WO2003096868A2 - Tapis de sol avec zone thermoformee pour element rapporte - Google Patents

Tapis de sol avec zone thermoformee pour element rapporte Download PDF

Info

Publication number
WO2003096868A2
WO2003096868A2 PCT/US2003/014610 US0314610W WO03096868A2 WO 2003096868 A2 WO2003096868 A2 WO 2003096868A2 US 0314610 W US0314610 W US 0314610W WO 03096868 A2 WO03096868 A2 WO 03096868A2
Authority
WO
WIPO (PCT)
Prior art keywords
floor mat
insert
area
insert area
overlay
Prior art date
Application number
PCT/US2003/014610
Other languages
English (en)
Other versions
WO2003096868A3 (fr
Inventor
Ronald D. Blum
William Kokonaski
Andrew Gentiluomo
Arthur Wildstein
Original Assignee
Tech Mats, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tech Mats, Llc filed Critical Tech Mats, Llc
Priority to EP03726736A priority Critical patent/EP1503651A2/fr
Priority to AU2003228959A priority patent/AU2003228959A1/en
Priority to CA002484848A priority patent/CA2484848A1/fr
Priority to BRPI0310066-9A priority patent/BR0310066A/pt
Publication of WO2003096868A2 publication Critical patent/WO2003096868A2/fr
Publication of WO2003096868A3 publication Critical patent/WO2003096868A3/fr

Links

Classifications

    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
    • A47L23/00—Cleaning footwear
    • A47L23/22—Devices or implements resting on the floor for removing mud, dirt, or dust from footwear
    • A47L23/26—Mats or gratings combined with brushes ; Mats
    • A47L23/266—Mats

Definitions

  • the present invention relates generally to floor mats, and more specifically to a cost-effective method for fabricating a floor mat with an insert area having an aesthetically pleasing appearance.
  • the floor mat For a floor mat that includes an area (hereinafter, "insert area") for receiving a dirt-trapping material such as a tacky insert as described above to be a commercially successful product, the floor mat needs to be not only functional and cost-effective to produce, but also aesthetically appealing.
  • One concern involving functionality is providing a suitable surface for the insert area.
  • the dirt-trapping material may have an adhesive lower surface to enable it to be securely seated in the insert area. Accordingly, the insert area should have a smooth surface to provide a high degree of contact area for the adhesive lower surface of the dirt-trapping material.
  • the dirt-trapping material may be a tacky insert designed to be a disposable commodity, comprising a plurality of separable, disposable tacky sheets as discussed in more detail below
  • the adhesive lower surface should not be so firmly adhered to the insert area that the tacky insert is difficult to remove when it is time to replace the tacky insert ,
  • a concern involving aesthetic appeal is giving the floor mat a uniform appearance where the tacky insert blends in smoothly with the rest of the upper floor mat surface. It is also desirable to reduce the visibility of dirt on the top exposed tacky surface of the insert.
  • Embodiments of the invention as described below address the foregoing concerns.
  • Fig. 1 illustrates a process of thermoforming an insert area in a floor mat material, according to embodiments of the present invention
  • Fig. 2A shows a floor mat with a thermoformed insert area having nodular treads configured to engage corresponding apertures in a tacky insert according to embodiments of the invention
  • Fig. 2B shows a floor mat with a thermoformed insert area having elongated treads configured to engage corresponding apertures in a tacky insert according to embodiments of the invention
  • Fig. 3A shows an alternative process for forming an insert area in a floor mat according to embodiments of the invention
  • Fig. 3B shows an assembled floor mat with an insert area formed according to the process illustrated in Fig. 3A;
  • Fig. 3C shows one possible form factor for marketing embodiments of the present invention
  • Fig. 3D shows an embodiment of an insert area formed separately using a different process than thermoforming, and later joined to a floor mat material.
  • Embodiments of the present invention relate to a floor mat comprising an insert area configured to receive an insert comprising a dirt-trapping material, where the insert area includes a portion of a material of the floor mat compressed and smoothed by application of pressure and heat.
  • This compressing and smoothing may be done by an inexpensive process referred to herein as "thermoforming.”
  • the thermoforming process while flattening the floor mat material in the insert area, may leave the insert area with substantially the same appearance as the rest of the floor mat material, i.e., the material not treated by thermoforming.
  • the dirt-trapping material inserted in the insert area may be made transparent or semi-transparent, a uniform, aesthetically pleasing appearance is given to the floor mat.
  • the compressing and smoothing of the insert area may provide for better adhesion of the insert material.
  • an additional smooth overlay may be provided for the thermoformed insert area for improved adhesion of the insert material, while also enabling easy removal of the insert material from the insert area.
  • the insert area may comprise a portion of the floor mat material that is left uncompressed during the thermoforming. This uncompressed portion may be configured to engage an aperture in the insert material, and act as an anti-slip tread as discussed in more detail below.
  • FIG. 1 A process according to embodiments of the present invention is illustrated in Fig. 1.
  • the process may be applied to any suitable floor mat material, including, by way of example only, carpet, plastic, rubber and the like.
  • An extent of floor mat material 110 may be arranged between parts 115, 120 of a two-part thermoforming tool. If carpet, the floor mat material 110 may comprise, by way of example only, olefin fibers.
  • the parts 115, 120 may be, for example, heated platens.
  • the parts 115, 120 may be brought into contact with the floor mat material 110 in an area of the floor mat material designated for receiving an insert material, and pressure applied thereby to the floor mat material to compress it.
  • One of the two parts 115, 120 (120 in Fig. 1 ) may have recesses 125 formed therein to prevent portions of the floor mat material aligning with the recesses from being compressed.
  • the parts 115, 120 may be heated to a temperature just above the melt temperature of the floor mat material. This temperature, in combination with the applied pressure, may cause the floor mat material in contact with the tool parts to at least partly melt, forming a smoothed, compressed portion 140 when the tool parts 115, 120 are withdrawn and the floor mat material is allowed to cool.
  • the portions 135 of floor mat material aligned with the recesses 125, and thus uncompressed, may be unmelted or only slight melted around their edges.
  • the smoothed, compressed portion 140 and uncompressed portions 135 constitute an insert area 141 which may be used to receive an insert material.
  • the insert area may be at least large enough to accommodate a pair of adult-sized shoes.
  • a resulting thermoformed floor mat 130 comprising an insert area 141 may then be ready to receive an insert material in the insert area 141.
  • the insert material may have an adhesive lower surface to secure the insert material within the insert area by adhesive engagement with a superior exposed surface of the insert area.
  • the insert material may be a tacky insert 200 comprising a plurality of separable, disposable layers or sheets formed as a stack, each sheet having a top tacky surface. Sheets of the tacky insert may be removed and disposed of one by one as they are used over time.
  • the tacky insert may include a bottom layer or sheet 202, having adhesive on a lower surface thereof, as well as its top surface, in order to secure the stack of sheets within the insert area by adhesive engagement with the superior exposed surface of the insert area.
  • the tacky insert may further include apertures 205 therein configured to receive and be engaged by the uncompressed portions 135 of the floor mat material. More specifically, the uncompressed portions 135 may act as treads for preventing slipping of a person on the tacky insert when it is wet, by projecting above the top exposed surface of the tacky insert and presenting a textured surface to engage the soles of shoes.
  • the overall floor mat material 110 was carpet, at least a portion of a top exposed surface of an uncompressed portion 135 would present the texture of the original carpet surface, thereby providing friction for preventing slippage.
  • the treads 135 could have any arbitrary form, including the round, nodular form illustrated in Figs. 1 and 2A, or, for example, a thin, elongated form as shown in Fig. 2B. Recesses in the thermoforming tool and apertures in the tacky insert would of course have a corresponding shape.
  • uncompressed areas or treads need not be included in the insert area. Instead, the entire insert area could be compressed and smoothed, with uncompressed floor mat material forming a border around the insert area. A dirt-trapping material could be received within the insert area and need not include apertures.
  • treads or other anti-slip features within the insert area need not have the same texture, color, or be formed from the same material as the floor mat. Instead, the treads could be made of a different material and added to the insert area after its formation. Examples of alternative tread materials include carpet, plastic, rubber, wood and metal.
  • the smoothed, compressed portion 140 of the insert area should provide for good contact with the adhesive lower surface of an insert material.
  • an overlay 150 could be provided for improved contact with the adhesive lower surface of the insert material and for easy release of the insert material from the insert area when, for example, the insert material is a stack of insert sheets that has been used up and it is time to replace the insert material.
  • the overlay 150 could be configured to be received within the insert area 141 , and could include apertures 155 for receiving and engaging the uncompressed portions or treads 135.
  • the insert area need not include treads, and accordingly, the overlay need not include apertures.
  • the overlay 150 could be bonded, for example, by adhesive, to the smoothed, compressed portion 140 of the insert area.
  • the overlay 150 could be made of a material with a melt temperature close to that of the floor mat material, and bonded by the application of pressure and heat to the insert area 141. This could be done, for example, in the same step as the initial forming of the insert area, or in a separate step.
  • the overlay 150 material may be chosen based on its smoothness; i.e., preferably the overlay material would have a smoother surface than was readily achievable by simply compressing and partly melting the overall floor mat material as described above.
  • the overlay material could be, by way of example only, MylarTM (polyester) or plastic.
  • Reference number 145 in Fig. 1 designates an embodiment including an overlay 150.
  • a factor that figures into the function of a tacky insert is the comparative strength of the adhesive used on the bottom layer and the rest of the sheets of the insert stack. Experimentation has shown that good results are achieved when a strength of approximately 14 ounce/in. adhesion to steel or 170 g/cm2 as measured on a tack probe is used on the lower surface of the bottom insert layer that is configured to bond to the superior exposed surface of the insert area.
  • the adhesive strength of the top surface of the bottom layer and the remaining tacky sheets in the stack are about half these values, so that the bond between the bottom layer and the insert area is stronger than the bond between sheets, thus allowing sheets of the insert stack to be peeled off without removing the bottom layer until it is time to install a new stack.
  • the thermoforming process should leave the insert area with substantially the same appearance (e.g., color and/or pattern) as the rest of the floor mat material, to give a finished floor mat a uniform, pleasing appearance when a transparent or semi-transparent tacky insert is received therein.
  • the overlay 150 may also be transparent or semi-transparent to allow the underlying color and/or pattern of the insert area to be seen therethrough.
  • the overlay could be made with a custom printed, opaque or translucent material of a color and/or pattern that is coordinated with a color and/or pattern of the floor mat material, or provides a message, advertisement, logo, name or insignia.
  • Fig. 3A illustrates an alternative process according to embodiments of the present invention.
  • a separate section 320 of arbitrary shape is formed, for example by die cutting, from an extent of floor mat material 310.
  • Pressure and heat may be applied to the section 320 using a two-part thermoforming tool as described above. More specifically, pressure and heat may be applied for a predetermined amount of time to form a smoothed, compressed portion 340, while recesses 125 in one of the parts 120 of the thermoforming tool allow for uncompressed portions 335, which may function as anti-slip treads as described above.
  • the section 320 need not include treads.
  • An overlay 345 may be provided which includes a raised portion 350 configured to receive the section 320.
  • the overlay may include apertures 355 for receiving and engaging the uncompressed portions 335 of the thermoformed section 320. However, the overlay need not include apertures. Portions 351 of the overlay 345 may extend beyond and around the raised portion 350.
  • the overlay 345 may be provided in order to have better adhesion of the insert material within the insert area. Accordingly, the overlay 345 could, by way of example only, be made of a smooth material like MylarTM or plastic.
  • the overlay 345 may be transparent or semi-transparent, or could be made with a custom printed, opaque or translucent material of a color and/or pattern that is coordinated with a color and/or pattern of the floor mat material, or provides a message, advertisement, logo, name or insignia.
  • the overlay 345 and the section 320 may be joined to an extent 310 of floor mat material.
  • This extent of floor mat material need not be the same extent from which the section was formed, nor even be the same kind of material.
  • the section 320 could be, for example, carpet of a different texture and/or color, or of a different material than carpet.
  • the extent of floor mat material may include an opening 315 configured to receive the raised portion 350 of the overlay.
  • the raised portion 350 receives the section 320.
  • the overlay 345 may be bonded to the underside of the floor mat material 310 by, for example, VelcroTM or an adhesive which is applied to portions 351 bordering the raised portion 350.
  • the overlay 345 and associated section 320 thereby form an insert area 360 which may receive a tacky insert as described above in the discussion of Figs. 1 , 2A and 2B.
  • Fig. 3C illustrates one possible form in which a floor mat according to embodiments of the invention could be commercially marketed.
  • the overlay 345 and associated section 320 could be sold as one part of a two-part floor mat that is assembled by a consumer.
  • An extent of floor mat material with an opening 315 configured to receive the raised portion 350 of the overlay could be provided as the other half. This would enable the extent of floor mat material 310 to be, for example, folded or rolled up for packaging, allowing for a compact form factor that economizes on shelf space, an important advantage in product merchandising.
  • an insert area could be formed separately from, and then later joined to, an extent of floor mat material having an opening configured to receive the insert area as described above, but where the insert area is not made by thermoforming a section of floor mat material.
  • the insert area could be made by some different process of some different material.
  • the insert area could be formed by injection molding entirely of smooth plastic, rubber, or other material or combination of materials. This may or may not obviate the need for a smooth overlay as described above.
  • separately- formed insert area 370 made of, for example, injection-molded plastic, may be joined to an extent of floor mat material 310 at an opening 315 in the floor mat material.
  • the insert area 370 may or may not include treads 375.
  • Embodiments of the invention could be provided with an anti-skid layer on the underside of the floor mat material and insert area, i.e., the surfaces that are in contact with the floor, to prevent the floor mat from sliding along the floor.
  • This anti-skid layer could be made from, for example, latex, vinyl, rubber or TPR (thermoplastic rubber).

Landscapes

  • Carpets (AREA)
  • Securing Of Glass Panes Or The Like (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Passenger Equipment (AREA)

Abstract

Dans certaines formes de réalisation, cette invention concerne la formation, dans un tapis de sol, d'une zone conçue de manière à pouvoir recevoir un matériau servant à piéger la saleté.
PCT/US2003/014610 2002-05-16 2003-05-12 Tapis de sol avec zone thermoformee pour element rapporte WO2003096868A2 (fr)

Priority Applications (4)

Application Number Priority Date Filing Date Title
EP03726736A EP1503651A2 (fr) 2002-05-16 2003-05-12 Tapis de sol avec zone thermoformee pour element rapporte
AU2003228959A AU2003228959A1 (en) 2002-05-16 2003-05-12 Floor mat with thermoformed insert area
CA002484848A CA2484848A1 (fr) 2002-05-16 2003-05-12 Tapis de sol avec zone thermoformee pour element rapporte
BRPI0310066-9A BR0310066A (pt) 2002-05-16 2003-05-12 tapete de piso com área de inserção termoformada e método de fabricação do mesmo

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US37805602P 2002-05-16 2002-05-16
US37805702P 2002-05-16 2002-05-16
US60/378,057 2002-05-16
US60/378,056 2002-05-16

Publications (2)

Publication Number Publication Date
WO2003096868A2 true WO2003096868A2 (fr) 2003-11-27
WO2003096868A3 WO2003096868A3 (fr) 2004-02-19

Family

ID=29553473

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2003/014610 WO2003096868A2 (fr) 2002-05-16 2003-05-12 Tapis de sol avec zone thermoformee pour element rapporte

Country Status (6)

Country Link
EP (1) EP1503651A2 (fr)
AR (1) AR039549A1 (fr)
AU (1) AU2003228959A1 (fr)
BR (1) BR0310066A (fr)
CA (1) CA2484848A1 (fr)
WO (1) WO2003096868A2 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2011695A2 (fr) * 2007-06-18 2009-01-07 Roberto Nusca Procédé de fabrication d'un élément de revêtement de coffre de voiture et élément de revêtement ainsi obtenu

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3703424A (en) * 1968-07-30 1972-11-21 Dunlop Holdings Ltd Method of producing a wear-resistant area in a surface-covering material
US4143194A (en) * 1977-03-01 1979-03-06 Arbrook, Inc. Disposable floor mat combination
EP0279810A1 (fr) * 1986-11-07 1988-08-31 CORONET-WERKE Heinrich Schlerf GmbH Procede de production de nattes de nettoyage et nattes de nettoyage
US6219876B1 (en) * 1999-05-04 2001-04-24 Tech Mats, L.L.C. Floor mat
US6233776B1 (en) * 1999-05-04 2001-05-22 Tech Mats, L.L.C Advanced floor mat
WO2002017768A2 (fr) * 2000-08-25 2002-03-07 Tech Mats, Llc. Paillasson ameliore

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3703424A (en) * 1968-07-30 1972-11-21 Dunlop Holdings Ltd Method of producing a wear-resistant area in a surface-covering material
US4143194A (en) * 1977-03-01 1979-03-06 Arbrook, Inc. Disposable floor mat combination
EP0279810A1 (fr) * 1986-11-07 1988-08-31 CORONET-WERKE Heinrich Schlerf GmbH Procede de production de nattes de nettoyage et nattes de nettoyage
US6219876B1 (en) * 1999-05-04 2001-04-24 Tech Mats, L.L.C. Floor mat
US6233776B1 (en) * 1999-05-04 2001-05-22 Tech Mats, L.L.C Advanced floor mat
WO2002017768A2 (fr) * 2000-08-25 2002-03-07 Tech Mats, Llc. Paillasson ameliore

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2011695A2 (fr) * 2007-06-18 2009-01-07 Roberto Nusca Procédé de fabrication d'un élément de revêtement de coffre de voiture et élément de revêtement ainsi obtenu
EP2011695A3 (fr) * 2007-06-18 2010-03-10 Roberto Nusca Procédé de fabrication d'un élément de revêtement de coffre de voiture et élément de revêtement ainsi obtenu

Also Published As

Publication number Publication date
CA2484848A1 (fr) 2003-11-27
BR0310066A (pt) 2007-04-10
WO2003096868A3 (fr) 2004-02-19
EP1503651A2 (fr) 2005-02-09
AU2003228959A1 (en) 2003-12-02
AR039549A1 (es) 2005-02-23
AU2003228959A8 (en) 2003-12-02

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