GB2477105A

GB2477105A - Mat comprising a sandwich panel with outer layers having non-uniform thickness

Info

Publication number: GB2477105A
Application number: GB1000966A
Authority: GB
Inventors: Richard Ian Chambers; Matthew Douglas Chambers
Original assignee: STAGEWORKS GEAR Co
Current assignee: STAGEWORKS GEAR Co
Priority date: 2010-01-21
Filing date: 2010-01-21
Publication date: 2011-07-27
Also published as: GB201000966D0

Abstract

The mat comprises a structural panel having an internal core layer 4 and face layers 2, 6 bonded thereto. The core layer 4 has a uniform thickness, but the face layers 2, 6 have an uneven thickness, preferably in the form of symmetrical, outwardly facing protuberances 8 with voids 10 (providing a suction type effect). The mat preferably comprises polyvinyl chloride (PVC) foam. The mat forms an anti-slip surface on which musical instruments (drums, cellos or double bases) or their effects units (pedals) can be placed.

Description

MAT

FIELD OF THE INVENTION

The present invention relates to mats. In particular, the present invention relates to non-slip mats for use with musical instruments, effects units (or pedals) for musical instruments, and the like.

BACKGROUND

Many musical instruments, and/or devices used with musical instruments (such as effects units) are placed on the floor during use. When the instrument or device is operated (for example by stamping on an effects unit) the force applied to the instrument or device by the musician tends to act in a way that would move, or slide, the instrument or device across the floor. This may cause damage to a floor or a musical instrument, or cause an effect unit to move to a position that is inconvenient for the musician.

Many instruments or devices attempt to alleviate this problem. For example, many effects units have a layer of rubber type material on their bottom surface. However, these rubber layers tend not to provide sufficient grip between a device and the floor. Many musicians opt to use adhesive tape to attach an effect pedal to the floor to ensure secure placement of the unit. This solution may damage the floor, tends to looks untidy and tends to be time * ** consuming. ** *

::.: Also, instruments such as drums, cellos, double basses are equipped with spikes that are forced into the floor. These spikes tend to damage the floor.

SUMMARY OF THE INVENTION

In a first aspect the present invention provides a mat for use with musical instruments and effects units for musical instruments, comprising: a first layer of material; a second layer of material; and a third layer of material; wherein the first layer is bonded to a first side of the second layer; the third layer is bonded to a second side of the second layer, the second side being opposite the first side; the first layer has non-uniform thickness; the second layer has substantially uniform thickness; and the third layer has non-uniform thickness.

The non-uniform thickness of the first layer may be such that, when the first layer is bonded to the second layer, the first layer in effect provides a plurality of protuberances from the surface of the second layer to which the first layer is bonded.

The non-uniform thickness of the third layer may be such that, when the third layer is bonded to the second layer, the third layer in effect provides a plurality of protuberances from the surface of the second layer to which the third layer is bonded.

Each of the plurality of protuberances provided by the first layer may be substantially opposite a protuberance provided by the third layer.

A layer of non-uniform thickness may be produced by perforating a layer of substantially uniform thickness.

One or more of the first layer, the second layer, or the third layer may be made of polyvinyl chloride (PVC) foam.

* The second layer may have a thickness of I to 3mm.

A protuberance may extend from a surface of the second layer by a distance of I to 3mm.

The mat may have a length of 40-50cm, a width of 15-25cm, and a thickness of 1-9mm.

In a further aspect, the present invention provides a method of fabricating a mat, the method comprising: providing a first layer of material, a second layer of material, and a third layer of material; bonding the first layer to a first side of the second layer; bonding the third layer to a second side of the second layer, the second side being opposite the first side; wherein the first layer has non-uniform thickness; the second layer has substantially uniform thickness; and the third layer has non-uniform thickness.

The method may further comprise producing quantity of polyvinyl chloride (PVC) foam from PVC raw material, wherein one or more of the first layer, the second layer, or the third layer is made of polyvinyl chloride (PVC) foam.

The method may further comprise cutting the bonded layers to produce a mat having a length of 40-50cm, and a width of 15-25cm.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a schematic illustration of an exploded perspective view of an embodiment of a mat; * ***** * Figure 2 is a schematic illustration of a cross section of the mat; * ,.e..

Figure 3 is a schematic illustration of a cross section of the mat during an d * example use of the mat; and Figure 4 is a process flow chart showing certain steps of a fabrication *..: process of an embodiment of the mat.

DETAILED DESCRIPTION

Figure 1 is a schematic illustration (not to scale) of an exploded perspective view of an embodiment of a mat 1. The mat 1 comprises an upper layer 2, a middle layer 4, and a lower layer 6.

In this embodiment, the first layer 2 is secured to a first surface of the second layer 4 using an adhesive. Also, the third layer 6 is secured to a second surface, opposite the first surface, of the second layer 4 using an adhesive.

The first layer 2 comprises a plurality of blocks 8. In this embodiment, the blocks 8 are made of polyvinyl chloride (PVC) foam. Each of the blocks 8 has the shape of substantially a squared-based dome. In this embodiment, the square base of each block 8 is 4mm by 4mm. Also, the height of each block, i.e. the distance from the bottom of the square base to the top of the dome of the block 8, is 2mm.

In this embodiment, the blocks 8 are arranged such that a block 8 not positioned along an edge or at a corner of the first layer 2 is joined at each of its four corners to a corner of a further block 8. Also, a block 8 along an edge or at a corner of the first layer 2 is joined at its corners that are not congruent with an edge of the first layer 2 to a corner of a further block 8.

The edges of the blocks 8 define air gaps, or voids 10, between adjacent blocks 8 in a common row or column. The blocks 8 and voids 10 of the first layer 2 may be considered to be in a "chess board" formation.

In this embodiment, the first layer 2 is produced by perforating a layer of **** 2mm thick PVC foam to form the voids 10. The PVC foam remaining after perforation is that of the blocks 8.

* ,t *.* !n this embodiment, the second layer 4 made of polyvinyl chloride (PVC) ole * foam. The second layer 4 is 2mm thick.

In this embodiment, the third layer 6 is substantially the same as the first layer 2. Also, in this embodiment the third layer 6 is produced in substantially the same way as the first layer 2. The third layer is positioned such that the first layer 2 and the third layer 6 are symmetrical about the second layer 2, as described in more detail below with reference to Figure 2.

Figure 2 is a schematic illustration (not to scale) of a cross section of the mat 1.

The first layer 2 and the third layer 6 are secured to opposite sides of the second layers such that each block 8 of the first layer 2 is opposite a block 8 of the third layer 6 and vice versa. In other words, the mat I is substantially symmetrical about a plane parallel to the second layer 4 and equidistant from the first and second sides of the second layer 4.

The securing of the perforated first and third layers 2, 6 to both sides of the second layer 4 provides that the mat I has two opposite "pimpled", or "bobbled", surfaces. Such surfaces advantageously tend to increase the friction between the mat I and an object placed upon the mat I and/or a surface upon which the mat I is placed. Also, the use of PVC foam for the first and third layers 2, 6 advantageously tends to provide a relatively high degree of friction, or grip, between the mat I and an object placed upon the mat I and/or a surface upon which the mat I is placed.

The perforated first and third layers 2, 6 tend to have decreased rigidity and durability relative to an unperforated, or solid, layer of the same material due to the presence of the voids 10 and the blocks 8 being connected only at their corners. The securing of the first and third layers 2, 6 to the unperforated second layer 4 tends to advantageously increase the durability of the mat 1.

Figure 3 is a schematic illustration (not to scale) of a cross section of the mat I during an example use of the mat 1.

S.... In this example, the mat I is placed such that the third layer is in contact with the ground 12, Also a load 14, for example a volume or effects pedal for use with a musical instrument, is placed on the mat I such that it is in contact * . .S..

with at least a part of the first layer 2. S.. *

The portion of the perforated surface of the first layer 2 that is in contact with the load 14 provides a relatively high level of friction between the load 14 and the first layer 2, thereby advantageously opposing movement of the load 14 across the surface of the first layer 2.

The perforated surface of the third layer 6, which is in contact with the ground 12, provides a relatively high level of friction between the ground 12 and the third layer 6, thereby advantageously opposing movement of the mat 1, and therefore the load 14, across the ground 12.

For ease of understanding, certain of the forces described in the below description of this example are represented by arrows in Figure 3.

In this example, the load 14 exerts a downward force (its weight) on the blocks 8 of the first layer 2 with which the load 14 is in contact with. These blocks 8 are compressed by the load 14 as air is forced out of them or as air within the cells of the foam is compressed. The weight of the load 14 is transferred through these blocks 8 to the second layer 4. The second layer 4 tends to distribute, or spread, the force transferred to it from the first layer 2 downwards towards to third layer 6 and away from the load 14. In this way the weight of the load 14 is transferred through the second layer 4 to the third layer 6. The blocks 8 of the third layer 6 to which the weight of the load 14 is transferred, via the second layer 4, are compressed as air is forced out of them or as air within the cells of the foam is compressed. In this way, the weight of the load 14 is spread over a wider area of the ground 12 than it would be without the presence of the mat 1. This advantageously tends to increase the level of friction produced by the load 14 on the ground 12, thereby increasing the grip between the load 14 and the ground 12 and opposing movement of the load 14 acrossthe surface of theground 12.

Moreover, in this example the voids 10 of the first layer 2 that are in contact with the load 14, and the voids 10 of the third layer 6 that are adjacent to compressed block 8, are also compressed. Air is forced out of voids 10 under * the application of the weight of the load 14 until the pressure of the air remaining in the voids 10 is substantially that of the atmosphere. Actions such as the removal of the load 14 from the mat I or the removal of the mat I from *:*. the ground 12, tends to act to reduce the air pressure in the compressed voids by increasing the volume of these voids 10. This expansion of the volume of these voids 10 tends to occur more rapidly than air is drawn back into these voids 10. Thus, a "suction-type" effect tends to be provided between the load 14 and the mat 1, and the mat I and the ground 12. This effect tends to advantageously increase the grip between the load 14 and the mat I, and the mat 1 and the ground 12, thereby opposing movement of the load 14 across the surface of the mat 1, and of the mat I across the surface of the ground 12.

Thus a three layer mat I is provided. The mat advantageously tends to oppose the sliding or slipping of a object placed on the mat I across the surface of the mat 1. Also, the mat I advantageously tends to oppose sliding or slipping of the mat I along a surface upon which the mat I is placed. Moreover, this opposition to the sliding or slipping of the mat I along a surface upon which the mat I is placed is increased by a surprising amount under the application of a force (e.g. the weight of an object or load) applied to the surface of the mat not in contact with the surface.

A further advantage of the mat I is that the PVC foam material is relatively soft. Thus, the risk of damage to a surface or object tends to be reduced. For example the risk of damage to a floor caused by the placement of an object on it may be reduced by placing the object on the mat on the floor.

This advantage tends to be particularly true in cases where the object is a musical instrument or for use with a musical instrument. For example, during use drums and instrument effect pedals tend to be subject to sudden and relatively large forces that act as to slide the object across the ground. Use of the above described mat tends to provide a cushion between the object and the floor, and also oppose the sliding of the object across the floor, thereby * .** reducing the risk of damage to the floor. S...

Figure 4 is a process flow chart showing certain steps of a fabrication process of an embodiment of the mat 1.

*5S*SS At step s2, a quantity of PVC foam is produced from PVC raw material.

At step s4, the first layer 2, the second layer 4, and the third layer 6 are formed from the PVC foam.

At step s6, the layers 2, 4, 6 are bonded together as described above. In this embodiment, the layers 2, 4, 6 are bonded using adhesive.

At step s8, a mat I of a required shape is cut out of the sheet of bonded layers.

Thus, a process for the fabrication of the mat I is provided. An advantage of the above process is that a mat having any shape may be produced. Moreover, more than one mat may be cut from a single sheet of bonded PVC layers.

In this embodiment, the mat I has a length of 45.5cm, a width of 20.5cm, and a thickness of approximately 6mm. These dimensions tend to provide that the mat is particularly convenient when used to support musical instruments or devices for use with musical instruments (e.g. effects pedals). For example, these dimensions provide a number of effects pedals can be supported on the same mat and that the mat is of a size whereby it can easily stored and transported, for example by rolling the mat up and carrying it in a musical instrument case. In other embodiments, a mat of any appropriate size may be produced. For example a mat may have a length of 40-50cm, a width of 15- 25cm, and a thickness of approximately 1-9mm. A mat with these dimensions tends to benefit from the same advantages of being particularly convenient when used to support musical instruments or devices for use with musical instruments as mentioned above. Furthermore, a mat with the aforementioned dimensions tends to be particularly advantageous when used to support devices for use with musical instruments, particularly keyboard pedals. The mat is of a size such that a keyboard pedal may be positioned towards one end of the mat whilst maintaining enough space on the rest of the mat for a keyboardist to place his entire foot. This is advantageous over the situation in * which the keyboard pedal is placed on the mat with the foot on the floor as it * :.: tends to alleviate the risk of the mat to slip along the floor caused by movement of the keyboardist's foot.

* ** Further process steps may be performed on the mat produced by performing the process described above with reference to Figure 4. For * example, a process of screen printing may be performed on the mat.

It should be noted that certain of the process steps depicted in the flowchart of Figure 4 and described above may be omitted or such process steps may be performed in differing order to that presented above and shown in Figure 4. Furthermore, although all the process steps have, for convenience and ease of understanding, been depicted as discrete temporally-sequential steps, nevertheless some of the process steps may in fact be performed simultaneously or at least overlapping to some extent temporally.

In the above embodiments, the first, second, and third layers are made of Pvc foam. However, in other embodiments one or more of the layers are made from a different appropriate material.

In the above embodiments, the first and third layers each comprise blocks which are substantially square-based domes in shape. The square base of each block is 4mm by 4mm. Also, the height of each block is 2mm. However, in other embodiments the first and/or third layer may comprise blocks having any appropriate shape or dimensions. The first andlor third layer may therefore be a mesh of any appropriate shape of block configured in any manner so as to provide the above described functionality. For example, the firth and or third layer may comprise blocks having the shape of a triangular based dome, the blocks being connected to other blocks at each of their three corners.

In this embodiment, the first layer and third layer are produced by perforating a layer of 2mm thick PVC foam to form the voids. However in other embodiments, the first layer and/or the third layer may be produced using a different appropriate technique to produce the voids. Also, in other embodiments the first layer and/or third layer may produced by perforating a layer of PVC foam of a different thickness (e.g. 1-3mm) to form the voids, thereby producing blocks having a different dimension to those described above with reference to Figure 1.

S.....

In the above embodiments, the second layer is 2mm thick. However, in other embodiments the second layer is any appropriate thickness, for example 1-3mm thick, 1-5mm thick etc. In the above embodiments, the layers are bonded, or secured, to each other using an adhesive. However, in other embodiments the layers are bonded to each other using a different appropriate technique.

In the above embodiments the blocks of the first layer and the third layer are positioned relative to each other such that each block of the first layer is opposite a block of the third layer and vice versa. However, in other embodiments, the blocks of the first layer and the third layer have a different arrangement relative to each other. For example, in other embodiments the blocks of the first layer and the third layer are positioned relative to each other such that each block of the first layer is opposite a void of the third layer and each block of the third layer is opposite a void of the first layer. * * *S*.

* S. *S* * S

S

* *55 S. * S

S S.. * S. * S * *.. . *5 S * S S * S. -11 -

Claims

CLAIMS1. A mat for use with musical instruments and effects units for musical instruments, comprising: a first layer (2) of material; a second layer (4) of material; and a third layer (6) of material; wherein the first layer (2) is bonded to a first side of the second layer (4); the third layer (6) is bonded to a second side of the second layer (4), the second side being opposite the first side; the first layer (2) has non-uniform thickness; the second layer (4) has substantially uniform thickness; and the third layer (6) has non-uniform thickness.
2. A mat according to claim 1, wherein the non-uniform thickness of the first layer (2) is such that, when the first layer (2) is bonded to the second layer (4), the first layer (2) in effect provides a plurality of protuberances (8) from the surface of the second layer (4) to which the first layer (2) is bonded. * *

* 20
3. A mat according to claim I or claim 2, wherein the non-uniform thickness S.....of the third layer (6) is such that, when the third layer (6) is bonded to the second layer (4), the third layer (6) in effect provides a plurality of protuberances (8) from the surface of the second layer (4) to which the third layer (6) is bonded.
4. A mat according to claim 3 when dependent on claim 2, wherein each of the plurality of protuberances (8) provided by the first layer (2) is substantially opposite a protuberance (8) provided by the third layer (6).

-12 -
5. A mat according to any of claims I to 4, wherein a layer of non-uniform thickness is produced by perforating a layer of substantially uniform thickness.
6. A mat according to any of claims I to 5, wherein one or more of the first layer (2), the second layer (4), or the third layer (6) is made of polyvinyl chloride (PVC) foam.
7. A mat according to any of claims I to 6, wherein the second layer (4) has a thickness of I to 3mm.
8. A mat according to any of claims 2 to 7, wherein a protuberance (8) extends from a surface of the second layer (4) by a distance of 1 to 3mm.
9. A mat according to any of claims I to 8, wherein the mat has a length of 40-50cm, a width of 15-25cm, and a thickness of 1-9mm.
10. A method of fabricating a mat, the method comprising: *S..* providing a first layer (2) of material, a second layer (4) of material, and a third layer (6) of material; S.....* bonding the first layer (2) to a first side of the second layer (4); S..bonding the third layer (6) to a second side of the second layer (4), the :.. second side being opposite the first side; wherein the first layer (2) has non-uniform thickness; the second layer (4) has substantially uniform thickness; and the third layer (6) has non-uniform thickness. -13-
11. A method according to claim 10, wherein the non-uniform thickness of the first layer (2) is such that, when the first layer (2) is bonded to the second layer (4), the first layer (2) in effect provides a plurality of protuberances (8) from the surface of the second layer (4) to which the first layer (2) is bonded.
12. A mat according to claim 10 or claim 11, wherein the non-uniform thickness of the third layer (6) is such that, when the third layer (6) is bonded to the second layer (4), the third layer (6) in effect provides a plurality of protuberances (8) from the surface of the second layer (4) to which the third layer (6) is bonded.
13. A method according to any of claims 10 to 12, further comprising producing quantity of polyvinyl chloride (PVC) foam from PVC raw material, wherein one or more of the first layer (2), the second layer (4), or the third layer (6) is made of polyvinyl chloride (PVC) foam.
14. A method according to any of claims 10 to claim 13, further comprising cutting the bonded layers to produce a mat having a length of 40-50cm, and a width of 15-25cm. S... * .***. 20 S.....*
15. A mat substantially as hereinbefore described with reference to the accompanying drawings. * S* * . *S S. * S * * S *S