic cross-section, a yarn 12 of the type used in the invention to form a woven textile material that forms the absorbent layer 8 of the bath mat. The yarn includes a number of strands of fibers 14, which are divided out from a source fiber and then woven together with a plurality of additional fibers, to form the yarn 12. The provision of the yarn allows the strands and hence the material to be 15 absorbent to water 15 and thereby, rather than deflect liquid from the same, liquid is absorbed quickly and hence removes liquid from the other surface such as the user onto which the material has been applied and provides a drying effect on the other surface. In the preferred embodiments, each fiber 14 has a diameter of the order of a few microns. 20 [0035] For example, an appropriate range may be 1-20pm and a more particular useful range may be 5-lOpm. By way of comparison, this range may be thought of as being approximately 100 times finer than human hair and typically 100's of fibers will be used to form each piece of yarn. It will therefore be appreciated that each strand is particularly small in cross-sectional area and, each strand is then used, in combination with 25 other strands, to form a woven material as illustrated in Figure 4. The fibers are microfibers, having a linear density of less than 1 denier/filament. [0036] The weaving process to form the material from the yarn includes weaving the yarn together with other stands of yarn to form a woven textile material 8 of the type 30 shown in Figure 4.
[0037) In an embodiment, the woven material comprises a combination of strands of polyester and polyamide, for example, nylon. In particular, an embodiment includes from 60-90% polyester by weight with the remaining polyamide. In order to form a bath mat 18 as illustrated in FIG 1, a plurality of yarns 2 are woven together to form a woven 5 textile material 8 that has very good absorbency and drying properties. In an embodiment, the fabric is woven into a material having weight between 200 and 300g/m 2 , and in a particular embodiment, a material having a weight between about 250 and 275 g/m2 [0038] In practice, such a material may have an absorbency greatly in excess of 10 conventional cotton terry or polyester woven material. Furthermore, it may have drying speeds faster than conventional cotton terry or even 100% polyester materials. In an embodiment, the woven textile material 6 has a pile height of approximately 0. 1-0.175 in particular approximately 0.157 in. 15 [0039) The woven textile material 8 is glued to a cushioning layer 4 using a glue that is, in an embodiment, selected to both provide a strong bond between the polyurethane and the woven material and be sufficiently flexible to allow for bending of the mat without significant cracking of the glue layer. The glue allows for moisture to pass from the urethane foam to the woven material without blocking the wicking/drying function of the 20 woven material. In a particular embodiment, the glue may be a sprayable upholstery glue suited for use with foam such as 680S, available from Tai Jia of Guangdong, China. [0040] The cushioning layer 4 is made from a memory foam material, comprising a viscoelastic polyurethane foam having an open cell structure. Such material is, in general, 25 absorbent but slow drying particularly as compared to the micro woven material described above. [0041] As an example, the cushioning layer may be about 2.5cm in thickness, and may generally be within range of 1cm to 5cm. For thinner cushioning layer, an insufficient 30 cushioning function may result, while for thicker layers, the overall mat thickness becomes too great and the user may feel as though he or she is sinking too deep into the mat. In a typical mat, the foam density may be approximately 2.8lbs/ft. [0042] The inventor has determined that in the above described combination the absorbency and drying properties of the woven textile material layer 8 of the same allows 5 for the use of the relatively absorbent and slow-drying polyurethane foam, even in a generally wet/humid environment such as a bathroom, In this combination the absorbent woven textile material 8 wicks moisture away from the polyurethane layer 4. [0043] Once the woven material layer 8 is glued to the cushioning layer 4 the two 10 are sewn together for additional strength, and optionally to produce a decorative design on the upper surface 6 of the woven textile material layer 8 not shown. [0044] The sewed and glued combination comprising the layers 4, 8 is then glued to the non-slip rubber base material 2. For example, the non-slip layer may be made from a 15 polyurethane material including, for example, polyurethane-polyurea based spandex. The assembly can then be attached to a border which may be made, for example, from a woven polyester material. [0045] In an embodiment, the mat may be between about 4 and 8 square feet in 20 area. [0046] Although the invention has been described in detail for the purpose of illustration based on what is currently considered to be the most practical and preferred embodiments, it is to be understood that such detail is solely for that purpose and that the 25 invention in not limited to the disclosed embodiments, but, on the contrary, is intended to cover modifications and alternative arrangements that are within the spirit and scope of the appended claims. For example, it is to be understood that the present invention contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment. 30 [0047] Throughout this specification and the claims which follow, unless the -9 context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. 5 [0048] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general 10 knowledge in the field of endeavour to which this specification relates.