WO2011090510A1 - Cushioned absorbent mat - Google Patents

Cushioned absorbent mat Download PDF

Info

Publication number
WO2011090510A1
WO2011090510A1 PCT/US2010/046046 US2010046046W WO2011090510A1 WO 2011090510 A1 WO2011090510 A1 WO 2011090510A1 US 2010046046 W US2010046046 W US 2010046046W WO 2011090510 A1 WO2011090510 A1 WO 2011090510A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
foam
absorbent
textile
mat
Prior art date
Application number
PCT/US2010/046046
Other languages
French (fr)
Inventor
Iain Scorgie
Original Assignee
Mindsinsync Inc.
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
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=43514398&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=WO2011090510(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Mindsinsync Inc. filed Critical Mindsinsync Inc.
Priority to CA2781852A priority Critical patent/CA2781852A1/en
Publication of WO2011090510A1 publication Critical patent/WO2011090510A1/en

Links

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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • 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
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0207—Elastomeric fibres
    • B32B2262/0215—Thermoplastic elastomer fibers
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • 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
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • 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
    • B32B2266/00—Composition of foam
    • B32B2266/06—Open cell foam
    • 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
    • B32B2274/00—Thermoplastic elastomer material
    • 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
    • B32B2307/718—Weight, e.g. weight per square meter
    • 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
    • B32B2307/726—Permeability to liquids, absorption
    • 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
    • B32B2307/732—Dimensional properties
    • 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
    • B32B2451/00—Decorative or ornamental articles
    • 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

Definitions

  • the invention relates generally to a mat and more particularly to a mat having an absorbent surface and a cushioning layer.
  • One aspect of the invention relates to a method of manufacturing a cushioned, absorbent mat comprising, in the following order, providing an absorbent, quick-drying woven textile material in a sheet sized for use as a mat, gluing the absorbent, quick-drying woven textile material to a sheet of viscoelastic polyurethane foam material having an open cell structure, sewing the textile material to the foam material to obtain a sewed textile and foam assembly, and gluing a foam material side of the sewed textile and foam assembly to a sheet of non-slip rubberized base material.
  • a cushioned mat including a layer of absorbent, quick-drying woven textile material, a layer of viscoelastic polyurethane foam material having an open cell structure, the layer of foam material being glued and sewed to the layer of woven textile material to form a textile and foam assembly, and a layer of rubberized base material, glued to a foam material side of the textile and foam assembly.
  • FIG. 1 schematically illustrates a cross-sectional view of a strand used in the manufacture of an absorbent layer of an embodiment of a bath mat in accordance with the current invention
  • FIG. 2 schematically illustrates a cross-sectional view of a plurality of the strands of FIG. 1 used to form the material of an absorbent layer of an embodiment of a bath mat in accordance with the current invention
  • FIG. 3 schematically illustrates a cross-sectional view of a bath mat in accordance with an embodiment of the current invention.
  • FIG. 1 illustrates in schematic cross-section, a yarn 2 of the type used in the invention to form a woven textile material that forms an absorbent layer of the bath mat.
  • the yarn includes a number of strands of fibers 4, which are divided out from a source fiber and then woven together with a plurality of additional fibers, to form the yarn 2.
  • the provision of the yarn allows the strands and hence the material to be absorbent to water 5 and thereby, rather than deflect liquid from the same, liquid is absorbed quickly and hence removes liquid from the other surface onto which the material has been applied and provides a drying effect on the other surface.
  • each fiber 4 has a diameter on the order of a few microns.
  • an appropriate range may be 1 -20 ⁇ and a more particularly useful range may be 5-10 ⁇ .
  • this range may be thought of as being approximately 100 times finer than human hair and typically 100's of fibers will be used to form each piece of yarn. It will therefore be appreciated that each strand is particularly small in cross-sectional area and, each strand is then used, in combination with other strands, to form a woven material as illustrated in FIG. 2.
  • the fibers are microfibers having a linear density of less than about 1 denier/filament.
  • the weaving process to form the material from the yarn includes weaving the yarn together with other strands of yarn to form a woven textile material 6 of the type shown in FIG. 2.
  • the woven material comprises a combination of strands of polyester and polyamide, for example, nylon. In particular, an embodiment includes from 60- 90% polyester by weight with the remainder polyamide.
  • a plurality of yarns 2 are woven together to form a woven textile material 6 that has very good absorbency and drying properties.
  • the fabric is woven into a material having a weight between 200 and 300 g/m 2 , and in a particular embodiment, a material having a weight between about 250 and 275 g/m 2 .
  • such a material may have an absorbency greatly in excess of
  • the woven textile material 6 has a pile height of approximately 0.1-0.175 in., particularly approximately 0.157 in.
  • the woven textile material 6 is glued to a cushioning layer 8 using a glue that is, in an embodiment, selected to both provide a strong bond between the polyurethane and the woven material and be sufficiently flexible to allow for bending of the mat without significant cracking of the glue layer.
  • the glue should allow for moisture to pass from the urethane foam to the woven material without blocking the wicking/drying function of the woven material.
  • the glue may be a sprayable upholstery glue suited for use with foam such as 680S, available from Tai Jia of Guangdong, China.
  • the cushioning layer 8 may be made from a memory foam material, for example a viscoelastic polyurethane foam having an open cell structure. Such material is, in general, absorbent, but slow drying, particularly as compared to the microfiber woven material described above.
  • the cushioning layer may be about 2.5cm in thickness, and may generally be within the range of 1 cm to 5cm. For thinner cushioning layers, an insufficient cushioning function may result, while for thicker layers, the overall mat thickness becomes too great and the user may feel as though he or she is sinking too deep into the mat.
  • the foam density may be approximately 2.8 lbs/ft 3 .
  • absorbency and drying properties of the woven textile material 6 allows for the use of the relatively absorbent and slow-drying polyurethane foam, even in a generally wet/humid environment such as a bathroom.
  • the absorbent woven textile material 6 wicks moisture away from the polyurethane at one side 22, and dries relatively quickly at the other 24.
  • the woven textile material 6 is glued to the cushioning layer 8
  • the two are sewed together for additional strength, and optionally to produce a decorative design on an upper surface 24 of the woven textile material, not shown.
  • the sewed and glued combined mat is then glued to a non-slip rubberized base material 10.
  • the non-slip layer may be made from a polyurethane material including, for example, polyurethane-polyurea based spandex. This assembly is then attached to a border which may be made, for example, from a woven polyester material.
  • the mat may be between about 4 and 8 square feet in area.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Carpets (AREA)
  • Bathtub Accessories (AREA)
  • Laminated Bodies (AREA)
  • Mattresses And Other Support Structures For Chairs And Beds (AREA)

Abstract

A cushioned, absorbent mat includes a layer of absorbent, quick-drying woven textile material, a layer of viscoelastic polyurethane foam material having an open cell structure, the layer of foam material being glued and sewed to the layer of woven textile material to form a textile and foam assembly and a layer of rubberized base material, glued to a foam material side of the textile and foam assembly.

Description

CUSHIONED ABSORBENT MAT
1. Field of the Invention
The invention relates generally to a mat and more particularly to a mat having an absorbent surface and a cushioning layer.
2. Description of the Related Art
In a tiled bathroom, it is common to provide a bath mat that can both offer a slip- resistant, non-tiled surface on which to stand and some absorbent properties to handle inevitable water from sinks, baths or showers. As a result, the inventor has determined that there is a need to provide a comfortable, slip-resistant, and absorbent bath mat that is also quick drying.
SUMMARY OF THE INVENTION
One aspect of the invention relates to a method of manufacturing a cushioned, absorbent mat comprising, in the following order, providing an absorbent, quick-drying woven textile material in a sheet sized for use as a mat, gluing the absorbent, quick-drying woven textile material to a sheet of viscoelastic polyurethane foam material having an open cell structure, sewing the textile material to the foam material to obtain a sewed textile and foam assembly, and gluing a foam material side of the sewed textile and foam assembly to a sheet of non-slip rubberized base material.
Another aspect of the invention relates to a cushioned mat including a layer of absorbent, quick-drying woven textile material, a layer of viscoelastic polyurethane foam material having an open cell structure, the layer of foam material being glued and sewed to the layer of woven textile material to form a textile and foam assembly, and a layer of rubberized base material, glued to a foam material side of the textile and foam assembly.
These and other objects, features, and characteristics of the present invention, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. As used in the specification and in the claims, the singular form of "a", "an", and "the" include plural referents unless the context clearly dictates otherwise.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates a cross-sectional view of a strand used in the manufacture of an absorbent layer of an embodiment of a bath mat in accordance with the current invention;
FIG. 2 schematically illustrates a cross-sectional view of a plurality of the strands of FIG. 1 used to form the material of an absorbent layer of an embodiment of a bath mat in accordance with the current invention; and
FIG. 3 schematically illustrates a cross-sectional view of a bath mat in accordance with an embodiment of the current invention.
DETAILED DESCRIPTION
FIG. 1 , illustrates in schematic cross-section, a yarn 2 of the type used in the invention to form a woven textile material that forms an absorbent layer of the bath mat. The yarn includes a number of strands of fibers 4, which are divided out from a source fiber and then woven together with a plurality of additional fibers, to form the yarn 2. The provision of the yarn allows the strands and hence the material to be absorbent to water 5 and thereby, rather than deflect liquid from the same, liquid is absorbed quickly and hence removes liquid from the other surface onto which the material has been applied and provides a drying effect on the other surface. In an embodiment, each fiber 4 has a diameter on the order of a few microns. For example, an appropriate range may be 1 -20μηι and a more particularly useful range may be 5-10 μηη. By way of comparison, this range may be thought of as being approximately 100 times finer than human hair and typically 100's of fibers will be used to form each piece of yarn. It will therefore be appreciated that each strand is particularly small in cross-sectional area and, each strand is then used, in combination with other strands, to form a woven material as illustrated in FIG. 2. In an embodiment, the fibers are microfibers having a linear density of less than about 1 denier/filament.
The weaving process to form the material from the yarn includes weaving the yarn together with other strands of yarn to form a woven textile material 6 of the type shown in FIG. 2.
In an embodiment, the woven material comprises a combination of strands of polyester and polyamide, for example, nylon. In particular, an embodiment includes from 60- 90% polyester by weight with the remainder polyamide. In order to form a bath mat 20 as illustrated in FIG. 3, a plurality of yarns 2 are woven together to form a woven textile material 6 that has very good absorbency and drying properties. In an embodiment, the fabric is woven into a material having a weight between 200 and 300 g/m2, and in a particular embodiment, a material having a weight between about 250 and 275 g/m2.
In practice, such a material may have an absorbency greatly in excess of
conventional cotton terry or polyester woven materials. Furthermore, it may have drying speeds faster than conventional cotton terry or even 100% polyester materials. In an embodiment, the woven textile material 6 has a pile height of approximately 0.1-0.175 in., particularly approximately 0.157 in.
The woven textile material 6 is glued to a cushioning layer 8 using a glue that is, in an embodiment, selected to both provide a strong bond between the polyurethane and the woven material and be sufficiently flexible to allow for bending of the mat without significant cracking of the glue layer. In a particular embodiment, the glue should allow for moisture to pass from the urethane foam to the woven material without blocking the wicking/drying function of the woven material. In a particular embodiment, the glue may be a sprayable upholstery glue suited for use with foam such as 680S, available from Tai Jia of Guangdong, China.
The cushioning layer 8 may be made from a memory foam material, for example a viscoelastic polyurethane foam having an open cell structure. Such material is, in general, absorbent, but slow drying, particularly as compared to the microfiber woven material described above.
As an example, the cushioning layer may be about 2.5cm in thickness, and may generally be within the range of 1 cm to 5cm. For thinner cushioning layers, an insufficient cushioning function may result, while for thicker layers, the overall mat thickness becomes too great and the user may feel as though he or she is sinking too deep into the mat. In a typical mat, the foam density may be approximately 2.8 lbs/ft3.
The inventor has determined that in the above described combination, the
absorbency and drying properties of the woven textile material 6 allows for the use of the relatively absorbent and slow-drying polyurethane foam, even in a generally wet/humid environment such as a bathroom. In this combination, the absorbent woven textile material 6 wicks moisture away from the polyurethane at one side 22, and dries relatively quickly at the other 24.
Once the woven textile material 6 is glued to the cushioning layer 8, the two are sewed together for additional strength, and optionally to produce a decorative design on an upper surface 24 of the woven textile material, not shown. The sewed and glued combined mat is then glued to a non-slip rubberized base material 10. For example, the non-slip layer may be made from a polyurethane material including, for example, polyurethane-polyurea based spandex. This assembly is then attached to a border which may be made, for example, from a woven polyester material.
In an embodiment, the mat may be between about 4 and 8 square feet in area.
Although the invention has been described in detail for the purpose of illustration based on what is currently considered to be the most practical and preferred embodiments, it is to be understood that such detail is solely for that purpose and that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. For example, it is to be understood that the present invention contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment.

Claims

What is Claimed is:
1. A method of manufacturing a cushioned, absorbent mat comprising, in the following order:
providing an absorbent, quick-drying woven textile material in a sheet sized for use as a mat;
gluing the absorbent, quick-drying woven textile material to a sheet of viscoelastic polyurethane foam material having an open cell structure;
sewing the textile material to the foam material to obtain a sewed textile and foam assembly; and
gluing a foam material side of the sewed textile and foam assembly to a sheet of non- slip rubberized base material.
2. A cushioned, absorbent mat comprising:
a layer of absorbent, quick-drying woven textile material;
a layer of viscoelastic polyurethane foam material having an open cell structure, the layer of foam material being glued and sewed to the layer of woven textile material to form a textile and foam assembly; and
a layer of rubberized base material, glued to a foam material side of the textile and foam assembly.
PCT/US2010/046046 2009-12-28 2010-08-20 Cushioned absorbent mat WO2011090510A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA2781852A CA2781852A1 (en) 2009-12-28 2010-08-20 Cushioned absorbent mat

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US29039809P 2009-12-28 2009-12-28
US61/290,398 2009-12-28

Publications (1)

Publication Number Publication Date
WO2011090510A1 true WO2011090510A1 (en) 2011-07-28

Family

ID=43514398

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2010/046046 WO2011090510A1 (en) 2009-12-28 2010-08-20 Cushioned absorbent mat

Country Status (5)

Country Link
JP (1) JP2011136140A (en)
KR (1) KR20110076739A (en)
CN (2) CN101961201B (en)
CA (1) CA2781852A1 (en)
WO (1) WO2011090510A1 (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
USD747583S1 (en) 2013-10-24 2016-01-12 Schroeder & Tremayne, Inc. Drying mat
US11389024B2 (en) 2019-09-16 2022-07-19 MindsInSync, Inc. Cushioned bath mat

Families Citing this family (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2475979A (en) * 2009-12-04 2011-06-08 Mindsinsync Ltd Mat or cushion
TWI480187B (en) * 2012-03-23 2015-04-11 Formosa Saint Jose Corp Car foot pad construction
KR101674174B1 (en) 2014-04-17 2016-11-08 (주)동우산업 Method for Manufacturing Material of Safety Soundproof Mat for child
CN104260529B (en) * 2014-09-25 2016-06-22 沈阳际华三五四七特种装具有限公司 A kind of sponge ball and preparation method
CN104309236A (en) * 2014-10-10 2015-01-28 浙江芬力针织有限公司 Composite knitted fabric for car seat cushion
CZ31230U1 (en) * 2017-10-25 2017-11-21 Tescoma S.R.O. A two-layer pad for the refrigerator
TWI693909B (en) * 2019-03-27 2020-05-21 簡單綠能股份有限公司 Elastic absorbent floor mat
WO2021220038A1 (en) * 2020-04-30 2021-11-04 Александр ЛЕМИШЕВ Sanitary mat
CN113696585A (en) * 2021-07-09 2021-11-26 牛红武 Sound-insulation anti-skidding volcanic flexible material and preparation method thereof
TWI787011B (en) * 2021-12-23 2022-12-11 陳瑞琪 Cushion (1)

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5599617A (en) * 1995-08-02 1997-02-04 Struckmeyer Corporation Nonslip article support pad
US6223362B1 (en) * 2000-02-05 2001-05-01 Betty Bei Liang Water-absorbing sink apron for bathroom counters
US20030203164A1 (en) * 2002-04-04 2003-10-30 New Pig Corporation Anti-fatigue mat
US20040235382A1 (en) * 2003-05-23 2004-11-25 Carl Freudenberg Kg Mat for the computer input device known as a mouse
US7137157B2 (en) * 2003-07-03 2006-11-21 Susan Nichols Absorbent towel with projections
US20100143645A1 (en) * 2009-09-29 2010-06-10 Schroeder & Tremayne, Inc. Drying mat
US20100143640A1 (en) * 2009-09-29 2010-06-10 Schroeder & Tremayne, Inc. Drying mat

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DK0647111T3 (en) * 1992-06-30 1997-10-13 Tac Fast Systems Sa Carpet Construction
US20020142126A1 (en) * 2000-11-24 2002-10-03 Higgins Kenneth B. Textile product and method
US7601655B2 (en) * 2003-09-27 2009-10-13 Tactix Llc Engineered toweling
US20050112320A1 (en) * 2003-11-20 2005-05-26 Wright Jeffery J. Carpet structure with plastomeric foam backing
US7185604B2 (en) * 2004-04-12 2007-03-06 Debra Leah Holte Orthopedic pet cushion

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5599617A (en) * 1995-08-02 1997-02-04 Struckmeyer Corporation Nonslip article support pad
US6223362B1 (en) * 2000-02-05 2001-05-01 Betty Bei Liang Water-absorbing sink apron for bathroom counters
US20030203164A1 (en) * 2002-04-04 2003-10-30 New Pig Corporation Anti-fatigue mat
US20040235382A1 (en) * 2003-05-23 2004-11-25 Carl Freudenberg Kg Mat for the computer input device known as a mouse
US7137157B2 (en) * 2003-07-03 2006-11-21 Susan Nichols Absorbent towel with projections
US20100143645A1 (en) * 2009-09-29 2010-06-10 Schroeder & Tremayne, Inc. Drying mat
US20100143640A1 (en) * 2009-09-29 2010-06-10 Schroeder & Tremayne, Inc. Drying mat
US20100209661A1 (en) * 2009-09-29 2010-08-19 Schroeder & Tremayne, Inc. Drying mat

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
USD747583S1 (en) 2013-10-24 2016-01-12 Schroeder & Tremayne, Inc. Drying mat
US11389024B2 (en) 2019-09-16 2022-07-19 MindsInSync, Inc. Cushioned bath mat

Also Published As

Publication number Publication date
JP2011136140A (en) 2011-07-14
CN201900762U (en) 2011-07-20
CA2781852A1 (en) 2011-07-28
KR20110076739A (en) 2011-07-06
CN101961201B (en) 2016-01-20
CN101961201A (en) 2011-02-02

Similar Documents

Publication Publication Date Title
WO2011090510A1 (en) Cushioned absorbent mat
US20120213962A1 (en) Cushioned absorbent mat
US20140141198A1 (en) Cushioned mat with apertured foam
US7601655B2 (en) Engineered toweling
DK2778117T3 (en) Multilayer covering material and method for manufacturing multilayer cladding material for articles that make furniture more comfortable comprising upholstery, pillows, blankets and similar articles
EP2839064B1 (en) Fabric-faced floor coverings with micro-spring face structures
JP4805408B1 (en) Three-layer laminate fabric
US9873963B2 (en) Spacer mesh mat base
US20130065043A1 (en) Cushioned foam mat with porous backing
JP2019052391A (en) Composite fabric
AU2012100007A4 (en) Mat
JP6207717B2 (en) Nubuck-like sheet and method for producing the same
KR101873354B1 (en) Synthetic leather for seat and preperation method of the same
AU2011101252A4 (en) Cushioned absorbent mat
US11389024B2 (en) Cushioned bath mat
JP7444484B2 (en) tatami
EP3288754B1 (en) A fabric article
KR101296821B1 (en) Moisture-permeable and water-proof fabric for fall-winter wear, and process for producing the same
JP2007253570A (en) Flooring decorative sheet and its manufacturing method
AU2011100650A4 (en) An Improved Towel
PL226186B1 (en) Elastic mat and method for producing elastic mat
CN107772949A (en) Stop cloth material, its preparation method and the bedding wrap comprising the cloth material of anaphylactogen
JP2014073206A (en) Rush-mat rug

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 10844131

Country of ref document: EP

Kind code of ref document: A1

ENP Entry into the national phase

Ref document number: 2781852

Country of ref document: CA

NENP Non-entry into the national phase

Ref country code: DE

WPC Withdrawal of priority claims after completion of the technical preparations for international publication

Ref document number: 61/290,398

Country of ref document: US

Date of ref document: 20120608

Free format text: WITHDRAWN AFTER TECHNICAL PREPARATION FINISHED

122 Ep: pct application non-entry in european phase

Ref document number: 10844131

Country of ref document: EP

Kind code of ref document: A1