Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
  • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
  • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47G—HOUSEHOLD OR TABLE EQUIPMENT
  • A47G27/00—Floor fabrics; Fastenings therefor
  • A47G27/02—Carpets; Stair runners; Bedside rugs; Foot mats
  • A47G27/0212—Carpets; Stair runners; Bedside rugs; Foot mats to support or cushion
  • A47G27/0225—Carpets; Stair runners; Bedside rugs; Foot mats to support or cushion for bathrooms
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
  • B32B25/10—Layered products comprising a layer of natural or synthetic rubber next to a fibrous or filamentary layer
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
  • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
  • D06N7/0068—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the primary backing or the fibrous top layer
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
  • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
  • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
  • D06N7/0076—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being a thermoplastic material applied by, e.g. extrusion coating, powder coating or laminating a thermoplastic film
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
  • B32B2307/536—Hardness
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/744—Non-slip, anti-slip
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2323/00—Polyalkenes
  • B32B2323/16—EPDM, i.e. ethylene propylene diene monomer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2471/00—Floor coverings
  • B32B2471/04—Mats
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2203/00—Macromolecular materials of the coating layers
  • D06N2203/02—Natural macromolecular compounds or derivatives thereof
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2203/00—Macromolecular materials of the coating layers
  • D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • D06N2203/042—Polyolefin (co)polymers
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2203/00—Macromolecular materials of the coating layers
  • D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • D06N2203/045—Vinyl (co)polymers
  • D06N2203/047—Arromatic vinyl (co)polymers, e.g. styrene
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2211/00—Specially adapted uses
  • D06N2211/06—Building materials
  • D06N2211/066—Floor coverings
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2213/00—Others characteristics
  • D06N2213/06—Characteristics of the backing in carpets, rugs, synthetic lawn
  • D06N2213/061—Non-continuous back coating or pre-coat
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
  • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness

Definitions

• the present invention relates generally to slip resistant mats, and, more particularly, to mats having suction cups on the underside of the mats.
• cleats have been added to the bottom surface of the mats so that the mats can better grip the surfaces onto which they are placed and thereby reduce their movement.
• this approach did not prevent displacement of the mats on smooth floors, especially those floors with high traffic areas or loads being moved on them. This displacement results from the force of foot and vehicle traffic on the mats, which causes a deformation around the compressed area and then upon removal of such force the mats return to a different position.
• Fasteners have also been employed with floor mats to reduce or eliminate the movement of the mats. For example, clips have been employed for securing the mats to a particular surface. Additionally, frames have been employed to secure mats onto a particular surface.
• suction cups along the bottom surface of the mats. While this approach provides acceptable slip-resistance for applications involving lower traffic and lower load areas, such as bathrooms and showers, these suction cups do not provide sufficient anti-skidding forces to prevent slipping and movement in high traffic and high load areas such as grocery stores. Furthermore, traditional suction cups result in a wavy mat surface, which may be more difficult for individuals and loads to traverse. Finally, suction cups, which tend to have a thin edge, can break off from the mat when the mat is in use or cleaned. Accordingly, there exists a need for an improved mat construction that eliminates migration of the mat along the surface on which it is placed.
• the present invention is a mat having a base layer that is bonded to a top layer.
• the base layer of the mat includes a plurality of depressions along the bottom surface of the base layer, wherein the depth of the depressions does not exceed the depth of the base layer.
• the orientation of the depressions on the bottom surface of the mat may be such that there is a greater concentration of depressions along the edges of the mat.
• the top layer of the mat is preferably a layer of carpet tuft.
• the depressions of the mat suction the mat to the surface onto which the mat is placed once an initial force is applied to the mat, such as a footstep or vehicular traffic.
• the base layer of the mat is formed from a soft, low durometer rubber compound by being plied to smooth mold so that the bottom surface of the mat is smooth.
• a feature of the present invention is the use of a mat having a plurality of depressions along the bottom surface of the mat. These depressions effectively secure the mat to surfaces once an initial force is applied. Additionally, the depressions do not results in a wavy mat surface such as most mats including suction cups. Because the depressions do not have a thin edge such as most suction cups, but are instead molded into the bottom of the mat, the depressions are also able to better retain their shape and are more structurally sound thereby making the mat more durable.
• Another feature of the present invention is the use of a mat having a plurality of depressions with a particular pattern. This pattern prevents the edges of the mat from curling up or wrinkling, because there is a greater concentration along the edges of the mat.
• Still another feature of the present invention is the use of mat having a smooth bottom surface.
• the smooth surface results in a higher coefficient of friction and facilitates suction because the floor surface contact is increased. Accordingly, the movement of the mat along the surface is minimized.
• Yet another feature of the present invention is the use of mat formed from a soft, low durometer rubber material.
• the softness of the rubber enhances the effectiveness of both the depressions and the smooth backing of the mat in securing the mat to a surface.
• FIG. 1 is a perspective view of the underside of a mat according a preferred embodiment of the present invention
• FIG. 2 is a cross-sectional view of the mat taken across Line 2-2 according to a preferred embodiment of the present invention
• FIG. 2 A is a cross-sectional view of an alternate embodiment of the mat taken across Line 2-2;
• FIG. 2B is a cross-sectional view of another alternate embodiment of the mat taken across Line 2-2;
• FIG. 3 is a perspective view of a mat mold according to a preferred embodiment of the present invention.
• the present invention is a mat 10 having a base layer
• the bottom surface 16 of the mat 10 includes a plurality of depressions 14.
• the top surface 13 of the base layer 12 is laminated or otherwise bonded to a top layer 18 of fabric, such as carpet tuft.
• top layer 18 any type of fabric can be employed in the top layer 18, including fabric made of nylon, polyester, and polyolefm fibers.
• the mat 10 does not include a top layer 18 of fabric at all. If the top layer 18 is included in the mat 10, the thickness of the top layer 18 is preferably between approximately 0.100 and 1.00 inches.
• the base layer 12 is preferably made of rubber. However, other polymers may be used such as EPDM, which is sold by DuPont under the trademark NORDEL ® , or SBR (styrene-butadiene) which is sold by Poly Corp. under the trademark POLYSAR ® . More preferably, the base layer 12 is made of a rubber having a hardness between approximately 20 to 70 durometers, and, most preferably, between approximately 30 to 50 durometers.
• a base layer 12 that is made of a soft, low durometer rubber material is a particular feature of the present invention.
• the softness of the rubber enhances the effectiveness of the depressions 14 the mat in securing the mat 10 to a surface.
• the depressions 14 are positioned in parallel and perpendicular rows resulting in a grid arrangement. Although a majority of the depressions 14 are evenly spaced along the bottom surface 16 of the mat 10, there is a greater concentration of depressions 14 along the edges of the mat.
• An effective range of depression 14 spacing is approximately 3 to 10 inches. Most preferably, the spacing between the two outermost rows of depressions 14 along the edges of the mat 10, shown as space A, is approximately 3 inches, whereas the spacing between the remaining rows of depressions 14, shown as space B, is approximately 6 inches.
• this particular orientation is a feature of the present invention, because it helps to prevent the edges of the mat 10 from curling up or wrinkling thereby creating a tripping hazard.
• any suitable pattern, including random patterns, for the depressions may be used on the bottom of the mat.
• the depressions 14 are preferably shaped like a cylinder or a recessed circle having a diameter C and a depth D, which is less than the depth E of the base layer 12 of the mat 10. Most preferably, diameter C is approximately 1 inch, depth D is approximately 0.125 inches, and depth E is between approximately 0.140 and 0.250 inches.
• the depressions 14 in a most preferred embodiment are cylindrical in shape, where the sidewalls 20 of the depression are substantially perpendicular to the bottom planar surface 16 of the base layer 12, as shown in FIG. 2.
• the depressions may also be formed into other shapes, such as square or diamond shaped, so long as the shape of the depression does not in any way break or disturb the smooth plane of the bottom surface of the mat.
• One particularly useful shape for the depression is a frustum shape.
• FIGS. 2 A and 2B show the frustum shaped depressions in FIGS. 2 A and 2B.
• the frustum shaped depression is oriented so that the base of the frustum is positioned adjacent the bottom surface of the mat.
• FIG. 2B shows the frustum shaped depression being oriented so that the apex of the frustum is positioned adjacent the bottom surface of the mat.
• the base layer 12 of the mat 10 is formed by plying a material, such as rubber, to a mold 30, as shown in FIG. 3.
• the mold 30 is a smooth plate having a plurality of projections 32, which are used to form the depressions 14.
• the plate may be made of such materials as steel, aluminum, ceramics or any other material that can be molded or machined into a pattern and have a smooth surface.
• the use of an aluminum plate is advantageous, because aluminum transfers heat readily and will heat up and cool down quickly. Aluminum is also preferred because it is lighter than other metal, and can be molded, machined and shaped more easily than other materials.
• the resulting base layer 12 is formed with a smooth or slick bottom surface 16.
• having a smooth bottom surface 16 increases the coefficient of friction of the mat 10, and also facilitates the suction action against the floor surface. Therefore, movement of the mat 10 along the surface is decreased and minimized.
• the mat 10 becomes suctioned to a floor surface after an initial force, such as a footstep or vehicular traffic, is applied.
• an initial force such as a footstep or vehicular traffic
• the depressions 14 of the mat 10 are deformed and at least some of the air contained with the depressions 14 is forced out, which creates a low pressure area or near vacuum inside the depressions 14, thus creating a suction.
• the use of depressions 14 to suction the mat 10 to a surface further minimizes migration of the mat 10 along the surface. When used in combination, these features result in zero migration of the mat 10 along a surface to which it has been suctioned.
• zero migration refers to a calculation in inches of mat displacement based on the Kex Walk Test.
• markers such as tape, are placed below the corners of the mat 10 to designate the original position of the mat 10. Subsequently, an individual will either walk over or push a grocery cart over the mat 10. Variations can exist as to what type of floor surface on which the mat 10 is placed. After a certain number of passes have been completed, the difference in inches between the original location of the mat 10 and the ending location of the mat 10 is measured.
• Example 1 A first mat having a mat size of 3 feet by 10 feet, weighing approximately 21 lbs., and having the features described above, including a base layer made of rubber that is bonded to a top layer of fabric, a smooth bottom surface, and a plurality of depressions having diameter of approximately 1 inch and a depth of approximately 0.125 inches, was subjected to the Kex Walk Test as described above. The mat was first washed with a non-ionic detergent at 140° F. Thereafter, the mat was placed on a hard tile floor surface over tape markers. Next, a walker pushing a grocery cart that was loaded to give the cart a total weight of 100 lbs. passed over the mat 50 times.
• a second mat having a mat size of 3 feet by 10 feet and weighing approximately 12 lbs. was also subjected to the same Kex Walk Test.
• the second mat also included a base layer of rubber bonded to a top layer of fabric.
• the second mat did not include a smooth bottom surface and a plurality of depressions.
• the second mat was cleated on the bottom surface of the mat.
• This mat was also washed with a non- ionic detergent at 140° F. Thereafter, the mat was placed on a hard tile floor surface over tape markers.
• this examples demonstrates the effectiveness of the skid resistant features of the mat 10 of the present invention over other mats known in the art.

Landscapes

• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Carpets (AREA)
• Passenger Equipment (AREA)

Priority Applications (2)

Applications Claiming Priority (2)

Publications (2)

Family

ID=34135866

Family Applications (1)

Country Status (4)

Cited By (1)

Families Citing this family (19)

Family Cites Families (9)

• 2003
  • 2003-08-11 US US10/639,386 patent/US20050037177A1/en not_active Abandoned
• 2004
  • 2004-07-07 EP EP04756749A patent/EP1654112A4/en not_active Withdrawn
  • 2004-07-07 JP JP2006523186A patent/JP2007502145A/ja not_active Withdrawn
  • 2004-07-07 WO PCT/US2004/021789 patent/WO2005018992A2/en not_active Ceased

Non-Patent Citations (1)

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