US20190374069A1

US20190374069A1 - Rapid drying absorption mat

Info

Publication number: US20190374069A1
Application number: US16/433,876
Authority: US
Inventors: Jason Charles Klug
Original assignee: Dorai Home Inc
Current assignee: Dorai Home Inc
Priority date: 2018-06-08
Filing date: 2019-06-06
Publication date: 2019-12-12
Also published as: USD930391S1; WO2019236946A1

Abstract

An absorption mat includes an absorbent substrate including diatomaceous earth and a textile layer for placement upon the absorbent substrate. The absorbent substrate includes diatomaceous earth which draws moisture from the textile layer when placed adjacent to the textile layer. Absorption mats created with a fabric layer from which water is drawn into a diatomaceous earth layer are both sustainable and designed to instantly remove water from the surface thereof. Unlike traditional synthetic mats that absorb moisture and generate bacteria, according to the rapid drying absorption mats disclosed herein do not produce mold. Similar to a natural stone, the diatomaceous earth layer is made from ceramic-like material that holds firm under feet. Such mats can include a rubberized bottom pad to prevent slipping and allow for 360-degree drying.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority to and the benefit of U.S. Provisional Patent Application 62/682,775 filed Jun. 8, 2018. This patent application also claims priority to and the benefit of U.S. Provisional Patent Application 62/781,698 filed Dec. 19, 2018. The contents of both of the aforementioned provisional patent applications are hereby incorporated herein by reference for all purposes.

BACKGROUND

Use of an absorption mat such as a bathroom mat in bath and shower facilities at a private place or a public place is well known in the art. However, traditional bathroom mats are generally prone to becoming saturated and remaining wet for long durations of time especially under increased traffic and multiple daily use. Moreover, the extended use of such bathroom mats may cause a growth of fungus and bacteria thereon, which may produce an unpleasant odor or appearance. Additionally, the use of such conventional bathroom mats may cause spreading of germs during an extended use thereof. And, when used in a facility where multiple baths or showers are taken per day the concerns regarding the likelihood that a bathroom mat remains saturated causing such sanitary problems and lack of dry comfort during use is of increased concern.
One traditional Japanese solution is a hard diatomaceous earth mat as disclosed in Japanese utility model JP3214141 U and Japanese publication JP2002000483 A, the contents of which are hereby incorporated by reference herein. Such mats are capable of maintaining strength as a bath mat even when the content of diatomaceous earth is high, capable of suppressing the occurrence of cracks, excellent in quick drying and excellent in antifungal property by water absorption ability and excellent mold resistance. However, traditional use of such Japanese diatomaceous earth bath mats promote the cold hard surface and explicitly avoid any use of a cloth layer, textile layer or any other absorption materials therewith. This results in several design shortcomings as discussed in the aforementioned Japanese patent and utility model documents.
Another concern while using bath mats is a risk of slipping and falling. Specifically, floors around, or within, bathtubs and shower stalls may be slippery due to extended use and saturation. A bath mat positioned adjacent to the bath tub or shower stall may slip when a user steps out of the shower or bath and onto the bath mat, thereby causing an injury to the bather. This shortcoming may be particularly dangerous for young and elderly bathers who may be less coordinated and susceptible to slipping. Another shortcoming associated with the aforementioned Japanese solutions is an inability to securely bind a non-slip layer to such diatomaceous earth substrates. Therefore, such stone-like Japanese diatomaceous earth bath mats may be particularly prone to sliding upon a tile bathroom floor, for example.
Accordingly, there exists a need for an improved absorption mat in bathing facilities, such as adjacent to bathtubs and shower stalls, which avoids hygiene related problems that may occur due to an extended use of the often saturated bath mat. There also exists a need for a new design of an absorption mat that dries rapidly while providing improved comfort and slip resistance. Such environments and concerns are illustrative of a large number of applications and concerns discussed herein.
The subject matter claimed herein is not limited to embodiments that solve any disadvantages or that operate only in environments such as those described above. Rather, this background is only provided to illustrate one exemplary technology area where some embodiments described herein may be practiced.

SUMMARY

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential characteristics of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
Embodiments of the invention relate to a rapid drying absorption mat that also provides improved comfort, slip resistance, and advantageous manufacturing processes, designs, and assemblies of components, materials, and manufactures. An absorption mat, comprising includes an absorbent substrate including diatomaceous earth. The absorption mat further includes a textile layer for placement upon the absorbent substrate, wherein the absorbent substrate including diatomaceous earth draws moisture from the textile layer when placed adjacent to the textile layer. The textile layer can include a cotton woven material.
The absorption mat can further include mechanical features affixed to the textile layer for holding the textile layer immediately adjacent to the absorbent substrate. The mechanical features can include straps, corner pockets, and/or end pockets. The mechanical features can include one or more corner and side pockets formed by the textile layer being wrapped around the absorbent substrate. The mechanical features can include an elastic material affixed to a periphery of the textile layer.
A top portion of the absorbent substrate may be left uncovered by the textile layer when the textile layer is held against a top surface of the absorbent substrate. The absorbent substrate can include cuts or grooves disposed into a top surface of the absorbent substrate so as to increase surface area for evaporation of liquid absorbed by the absorbent substrate. Cuts and grooves can also provide increased non-slip features for a bather stepping upon the top of the substrate.
The absorption mat can further include a non-slip layer for placement underneath the absorbent substrate. The non-slip layer can be shaped to correspond to mechanical features for affixing the textile layer to the absorbent layer and allow for air to circulate underneath the absorption substrate for evaporation 360 degree evaporation therefrom. The non-slip layer can includes a silicone material cured to the textile layer. The non-slip layer can include a silicone material cured to elastic material sewn to outer periphery of the textile layer in some embodiments. The elastic material can be wrapped around a periphery of the absorbent layer and hold the textile layer around the periphery of the absorbent layer. The elastic material can include an elastic band that spans a bottom corner of the absorbent layer when the textile layer is held to the absorbent layer. The elastic band and textile layer can leave at least a corner of the absorbent layer uncovered.
A method of manufacturing an absorption mat can include manufacturing or providing a relatively soft cushioning textile layer, manufacturing or providing a relatively hard rapidly wicking and absorbent layer including diatomaceous earth adjacent to an underside of the textile layer; and manufacturing or providing a non-slip layer for placement to an underside of the absorbent layer during use. The method can further comprise manufacturing mechanical features affixed to the textile layer for holding the textile layer immediately adjacent to the absorbent substrate. The method can further include forming or cutting groove into an otherwise planar top surface of the absorbent layer for increasing surface area for promoting evaporation of absorbed water. The method can further include sewing, attaching, or melding an elastic material to the textile layer.
Methods assembling an absorption mat are disclosed, the absorption mat including an absorbent substrate including diatomaceous earth and a textile layer for placement upon the absorbent substrate. The absorbent substrate includes diatomaceous earth which draws moisture from the textile layer when placed adjacent to the textile layer. The method including wrapping the textile layer around a periphery of the absorbent substrate such that the textile layer covers a majority of an outer periphery of the absorbent substrate.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the invention. The features and advantages of the invention may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention relate to a rapid drying absorption mat that also provides improved comfort, slip resistance, and advantageous manufacturing processes, designs, and assemblies of components, materials, and manufactures.

FIG. 1A illustrates the top surface of an absorbent substrate, an assembled absorption mat from a top view and from a bottom view;

FIG. 1B illustrates the components of an absorption mat along with a bottom view of the assembled absorption mat at the top of FIG. 1B and a top view of the absorption mat shown at the left of FIG. 1B;

FIG. 1C illustrates the absorption mat during use when stepped upon by a bather;

FIG. 2A shows another embodiment of the absorption mat in an top assembled view on the left and in an un assembled view on the right of FIG. 2A;

FIG. 2B shows the embodiment of the absorption mat from FIG. 2A from a bottom assembled view on the left and an unassembled bottom view on the right side of FIG. 2B;

FIG. 2C shows a textile layer of the absorption mat with a non-slip layer adhered to a periphery thereof;

FIG. 2D illustrates use of the absorption mat by an infant;

FIG. 3 illustrates another embodiment of an absorption mat including the disassembled components as well as an assembled view thereof from top and bottom perspectives, in this embodiment the textile layer includes corner pockets and a non-slip layer is disposed underneath the absorbent layer;

FIG. 4 illustrates another embodiment of an absorption mat where the textile and non-stick layers form a sleeve into which the absorption layer is inserted and removed;

FIG. 5 is another embodiment of an absorption mat where the textile layer includes mechanical features in the form of end pockets for receiving and holding the absorbent layer to the textile layer; and

FIG. 6 illustrates a demonstration of the wicking and drying effect of the absorbent layer when placed adjacent to the textile layer.

DETAILED DESCRIPTION

Embodiments of the invention relate to rapid drying absorption mats that also provide improved comfort, slip resistance, and advantageous manufacturing processes. Such innovations include the disclosed designs, assemblies of components, materials, and manufacturing techniques. Unlike the users of the aforementioned Japanese bath mats for example, it has been discovered by the inventors of this patent application that many people taking baths and showers often prefer to step onto a comfortable surface as opposed to a cold tile floor, or other rigid surface. The comfortable surface is also particularly favorable for use in connection with children, elderly, and infants who are more sensitive to the cold hard surface of a stone mat or tile floor and are more likely to slip thereon.
As disclosed herein composite absorption mats including a fabric layer from which water is drawn into a diatomaceous earth absorption layer are both sustainable and designed to instantly remove water from the surface thereof. Unlike traditional synthetic mats that absorb moisture and generate bacteria, according to the rapid drying absorption mats disclosed herein do not produce mold. Similar to a natural stone, the diatomaceous earth layer is made from ceramic-like material that holds firm under feet. Such mats can include a rubberized bottom pad to prevent slipping and allow for 360-degree drying. If the diatomaceous layer gets stained it can be cleaned in two ways. For light stains or scuffs use the included sanding tool to gently rub off any marks. For more extreme stains, small amounts of bleach or hydrogen peroxide can be used. The comfort cover can be machine washed in cold water and tumble dried at medium or low heat. When moisture encounters the surface of the diatomaceous earth material, the material attracts and binds bacteria and parasites, causing them to dry out and die. Water rapidly evaporates from the product through millions of pores therein.
Therefore, several of the embodiments disclosed hereinafter combine a fabric or textile layer with a diatomaceous earth absorptive layer along with improved anti-slip, evaporation, and saturation isolation using the disclosed bath mat designs. This composite absorption mat can further allow the addition of a slip resistance layer enabled only by the teachings discussed hereinafter due to the comparative designs of the multiple layers thereof. Thus, the lack of abrasiveness, coldness, and relative softness to the touch can be realized while utilizing the firmness, wicking, and absorbent nature of the diatomaceous earth component. Moreover, thermal isolation from the often cold stone floor of a bathroom is also promoted by a relatively soft yet unsaturated bathroom mat as disclosed herein.
Embodiments disclosed herein are directed to a composite absorption mat and/or intermediate manufactures and methods related thereto. The composite absorption mat can be in the form of multiple assembled layers in the form of a planar substrate. The composite parts, elements, or layers of an absorption mat may be manufactured from distinct materials and assembled together. Assembly of one or more layers or components of the absorption mat can include mechanical features for assembling and fastening the components or layers together. The shape of the layers may interrelate in that an outer periphery of a layer may correspond or fit with a non-uniform thickness feature. In some embodiments, a non-planar layer corresponds or fits with the outer periphery or shape of another layer such that when assembled the composite assembly can be an aesthetically pleasing and functionally stable mat. Then, when assembled, the non-uniform assembly of one or more layers or components of an absorption mat can create a substantially planar mat. The absorption mat can also include adhesion or other chemical processes of manufacture or assembly for affixing the layers or components of the composite absorption mat together. For example, the non-slip layer may be bound or adhered to the textile layer and disposed on an underside of the absorption mat when assembled and used.
In some embodiments, the diatomaceous earth component can have surface features such as grooves or irregular surfaces which may be manufactured or cut into the diatomaceous earth layer so as to increase the evaporative surface area of the mat. Such surface features may also decrease the likelihood of slipping on the top layer of the absorption mat by introducing non-planar surfaces thereto.
As discussed herein, the layers or components of the absorption mat can include mechanical features for assembling and securing the layers thereof together. Mechanically attaching, assembling, or manufactured features can include straps, folds, pockets, clasps, straps, and other features for mechanically affixing components of the absorption mat together. Other layers may be affixed together via adhesives, epoxies or covalently bonded materials where possible. Other layers and components, such as elastic straps and pockets, may be affixed together using stitching, bonding, melding, etc. Use of the fabric and straps about an underside can provide a bottom layer to which a silicone or similar non-slip material can be introduced in order to prevent the mat from slipping on the floor surface disposed thereunder during use.
According to some embodiments, the absorption mat can include two or more layers or components with different relative comfort, evaporative, and/or non-slip attributes. Different layers or components of an absorption mat may include different materials. For example, a first layer or component may include a polymer component. A second layer or component may include a cotton or woven material component. And, a third layer or component can include a diatomaceous earth wicking and evaporative material. The diatomaceous earth layer, or wicking silica based component, can be pressed and/or include a binder so as to hold the diatomaceous earth in a layer as opposed to a traditional powder as generally found.
Diatomaceous earth—also known as D. E., diatomite, or kieselgur/kieselguhr—is a naturally occurring, soft, siliceous sedimentary rock that is traditionally easily crumbled into a fine white to off-white powder. It has a particle size ranging from less than 3 μm to more than 1 mm, but typically 10 to 200 μm. Depending on the granularity, this powder can have an abrasive feel, similar to pumice powder, and has a low density as a result of its high porosity. The typical chemical composition of oven-dried diatomaceous earth is 80-90% silica, with 2-4% alumina (attributed mostly to clay minerals) and 0.5-2% iron oxide.
Diatomaceous earth consists of fossilized remains of diatoms, a type of hard-shelled protist (chrysophytes). As disclosed herein the layer or component of diatomaceous earth of the mat is used as an absorbent and rapid evaporator for liquids. The thermal properties of diatomaceous earth also enable it to be used as the barrier material according to several embodiments disclosed herein. In some embodiments, the diatomaceous earth layer can include other components such as wood fiber, paper pasting agents, and other known fillers and binders so as to extrude, form, and cure a solid diatomaceous earth layer having the absorption properties disclosed herein.
For example, several embodiments disclosed herein include a diatomaceous earth layer or component adjacent to a woven textile component. While a mat is discussed herein other embodiments include other traditional textile products. The placement of the diatomaceous earth layer or component immediately adjacent to the woven textile layer or component allows for the diatomaceous earth to rapidly wick and absorb the moisture from the textile layer thereby rapidly removing saturation of water from the textile component. Once absorbed by the diatomaceous earth layer, the repeated saturation of the textile layer is more rapidly evaporated and dried as compared to traditional bath mats.
However, the use of the layer of textile cotton or other material on an upper-most layer of the mat also allows for comfort and the traditional look and feel of the mat according to some embodiments. Moreover, the diatomaceous earth layer may be harder and less comfortable to walk upon as compared to the textile layer. And, the textile layer may allow for a more traditional appearance or fanciful decoration of the fibers, such as cotton, of the textile layer. Nevertheless, according to some embodiments, the overall appearance of the top visible surface may include appearance of both portions of the textile layer and the portions of the diatomaceous earth layer where a composite functional design or decorative pattern or appearance may be manufactured in the upper layer of the diatomaceous earth layer which fits or corresponds in thickness with that of the textile layer as illustrated below.
Referring to FIG. 1A a rapid drying composite absorption mat 100 is shown according to an embodiment of the invention. The absorption mat 100 in this embodiment includes a textile layer 105 including a cloth fabric material similar to that of a towel or traditional bathroom floor mat. The material of the textile layer 105 may be woven and may include a blend of materials, such as polyester materials, in addition to cotton, or the material of the textile layer 105 may be 100% cotton. The material of the textile layer 105 is relatively soft and warm to the touch as opposed to the tile of the floor or other absorbent earth layer 110 of the absorption mat.
The rapid drying composite absorption mat 100 further includes an absorption layer 110 including a diatomaceous earth material. The diatomaceous earth material may include diatomaceous earth compressed or cured in a manner to produce the absorption layer 110 having a defined shape and configuration. The shape, design and configuration of the diatomaceous earth absorption layer 110 may be shaped or configured so as to correspond to, or partially correspond to, a shape, design or configuration of the textile layer 105. For example, as illustrated in FIGS. 1A and 1B, the shape of the textile layer 105 may include cutouts 125 that correspond to a design, shape or configuration of the absorbent layer 110. The design and shape of a top surface of the absorbent layer 110 can include cutouts, grooves, or other non-uniform surface features 112 which add slip resistance and top surface area for subsequent evaporation of the absorbed water.
Referring to FIGS. 1A and 1B, the textile layer 105 can include one or more straps 130 and/or corner pockets 132 so as to mechanically secure the textile layer 105 to the absorption layer 110. As shown, the edge of the textile layer 105 may be bound 120 to an end of the straps 130 and corner securement pockets 132 such as by stitching or bonding. The lowest portion of FIG. 1A illustrates how the absorbent layer 110 may be assembled with the textile layer 105 by placing the absorbent layers into the straps 130 and corner pockets 132 so as to secure and hold the fabric textile layer 105 against the absorbent layer 110. Thus, the middle figure of FIG. 1A illustrates a top view of the assembled absorption mat and FIG. 1A at the bottom illustrates a bottom of the assembled absorption mat 100.
Referring to FIGS. 1A and 1B, the rapid drying absorption mat 100 can further include a non-slip layer 115. For example, as illustrated in FIG. 1A a non-slip polymer layer 115 may be used to prevent the absorption mat 100 from moving relative to a floor placed thereupon. The gripping non-slip material 115 may be similar to carpet underlay materials such as made from PVC or other non-slip materials. The non-slip layer 115 may be cut to shape and held to the absorbent layer 110 by the straps 130 and/or pockets 132 or otherwise placed thereunder. The non-slip layer 115 may also be cut or designed to correspond to the mechanical features, shape and configuration of the absorbent layer 110 and any mechanical features securing the textile layer 105 thereto. For example, as shown at the bottom view of FIG. 1A, the non-slip layer 115 may be cut to the shape of the outer periphery of the absorbent layer and also be cut to shape around securement straps 130 and pockets 132. In this embodiment, the securement straps 130 and pockets 132 may be made of a Spandex or other stretchable and flexible material so as to secure the absorbent layer 110 to the textile layer 105. FIG. 1C illustrates the assembly of the various components of the absorption mat 100 previously discussed and FIG. 1A shows use of the absorption mat in a bathroom entryway to a shower.
Referring to FIGS. 2A, 2B, 2C and 2D another embodiment of a rapid drying composite absorption mat 200 is shown according to another embodiment of the invention. FIGS. 2A and 2B illustrate the assembly of the components of the absorption mat 200 according to a top view shown in FIG. 2A on the left, and a bottom view shown in FIG. 2B on the left respectively.
The absorption mat 200 includes a textile layer 205 including a cloth fabric material similar to that of a towel or traditional bathroom floor mat. The material of the textile layer 205 may be woven and may include a blend of materials, such as polyester materials, in addition to the cotton material. However 100% cotton may be used as the textile layer 205 according to the embodiments disclosed herein. The material of the textile layer 205 is relatively soft and warm to the touch as opposed to the tile of the floor or other layers of the absorption mat 200.
The rapid drying composite absorption mat 200 further includes an absorption layer 210 including a diatomaceous earth material for wicking and rapid drying of water from the textile layer 205. The diatomaceous earth material may include diatomaceous earth compressed, formed or bonded in a manner to produce the absorption layer 210 having a defined shape and configuration. The shape, design and configuration of the diatomaceous earth absorption layer 210 may be shaped and/or configured so as to correspond to a shape, design or configuration of the textile layer 205. For example, as illustrated in FIG. 2A, the outer periphery shape of the textile layer 205 corresponds to an outer periphery of absorbent wicking layer 210 except for a corner thereof held by an elastic band or material 215 thereby revealing an upper left corner of the diatomaceous ear wicking layer 210 according to this embodiment. According to some embodiments, approximately 5%-30% of the wicking layer 210 may be exposed, in this embodiment approximately 10%-15% of the wicking layer 210 is exposed by the textile layer 205.
Referring to FIG. 2B, the textile layer 205 can include one or more corner pockets 230 so as to mechanically secure the textile layer 205 to the absorption layer 210. As shown, the edges of the textile layer 205 may be sewn to an elastic member 225 so as to retain the textile layer 205 over the wicking absorbent layer 210 when assembled thereto.
FIGS. 2A and 2B illustrate how the absorbent layer 210 may be manufactured and assembled with the textile layer 205 by placing three corners of the absorbent layer 210 into the corner pockets 230 of the textile layer 205 in this embodiment so as to secure and hold the fabric textile layer 205 against the absorbent layer 210. After the three corners of the wicking layer 210 are fitted into the three corresponding corners of the textile layer 205 the elastic band 215 is stretched over the fourth corner thereby holding the textile layer 205 firmly to the absorbent layer 210. The elastic band 215 and elastic edge material 225 sewn to a peripheral edge of the textile layer 205 retain and pull the textile layer 205 over and against the wicking layer 210.
The rapid drying absorption mat 200 can further include a non-slip material 225 bound to, melded with, or cured to a bottom periphery of the absorption layer 205. For example, as illustrated in FIG. 2C a non-slip polymer layer 225 may be used to prevent the absorption mat 200 from moving relative to a floor placed thereupon. The gripping non-slip material 225 may a silicone or other non-slip relatively sticky or tacky polymer. The non-slip layer 225 can be bound to, sewn to, or cured to the elastic material 220 and band 215 of the textile layer 205 during manufacture thereof. The non-slip layer 225 may be a strip of silicon adhered to the elastic band 220 and elastic material 215 and cured thereto. The elastic band 220 and elastic material 215 may be formed from a single elastic material 215 or be separate elastic portions. An additional non-slip layer may also be cut or designed to correspond to the mechanical pocket securement features as previously discussed with regard to FIG. 1A and later discussed in reference to FIG. 3B (e.g. non-slip material 315), for example. As best shown in FIG. 2C, the non-slip layer 225 may be a non-stick layer that is bound to the elastic material 220 and elastic band 215 which run around a bottom periphery of the mat 200 when the textile layer 205 if secured to the wicking layer 210 thereby directly engaging a floor placed thereon.
Referring to FIG. 3 another embodiment of a rapid drying composite absorption mat 300 is illustrated according to an embodiment of the invention. FIG. 3 illustrates the assembly of the components of the absorption mat 300 from a top assembled view shown on the left and a disassembled view on the right. The absorption mat 300 includes a textile layer 305 including a cloth fabric material similar to that of a towel or traditional bathroom floor mat. The material of the textile layer 305 may be woven and may include a blend of materials, such as polyester materials, in addition to the cotton material. However 100% cotton may be used as the textile layer 305 according to the embodiments disclosed herein. The material of the textile layer 305 is relatively soft and warm to the touch as opposed to the tile of a floor (not shown) or other layers of the absorption mat 300.
The rapid drying composite absorption mat 300 further includes an absorption layer 310 including a diatomaceous earth material or other silica based wicking and rapid drying material. However, according to several embodiments a diatomaceous earth material or diatomaceous earth blend of materials may be preferred as forming the absorption layer 301. The diatomaceous earth material may include diatomaceous earth compressed, formed or bonded in a manner to produce the absorption layer 310 having a defined shape and configuration. The shape, design and configuration of the diatomaceous earth absorption layer 310 may be shaped and/or configured so as to correspond to a shape, design or configuration of the textile layer 305. For example, as illustrated in FIG. 3, the outer periphery shape of the textile layer 305 corresponds to an outer periphery of absorbent wicking layer 310.
Referring still to FIG. 3, the textile layer 305 can include one or more corner pockets 330 so as to mechanically secure the textile layer 305 to the absorption layer 310. As shown, the edges of the textile layer 305 may be bound 320 to ends of the corner securement pockets 330 so as to create the securement pockets 330.
FIG. 3 illustrates how the absorbent layer 310 may be manufactured and assembled with the textile layer 305 by placing the corners of the absorbent layer 310 into the corner pockets 330 so as to secure and hold the fabric textile layer 305 against the absorbent layer 310. Thus, FIG. 3 illustrates a top view on the left of the absorption mat 300 and FIG. 3 illustrates on the top right a bottom of the absorption mat 300.
The rapid drying absorption mat can further include a non-slip layer 315. For example, as illustrated in FIG. 3 a non-slip polymer layer 315 may be used to prevent the absorption mat 300 from moving relative to a floor placed thereupon. The gripping non-slip material 315 may be similar to commonly available carpet underlay materials such as made from PVC or other non-slip materials. The non-slip layer 315 may be cut to shape and bound to the absorbent layer 310 using adhesives, epoxies, glue, or other curing and chemically securement means. The non-slip layer 315 may also be cut or designed to correspond to the mechanical pocket securement features 330 as shown in FIG. 3. For example, as shown at the top-right in FIG. 3, the non-slip layer 315 may be cut to the shape of the outer periphery of the absorbent layer 310 and also be cut around securement pockets 330. In this embodiment, the securement pockets 330 may be made of a Spandex or other stretchable and flexible material so as to secure the absorbent layer 310 to the textile layer 305.
Referring to FIG. 4 another embodiment of a rapid drying composite absorption mat 400 is illustrated according to an embodiment of the invention. FIG. 4 illustrates the assembly of the components of the absorption mat 400 from a bottom isometric view on the right, and FIG. 4 shows an assembled top view of the absorption mat 400 on the left.
The absorption mat 400 in this embodiment includes a textile layer 405 including a cloth fabric material similar to that of a towel or traditional bathroom floor mat. The material of the textile layer 405 may be woven and may include a blend of materials, such as polyester materials, in addition to the cotton material. However 100% cotton may be used as the textile layer 405 according to the embodiments disclosed herein. The material of the textile layer 405 is relatively soft and warm to the touch as opposed to the tile of the floor or other layers of the absorption mat 400.
The rapid drying composite absorption mat 400 further includes an absorption layer 410 including a diatomaceous earth material or other silica based wicking and rapid drawing material. However, according to several embodiments, a diatomaceous earth material or other silica based rapid wicking and rapid evaporative blend of materials may be preferred as forming the absorption layer 401 according to various advantageous embodiments. The diatomaceous earth material may include diatomaceous earth compressed, formed or bonded in a manner to produce the absorption layer 410 having a defined shape and configuration. The shape, design and configuration of the diatomaceous earth absorption layer 410 may be shaped and/or configured so as to correspond to a shape, design or configuration of the textile layer 405 and a non-slip layer 415. For example, as illustrated in FIG. 4, the outer periphery shape of the textile layer 405 corresponds to an outer periphery of absorbent wicking layer 410.
Referring still to FIG. 4, three sides and two corners of the outer periphery of the textile layer 405 and non-slip layer 415 may be bonded, sewn or otherwise connected so as to create a sleeve having an opening for receiving the absorbent layer 410 therein. As shown on the right in FIG. 4, the absorbent layer 410 may be slid into and out of the sleeve formed by the connected textile layer 405 and non-slip layer 415. FIG. 4 illustrates how the absorbent layer 410 may be manufactured and assembled with the textile layer 405 and non-slip layer 415 by sliding the absorbent layer 410 into the sleeve formed by the opposing textile layer 405 and non-slip layer 415 similar to insertion of a pillow into a pillow case. The bottom of the textile layer can have a grippy non-slip texture or material integrated directly into the fabric.
Referring to FIG. 5 another embodiment of a rapid drying composite absorption mat 500 is illustrated according to an embodiment of the invention. FIG. 5 illustrates the assembly of the components of the absorption mat 500. FIG. 5 shows the assembled mat 500 from a top assembled view on the left, and FIG. 5 shows an assembled bottom view of the mat 500 on top-right.
The absorption mat 500 in this embodiment includes a textile layer 505 including a cloth fabric material similar to that of a towel or traditional bathroom floor mat. The material of the textile layer 505 may be woven and may include a blend of materials, such as polyester materials, in addition to the cotton material. However 100% cotton may be used as the textile layer 505 according to the embodiments disclosed herein. The material of the textile layer 505 is relatively soft and warm to the touch as opposed to the tile of the floor or other layers of the absorption mat 500.
The rapid drying absorption mat 500 further includes an absorption layer 510 including a diatomaceous earth material or other silica based rapid wicking and rapid drying material. The absorption layer 510 rapidly wicks moisture away from the textile layer 505 and causes evaporation thereof. However, according to several embodiments a diatomaceous earth material or diatomaceous earth blend of materials may be preferred as forming the absorption layer 510 according to advantageous embodiments. The diatomaceous earth material may include diatomaceous earth compressed, formed or bonded in a manner to produce the absorption layer 510 having a defined shape and configuration. The shape, design and configuration of the diatomaceous earth absorption layer 510 may be shaped and/or configured so as to correspond to a shape, design or configuration of the textile layer 505. For example, as illustrated in FIG. 5, the outer periphery shape of the textile layer 505 corresponds to an outer periphery of absorbent wicking layer 510.
Referring still to FIG. 5, the textile layer 505 can include one or more end pockets 530 so as to mechanically secure the textile layer 505 to the absorption layer 510. As shown, the ends of the textile layer 505 may be bound 520 to ends of the end securement features 530 so as to create the end securement pockets 530.
FIG. 5 illustrates how the component absorbent layer 510 may be manufactured and assembled with the textile layer 505 by placing the ends of the absorbent layer 510 into the end pockets 530 of the textile layer 505 so as to secure and hold the fabric textile layer 505 against the absorbent layer 510. Thus, FIG. 5 illustrates on the left a top view of the absorption mat 500 and FIG. 5 illustrates a bottom of the absorption mat 500 on the top-right.
The rapid drying absorption mat 500 can further include a non-slip layer 515. For example, as illustrated in FIG. 5 the non-slip layer 515 may be used to prevent the absorption mat 500 from moving relative to a floor placed thereupon. The gripping non-slip material 515 may be similar to commonly available carpet underlay materials such as made from PVC or other non-slip materials. The non-slip layer 515 may be cut to shape and bound to the underside of the absorbent layer 510 using adhesives, epoxies, glue, or other curing and chemically securement means. The non-slip layer 515 may also be cut or designed to correspond to the mechanical end pocket securement features 530 as shown in FIG. 5. For example, as shown on the right in FIG. 5, the non-slip layer 515 may be cut to the shape of the outer periphery of the absorbent layer 510 and also be cut around end securement pockets 530. In this embodiment, the end securement pockets 530 may be made of a Spandex or other stretchable and flexible material so as to secure the absorbent layer 510 to the textile layer 505.
The inventor of this patent application conducted various tests of the absorption mat according to the previous discussed embodiments. The inventor of this application saturated two pieces of the same textile floor mat as shown on the left in FIG. 6. However, the first floor mat was left on a stone tile floor akin to the traditional use of a conventional bathroom mat. However, the second piece of the textile floor mat was placed upon a layer of absorbent diatomaceous earth such as the embodiments previously discussed and as shown on the left in FIG. 6. After 24 hours, the saturation, or lack thereof, was compared by the inventor. As shown in FIG. 6 on the right, the inventor placed a piece of stone over both pieces of cloth. The traditional bathroom mat remained saturated and wet. However the textile layer placed adjacent to the absorbent diatomaceous earth layer was dry as shown in the middle and right of FIG. 6.
In fact, the extreme difference in saturation was visually apparent due to a visual comparison of the color of the bath mat as well the discoloration of a porous material placed spanning the two textile materials as shown on the right in FIG. 6. The porous material placed over the two pieces of bath mat as shown was quickly discolored by the clearly evident continued saturation of the traditional mat as compared to the textile mat portion overlaying and adjacent to the rapid wicking and absorbing diatomaceous earth material
Thus, the embodiments disclosed herein provided rapid drying of an absorption mat or other article that is subjected to repeated saturation or wet environments while providing for a comfortable, ergonomic and safe bathroom mat.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

What is claimed is:

1. An absorption mat, comprising:

an absorbent substrate including diatomaceous earth; and

a textile layer for placement upon the absorbent substrate, wherein the absorbent substrate including diatomaceous earth draws moisture from the textile layer when placed adjacent to the textile layer.

2. The absorption mat according to claim 1, further comprising mechanical features affixed to the textile layer for holding the textile layer immediately adjacent to the absorbent substrate.

3. The absorption mat according to claim 2, wherein the mechanical features include straps, corner pockets, and/or end pockets.

4. The absorption mat according to claim 2, wherein the mechanical features include one or more corner and side pockets formed by the textile layer being wrapped around the absorbent substrate.

5. The absorption mat according to claim 4, wherein the mechanical features include an elastic material affixed to a periphery of the textile layer.

6. The absorption mat according to claim 1, wherein a top portion of the absorbent substrate is left uncovered by the textile layer when the textile layer is held against a top surface of the absorbent substrate.

7. The absorption mat according to claim 1, wherein the absorbent substrate includes cuts or grooves disposed into a top surface of the absorbent substrate so as to increase surface area for evaporation of liquid absorbed by the absorbent substrate.

8. The absorption mat according to claim 1, further comprising a non-slip layer for placement underneath the absorbent substrate.

9. The absorption mat according to claim 8, the non-slip layer being shaped to correspond to mechanical features for affixing the textile layer to the absorbent layer and allow for air to circulate underneath the absorption substrate for evaporation therefrom.

10. The absorption mat according to claim 8, wherein the non-slip layer includes a silicone material cured to the textile layer.

11. The absorption mat according to claim 8, wherein the non-slip layer includes a silicone material cured to elastic material sewn to outer periphery of the textile layer.

12. The absorption mat according to claim 11, wherein the elastic material is wrapped around the absorbent layer and holds the textile layer around a periphery of the absorbent layer.

13. The absorption mat according to claim 12, wherein the elastic material includes an elastic band that spans a bottom corner of the absorbent layer when the textile layer is held to the absorbent layer.

14. The absorption mat according to claim 13, wherein the elastic band and textile layer leave at least a corner of the absorbent layer uncovered.

15. The absorption mat according to claim 1, wherein the textile layer includes a cotton woven material.

16. A method of manufacturing an absorption mat, comprising:

providing a relatively soft cushioning textile layer;

providing a relatively hard rapidly wicking and absorbent layer including diatomaceous earth adjacent to an underside of the textile layer; and

providing a non-slip layer for placement to an underside of the absorbent layer during use.

17. The method of manufacturing the absorption mat according to claim 16, further comprising manufacturing mechanical features affixed to the textile layer for holding the textile layer immediately adjacent to the absorbent substrate.

18. The method of manufacturing the absorption mat according to claim 16, further comprising forming a cut or groove into an otherwise planar top surface of the absorbent layer for increasing surface area for promoting evaporation of absorbed water.

19. The method of manufacturing the absorption mat according to claim 16 further comprising sewing, attaching, or melding an elastic material to the textile layer.

20. A method of assembling an absorption mat, the absorption mat comprising:

an absorbent substrate including diatomaceous earth; and

a textile layer for placement upon the absorbent substrate, wherein the absorbent substrate including diatomaceous earth draws moisture from the textile layer when placed adjacent to the textile layer, the method including wrapping the textile layer around a periphery of the absorbent substrate such that the textile layer covers a majority of an outer periphery of the absorbent substrate.