WO2001019230A1

WO2001019230A1 - Entrance matting

Info

Publication number: WO2001019230A1
Application number: PCT/GB2000/003549
Authority: WO
Inventors: Simon Kerr Macdonald
Original assignee: Simon Kerr Macdonald
Priority date: 1999-09-15
Filing date: 2000-09-15
Publication date: 2001-03-22
Also published as: AU7532600A; GB9921746D0; GB2354165A; GB0022824D0

Abstract

Matting (1), particularly suited for use as entrance matting, which comprises an upper and a lower surface wherein one surface comprises a moulded base (2) which has a plurality of upstanding strips (3), each strip comprising a plurality of surface scraper bars (4) interspersed with drainage ducts (5) containing drainage holes (8) and the second surface provides a second set of drainage ducts (10) to carry away fluid which has passed through the drainage holes (8).

Description

1 ENTRANCE MATTING

^*2

3 The present invention relates in general to the field of

4 matting and in particular to the field of building

5 entrance matting. 6

7 Entrance or threshold matting is often provided at the

8 entrances to stores, offices and public buildings in

9 order to minimise the amount of dirt and water that is 10 carried into the buildings on people's feet.

11

12 Several features are desirable in entrance matting.

13 Firstly, it must be effective in its role of reducing the

14 amount of dirt and water carried into buildings.

15 Secondly, it must be easy to walk over, providing grip

16 without containing gaps that might trap heels and walking

17 sticks. For common commercial reasons, it must also be

18 cheap, durable, easy to maintain and clean, aesthetically

19 pleasing, able to be laid on a variety of surfaces and

20 readily adaptable to particular size requirements. It is

21 also advantageous to avoid the use of metal as this can

22 affect the functioning of the security devices commonly

23 used in stores, libraries and the like. One type of entrance matting that aimed to provide the above attributes and which has proved commercially successful is described in WO93/07789. This comprises an extruded rubber mat with an upper layer that incorporates spaced upstanding strips which have ribbed upper surfaces that function as scrapers, removing the largest particles of dirt from shoes. In between these strips there are provided strips of carpet which remove finer particles of dust and retain moisture.

A disadvantage of this design is that the carpet strips can become saturated in wet conditions, making the matting less effective. In prolonged period of wet weather, it can become hard to keep this type of matting appropriately clean.

An improvement in the performance of entrance matting in wet weather was achieved by the invention disclosed in W096/36268. This publication described a bilayer matting in which an upper layer also contained a plurality of spaced upstanding strips with ribbed upper surfaces between which there are provided strips of carpet. However, the spaced upstanding strips in the upper layer were further provided with chevron-shaped channels which intersected with a series of drainage slots in a lower layer. This facilitated the draining of water from the mat and so improved the performance of the mat in wet weather.

However, there remains a few areas in which further innovation would lead to a better product. Firstly, slots in the lower layer may become blocked with dirt with time and so it would be advantageous to provide a drainage facility which did not clog. Secondly, the carpet strips must be fixed in place with adhesive. This step has implications for the cost of manufacture and the adhesive represents a joint which may potentially fail and limit the lifetime of the carpet.

It is a first object of the present invention to provide entrance matting with a drainage facility with a reduced tendency to clog up.

An additional object of the present invention is to provide entrance matting which does not require or does not rely solely on adhesive for fixing carpet strips in place.

A further object of the present invention is to provide further enhancements to drainage and therefore to tolerance of wet conditions.

Furthermore, the present invention aims to meet these objectives whilst still remaining effective, safe to walk over, cheap, durable, easy to maintain and clean, aesthetically pleasing and adaptable.

According to the present invention there is provided matting comprising an upper surface and a lower surface, the upper surface comprising a plurality of spaced upstanding strips and a plurality of strips of carpet located in some or all of the gaps between the spaced upstanding strips and supported by the lower layer; wherein the upper surface defines a substantially continuous tread surface; wherein the lower layer comprises a plurality of holes which pass through the lower layer and are located under the strips of carpet; wherein the holes are tapered so that they are narrower at their tops.

The holes may be circular.

Preferably, strips of carpet comprise on their underside a plurality of studs each of which is adapted to mate with a hole.

More preferably, the holes and studs are shaped to be readily mated but difficult to separate.

Preferably, the lower layer comprises on its underside a plurality of elongate channels.

Some or all of the elongate channels may comprise underside drainage ducts which intersect with the base of the holes.

Preferably also, the underside drainage ducts are tapered so that they are narrower towards their tops.

The underside drainage ducts may be orthogonal to the upstanding strips.

Preferably, the upper surfaces of the upstanding strips are slightly convex, such that water will tend to flow off the upper surfaces of the strips.

More preferably, the upstanding strips comprise a plurality of scraper blocks having surface drainage ducts therebetween, wherein the scraper blocks comprise on their upper surface a plurality of ridges.

The ridges on a scraper block may be orthogonal to the upstanding strip upon which the scraper block is mounted.

The surface drainage ducts may be orthogonal to the upstanding strip upon which the scraper block is mounted.

The matting may be made from a flexible material.

The matting may further comprise an underlay layer which has on its upper surface a plurality of plugs adapted to mate with the holes.

Alternatively, the matting may further comprise an underlay layer, the matting having on its underside a plurality of plugs which mate with holes provided in the underlay layer.

The underlay layer may further comprise a plurality of underlay drainage ducts which intersect the underside drainage ducts.

According to a second aspect of the present invention there is provided a method for manufacturing matting that comprises the steps of first manufacturing a base layer having holes and a plurality of carpet strips having studs and then fixing the carpet strips to the matting by mating the studs with the holes.

According to a third aspect of the present invention there is provided a method of laying matting comprising the steps of manufacturing matting according to the second aspect, manufacturing underlay which has a plurality of studs on its upper surface, laying the underlay and then laying the matting on the underlay, mating the holes in the matting with the studs in the underlay.

According to a fourth aspect of the present invention there is provided a method of laying matting comprising the steps of manufacturing matting according to the second aspect which further comprises a plurality of studs on its lower surface, manufacturing underlay which has a plurality of holes on its upper surface, laying the underlay and then laying the matting on the underlay, mating the studs in the matting with the holes in the underlay.

An example embodiment of the invention will now be illustrated with reference to the following Figures in which:

Figure 1 shows a plan view of a section of matting; Figure 2 shows a cross-section through this matting; Figure 3 shows a close-up perspective view of a small region of matting; and Figure 4 shows a cross-section through a carpet strip.

Figure 1 shows a plan view of a section of matting according to the present invention. Figure 2 shows a cross section through this matting. Figure 3 shows a close-up perspective view of a small region of the matting. The matting 1 comprises a moulded base 2 which has a plurality of spaced upstanding strips 3. Each upstanding strip 3 comprises a plurality of surface scraper bars 4 interspersed with drainage ducts 5. Each scraper bar 4 has a plurality of grooves 6 and the profile of each upstanding strip 3 and surface scraper bar 4 is such that the centre of each upstanding strip 3 and scraper bar 4 is raised, causing fluid to drain down the grooves 6 and drainage ducts 5.

Between some or all upstanding strips 3 there is mounted upon the base a strip of carpet 7 such as nylon brush fibre material or needlecord polypropylene inserts. Whereas the scraper bars act to remove the largest particles of dirt, the carpet 7 acts to remove the smaller particles of dirt.

For clarification, the term "carpet" within this document refers to any type of material commonly used in flooring, including conventional carpeting and coir or other fibrous materials.

Fluid which has drained from the upstanding strips 3 or the carpet strips 7 collects underneath the carpet strips 7 where it can drain through holes 8. Each hole 8 is tapered towards the top. This means that any fibrous or particulate matter which passes through the top of the hole 8 is able to pass through the hole rather than becoming trapped part way down. For drainage purposes, the holes 8 are best provided at the end of the drainage ducts 5; however, this is not essential.

However, the holes 8 have an important additional function. Each carpet strip 7 has a plurality of studs 9 which are distributed so as to correspond with the holes 8. Each stud 9 is shaped to be broader at its tip than its base and so to remain firmly inside each hole 8 when it has been pushed through the relatively narrow diameter of the top of the hole, in a similar manner to e.g. plastic wallplugs.

Underneath the each drainage hole 8 there is provided a second set of drainage ducts 10 to carry away fluid which has passed through the drainage holes 8. These second drainage ducts also become broader towards their base to ensure that any particles which can pass through the holes can be washed through and will not clog the ducts. There are also provided a series of air ventilation ducts 11 underneath the base which allow air to enter and water vapour to leave, preventing fouling from taking place.

Typically the base will be made from moulded rubber; however, it will be clear to one skilled in the art than many construction techniques could produce suitable components.

Entrance matting is typically fitted into inset areas of floor. The depth of inset varies from place to place but the top surface of mats must be level with the surrounding floor. It is preferable for economic reasons to manufacture mats in only one thickness and so at the present time, the depth of inset is adjusted for by pouring a layer of concrete upon which the mat sits. It would be desirable to simply provide underlay, e.g. made of rubber, which could sit in the inset area and act as spacers; however, using prior art mats it would be necessary to use adhesive to enable the mats to stay in place on the underlay.

An alternative embodiment of the present invention, there includes underlay which has studs that correspond with the holes 8 in the mat, allowing the mat to be mounted fixedly on the underlay. Alternatively, the mat itself may be provided with studs which correspond to holes in the underlay. In these embodiments, the underlay may or may not comprise further drainage channels which intersect the second set of drainage ducts 10 on the underside of the mat.

Further modifications and improvements may be incorporated without departing from the scope of the invention herein intended.

Claims

1. A matting comprising an upper surface and a lower surface, the upper surface comprising a plurality of spaced upstanding strips and a plurality of strips of carpet; wherein the upper surface defines a substantially continuous tread surface and wherein the lower surface comprises a plurality of holes which pass through the lower layer.

2. A matting as described in Claim 1 where the plurality of holes in the lower surface are tapered so that they are narrower at their tops.

3. A matting as described in Claim 1 or Claim 2 where the strips of carpet comprise on their underside a plurality of studs, each adapted to mate with a hole.

4. A matting as described in any of the previous Claims wherein the lower layer comprises on its underside a plurality of elongate channels.

5. A matting as described in Claim 4, wherein elongate channels may comprise underside drainage ducts.

6. A matting as described in Claim 5, wherein the drainage ducts are tapered so that they are narrower towards their tops.

7. A matting as described in Claim 5 or Claim 6, wherein the drainage ducts may be orthoganal to the upstanding strips.

8. A matting as described in any of the previous Claims wherein the upstanding strips are slightly convex.

9. A matting as described in any of the previous Claims wherein the upstanding strips comprise a plurality of scraper blocks having surface drainage ducts therebetween, wherein the scraper blocks comprise on their upper surface a plurality of ridges.

10. A matting as described in any of the previous Claims wherein the ridges on the scraper block are orthogonal to the upstanding strip upon which the scraper block is mounted.

11. A matting as described in any of the previous Claims wherein the matting is made from a flexible material.

12. A matting as described in any of the previous Claims wherein the matting further comprises an underlay layer which has on its surface a plurality of plugs.

13. A matting as described in any of the previous Claims wherein the matting has on its underside a plurality of plugs.

14. A matting as described in any of the previous Claims wherein the underlay may comprise a plurality of drainage ducts which intersect the underside drainage ducts .

15. A method for manufacturing matting that comprises the steps of manufacturing a base layer having holes and a plurality of carpet strips which have studs and then fixing the carpet strips to the matting by mating the studs with the holes.

16. A method of laying matting comprising the steps of manufacturing matting according to Claim 15, manufacturing underlay which has a plurality of studs on its upper surface, laying the underlay and then laying the matting on the underlay, mating the holes in the matting with the studs in the underlay.

17. A method of laying matting comprising the steps of manufacturing matting according to Claim 15, wherein the matting further comprises a plurality of studs on its lower surface, manufacturing underlay which has a plurality of holes on its upper surface, laying the underlay and then laying the matting on the underlay and mating the studs in the matting with the holes in the underlay.