WO2015140558A1 - Flooring - Google Patents
Flooring Download PDFInfo
- Publication number
- WO2015140558A1 WO2015140558A1 PCT/GB2015/050806 GB2015050806W WO2015140558A1 WO 2015140558 A1 WO2015140558 A1 WO 2015140558A1 GB 2015050806 W GB2015050806 W GB 2015050806W WO 2015140558 A1 WO2015140558 A1 WO 2015140558A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- contamination control
- layer
- core layer
- control mat
- mat according
- Prior art date
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Classifications
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- 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
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/18—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with two layers of different macromolecular materials
- D06N3/186—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with two layers of different macromolecular materials one of the layers is on one surface of the fibrous web and the other layer is on the other surface of the fibrous web
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- 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
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- 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
- A47G27/0206—Carpets; Stair runners; Bedside rugs; Foot mats to protect the underlying surface, e.g. temporary covers, disposable carpets, absorbent pads, wheelchair pads, hearth rugs
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- 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
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- 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
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
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- 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
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- 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
- B32B27/22—Layered products comprising a layer of synthetic resin characterised by the use of special additives using plasticisers
-
- 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
- B32B5/022—Non-woven fabric
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- 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
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
- D06N3/0011—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using non-woven fabrics
-
- 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
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
- D06N3/0059—Organic ingredients with special effects, e.g. oil- or water-repellent, antimicrobial, flame-resistant, magnetic, bactericidal, odour-influencing agents; perfumes
-
- 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
- D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
- D06N7/0039—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by the physical or chemical aspects of the layers
- D06N7/0044—Sealing or barrier layers, e.g. against solvents, asphalt, plasticisers
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- 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
- D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
- D06N7/006—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by the textile substrate as base web
-
- 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
- B32B2255/00—Coating on the layer surface
- B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
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- 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
- B32B2255/00—Coating on the layer surface
- B32B2255/26—Polymeric coating
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- 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
- B32B2270/00—Resin or rubber layer containing a blend of at least two different polymers
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- 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
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/402—Coloured
- B32B2307/4023—Coloured on the layer surface, e.g. ink
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- 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
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/402—Coloured
- B32B2307/4026—Coloured within the layer by addition of a colorant, e.g. pigments, dyes
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- 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
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/412—Transparent
-
- 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
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/414—Translucent
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- 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
- B32B2307/714—Inert, i.e. inert to chemical degradation, corrosion
- B32B2307/7145—Rot proof, resistant to bacteria, mildew, mould, fungi
-
- 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
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/75—Printability
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- 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
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- 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
- D06N2209/00—Properties of the materials
- D06N2209/08—Properties of the materials having optical properties
- D06N2209/0861—Transparent
-
- 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
- D06N2209/00—Properties of the materials
- D06N2209/16—Properties of the materials having other properties
- D06N2209/1671—Resistance to bacteria, mildew, mould, fungi
-
- 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
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- 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
- D06N2211/08—Cleaning articles
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- 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
- D06N2213/066—Characteristics of the backing in carpets, rugs, synthetic lawn having an adhesive on the undersurface to allow removal of the whole carpet, rug or synthetic lawn from the floor, e.g. pressure sensitive adhesive
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- 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
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
- D06N3/0063—Inorganic compounding ingredients, e.g. metals, carbon fibres, Na2CO3, metal layers; Post-treatment with inorganic compounds
Definitions
- This invention relates to the field of flooring.
- the invention relates to flooring for use in contamination control situations.
- Maintaining a controlled environment is essential in many academic, industrial and medical settings, and controlling contamination entering that environment is very important.
- a controlled environment which may be referred to as a cleanroom.
- Precautions are taken such as subjecting cleanroom staff to strict clothing regulations and using a gowning room where the staff can change clothes under "controlled" conditions so as to prevent any particulates from entering from the outside environment.
- Certain areas in a cleanroom may have more stringent measures than others, with packaging areas, corridors, gowning rooms and transfer hatches being incorporated to maintain strict contamination control measures.
- Contaminants are particles that enter an environment where they may potentially have a negative effect. There are many types of contaminants and they can have a wide variety of effects on different environments. Contaminants can be bacteria or other organisms that are potentially harmful to their surroundings. More familiar contaminants can be things such as dust and dirt. Contaminants can be carried on any surface entering a controlled environment, or in the air. Particles can be suspended in the air for hours where they undergo rapid proliferation, contaminating the surrounding environment. Once there is no movement and turbulence stops, airborne contaminants fall. If they fall onto an unprotected floor they may rise again and be redistributed into the air as a result of the vortices created by the movement of personnel and wheeled traffic.
- polymeric matting One type of flooring, known as polymeric matting, is particularly effective in certain situations in controlling particulate contamination. It is semipermanently installed and can be cleaned as required. Dycem's Protectamat flooring system is an example of this.
- the polymeric matting comprises a single layer of polymer, usually a specially blended polymer formulation comprising polyester plasticisers. This is typically at least 7mm thick, making it heavy to manoeuvre. As noted above, this is a semi-permanent or permanent solution, in that the polymeric matting is particularly long-lasting and can be used for 3-5 years before replacement. This works very well when long term contamination control is required and the operator has sufficient resources to invest in such a system. However, it is less suitable for a situation where contamination control flooring is needed for a short period or at a low cost, for example, a testing laboratory, where testing is going on for a few days or for a few weeks.
- “Peel off mats” also known as adhesive floor mats or tacky mats, are also used in contamination control situations particularly where the need for contamination control is short lived, or there is not enough resource to fund installation of permanent contamination control flooring.
- These mats comprise a laminate of thin (0.1 to 0.2 mm) synthetic material layers, typically thirty layers, which are stuck together by a pressure sensitive adhesive to form a mat which is several millimetres thick. The mat is then placed on a floor to capture contaminants, for example, from feet or the wheels of trolleys. In use, the upper layer of a mat is removed from the base on a regular basis, exposing a new clean layer.
- peel off mats have several disadvantages. Firstly, and most importantly, the peel off mats do not work very well in comparison to polymeric matting. The surface tack is not as good as polymeric matting and does not retain nearly as many contaminants. Second, adhesive can be removed from the uppermost layer to adjacent floor surfaces by feet and wheels which can itself attract contaminants, meaning that peel off mats can be counterproductive by actually encouraging contaminants into the controlled area. Third, when an upper layer is removed from the mat it creates a considerable volume of waste which is difficult to recycle. Fourth, when removing an upper layer, contaminate particles can be released which may be hazardous to a user who may breath them in.
- a contamination control mat comprising a core layer which is a non-woven substrate, wherein the core layer is coated on one surface with a contamination control polymeric top layer, and coated on the opposing surface with a polymeric backing layer.
- the top layer is uppermost and attracts, and at least substantially retains, contaminants.
- Contamination control mats in accordance with the invention with a three-layer structure having a non-woven substrate as a core layer, a contamination control polymeric coating as the top layer, and a polymeric coating as the backing layer, have several advantages over known contamination control mats. Falling between polymeric matting and peel off mats they are, in particular, inexpensive and easy to fit, requiring low capital investment by the user. The contamination control mats may be easily movable, allowing maximum flexibility for users in contamination control situations.
- the flexibility and light weight of the mats according to the present invention is achievable because of the new three-layered structure (Tri-Layer Technology), which is in contrast to the peel off mats, and to the traditional polymeric mats which contain a single polymer material all the way through.
- Tri-Layer Technology Tri-Layer Technology
- using a non-woven substrate core layer gives rigidity and cross dimensional stability to the mat which means that a much thinner product can be used than when using polymers alone.
- a further advantage of using a non-woven substrate as the core layer is that it can be printed as described below, to allow for a pattern to be visible to the user.
- the contamination control mat may not need cleaning, before replacement, on a regular, say weekly, basis. Additionally, the contamination control mat is unlikely to be deployed in the wrong orientation because the two outer surfaces, i.e. the top layer, and the backing layer can be visibly different to a user.
- the present invention provides a mat which is better suited to short term contamination control than existing polymeric products, and is much more effective in controlling contamination than peel off disposable mat products.
- the top layer provides the contamination control properties to the mat.
- contamination control polymeric top layer we mean that this layer must be made from a material that attracts, and at least substantially retains, contaminants.
- the top layer is preferably formed from a blended polymer comprising polyester plasticisers. Suitable materials are known to those skilled in the art. Suitable materials are described in WO2006/1 14599, GB1399191 , GB1475366, GB2025319, and GB2144139. Permanent versions of the contamination control floor coverings are available from Dycem, under the "CleanZone" and "WorkZone” trade names. The same materials can be used in the polymeric layer of the present invention, but in a much thinner layer than in the permanent version, and in combination with the non-woven substrate.
- the top layer may be dyed, and can be translucent, transparent, or solid in colour, but is preferably translucent or transparent. This is advantageous, as it allows any printing on the non-woven substrate to be visible from the surface.
- the contamination control mat may have antimicrobial properties.
- the top layer may include an antimicrobial ingredient.
- a preferred antimicrobial ingredient is silver ions which inhibit the growth of microorganisms, preferably derived from silver nitrate.
- the backing layer is a polymeric coating on the non- woven substrate. It can also be a blended polymeric formulation comprising polyester plasticisers. It may be the same as, or different from, the top layer in composition. In a preferred embodiment, the backing layer looks different from the top layer, so that consumers do not use the backing layer to try to provide contamination control.
- the backing layer preferably has non-slip properties, for example may be textured.
- the backing layer often has a black appearance, which can be through the polymer coating on the non-woven substrate being black in colour, or having an additional coating which is black.
- the top layer and backing layer are added onto the core layers as coatings on opposing surfaces of the core layer. Where they are coated directly onto the core layer, they can impregnate the non-woven substrate and encapsulate the core layer. This is preferable. Alternatively, there may be one or more other layers between the core layer and the top and/or backing layers. In this case the top and/or backing layers are coated onto the core layer indirectly, on top of any other layers that are present.
- the core layer is advantageous in that it adds rigidity and cross-dimensional stability to the mat.
- the core layer is formed from a non- woven substrate such as a fabric, for example, non-woven spun bond polyester. This is typically the type of material that is used in cleaning products, where cross-dimensional strength is important.
- the non-woven substrate is typically 0.5 to 3mm, preferably 1 to 2mm thick.
- the material of the core layer is preferably printed before the contamination control mat is formed.
- the outer edges of the core layer can be printed with a set pattern.
- the substrate is light in colour, often white, and the printed areas are darker. In this way, the printed area is relatively dark compared to the centre of the core layer, thus visually defining a border around the core layer.
- the print on the core layer is visible through the top layer.
- the backing layer is usually solid in colour, so the print on the core layer is not visible through the backing layer.
- the backing layer is typically a darker colour than the core layer and/or the top layer.
- the backing layer is often black.
- Further layers may be interposed between the top layer and core layer, and/or between the core layer and backing layer.
- the core layer is white
- an additional white polymeric layer may be interposed between the core layer and the backing layer which can, for example, be black.
- a contamination control mat in accordance with the invention will be relatively thin compared to conventional polymeric contamination control mats, preferably 0.5 to 3mm thick, more preferably 1 to 2 mm thick, most preferably, contamination control mats in accordance with the invention are about 1 .2 mm thick. This is substantially thinner than previous contamination control flooring.
- the use of the non-woven substrate core layer allows for the product to be this thin.
- the top and backing layers are very thin, with the core layer typically making up the majority (more than 50%) of the thickness of the mat.
- the contamination control mat includes or is supplied with means for indicating the length of use of the mat.
- the contamination control mat may include an area, preferably a strip, on which can be indicated the date of first deployment of the contamination control mat, or may include an indicator that changes with time and/or use.
- a separate indicator can be supplied, that can be displayed close to the mat, for example a chart on a piece of paper or card, which can be pinned to a wall adjacent the mat.
- a method of contamination control comprising deploying a contamination control mat in accordance with the first aspect of the invention in an environment where contamination is to be controlled, such that the top layer is uppermost.
- the contamination control mat may have double sided adhesive applied to the perimeter of the backing layer to allow it to be adhered to surfaces such as vinyl or a smooth epoxy resin.
- the top layer may be cleaned on an occasional basis, with water and a gentle surfactant product.
- the backing layer is preferably solid in colour, meaning that it is not transparent or translucent. This means that any print on the core layer would not be visible through the backing layer.
- the backing layer is often black.
- a contamination control mat is made by providing a) non-woven substrate as a core layer, b) coating one surface of the core layer with a contamination control polymeric material to provide a top layer, and c) coating the opposing surface of the core layer with a polymeric backing layer.
- the top layer is translucent or transparent and the core layer is printed, so that the print on the core layer is visible to the user through the top layer, whereas the backing layer is preferably solid in colour, so that the print on the core layer is not visible through the backing layer.
- the mat 10 comprises a top layer 12, a backing layer 14 and a core layer 16 which is coated on opposing surfaces by the top layer 12 and the backing layer 14.
- the top layer 12 is formed from a blend of polymers comprising polyester plasticisers.
- the top layer is tinted blue, and is substantially translucent so that the core layer 16 is visible to a user.
- An area 13 is provided on the upper surface of the top layer 12 for a user to mark the date of first deployment of the contamination control mat.
- an indicator can be a separate item, which can be mounted on an adjacent wall, such as a sheet of paper specifically designed to allow use of the mat to be monitored.
- the backing layer 14 is formed from black polymeric material and has surface adhesive qualities to allow a temporary bond to the subfloor.
- the core layer 16 is formed from a nonwoven substrate which is a spun bond polyester of the type used in cleaning products where cross-dimensional strength is important. In this embodiment the core layer is white.
- a black awareness border 17 is printed around the perimeter of the core layer 16 and is visible to a user through the top layer 12. The awareness border 17 visually defines the periphery of the mat to a user.
- the top layer 12, the backing layer 14 and the core layer 16 are thermally bonded together.
- the contamination control mat 10 is deployed in an environment where contamination is to be controlled.
- the contamination control mat 10 is deployed with the backing layer 14 lowermost and the top layer 12 uppermost.
- the contamination control mat may be changed on a regular basis. For example weekly.
- the contamination control mat may be cleaned, for example with water and a cleaning product.
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Abstract
A contamination control mat (10) comprising a core layer (16) which is a non-woven substrate, wherein the core layer (16) is coated on one surface with a contamination control polymeric top layer (12), and coated on the opposing surface with a polymeric backing layer (14) wherein the core layer (16) is printed, the top layer(12) is translucent or transparent, and the print on the core layer (16) is visible through the top layer (12). The contamination control mat (10) is, in particular, for use as flooring in contamination control situations.
Description
Flooring
Field of the Invention
This invention relates to the field of flooring. In particular, the invention relates to flooring for use in contamination control situations.
Background to the Invention
Maintaining a controlled environment is essential in many academic, industrial and medical settings, and controlling contamination entering that environment is very important. For example, many hospitals, factories, food preparation areas, spray-paint booths and laboratories utilise a controlled environment, which may be referred to as a cleanroom. Precautions are taken such as subjecting cleanroom staff to strict clothing regulations and using a gowning room where the staff can change clothes under "controlled" conditions so as to prevent any particulates from entering from the outside environment. Certain areas in a cleanroom may have more stringent measures than others, with packaging areas, corridors, gowning rooms and transfer hatches being incorporated to maintain strict contamination control measures.
In hospitals, cleanroom precautions can be used to try to reduce the incidence of infectious diseases spreading. In industry, particularly in the pharmaceutical, electronics, aerospace, catering, automotive, biomedical, IT, nuclear, optical and medical devices industries, it is often essential to ensure that the products are free from contamination. Contamination of a controlled environment poses a threat to product processes, the consequences of which are lower product yields, raised costs and decreased profits.
Contaminants are particles that enter an environment where they may potentially have a negative effect. There are many types of contaminants and they can have a wide variety of effects on different environments. Contaminants can be bacteria or other organisms that are potentially harmful to their surroundings. More familiar contaminants can be things such as dust and dirt.
Contaminants can be carried on any surface entering a controlled environment, or in the air. Particles can be suspended in the air for hours where they undergo rapid proliferation, contaminating the surrounding environment. Once there is no movement and turbulence stops, airborne contaminants fall. If they fall onto an unprotected floor they may rise again and be redistributed into the air as a result of the vortices created by the movement of personnel and wheeled traffic.
Studies have shown that over 80% of contamination enters a controlled environment through entrances and exits, mostly at or near floor level. As a result of this, attempts have been made to reduce the contamination entering a controlled environment by using particular floor coverings.
It is known to use particular floor coverings in entry and exit areas to controlled environments to attract, collect and retain foot and wheel borne contaminants, thereby reducing the contamination entering the controlled environment.
One type of flooring, known as polymeric matting, is particularly effective in certain situations in controlling particulate contamination. It is semipermanently installed and can be cleaned as required. Dycem's Protectamat flooring system is an example of this. The polymeric matting comprises a single layer of polymer, usually a specially blended polymer formulation comprising polyester plasticisers. This is typically at least 7mm thick, making it heavy to manoeuvre. As noted above, this is a semi-permanent or permanent solution, in that the polymeric matting is particularly long-lasting and can be used for 3-5 years before replacement. This works very well when long term contamination control is required and the operator has sufficient resources to invest in such a system. However, it is less suitable for a situation where contamination control flooring is needed for a short period or at a low cost, for example, a testing laboratory, where testing is going on for a few days or for a few weeks.
"Peel off mats, also known as adhesive floor mats or tacky mats, are also used in contamination control situations particularly where the need for contamination control is short lived, or there is not enough resource to fund installation of
permanent contamination control flooring. These mats comprise a laminate of thin (0.1 to 0.2 mm) synthetic material layers, typically thirty layers, which are stuck together by a pressure sensitive adhesive to form a mat which is several millimetres thick. The mat is then placed on a floor to capture contaminants, for example, from feet or the wheels of trolleys. In use, the upper layer of a mat is removed from the base on a regular basis, exposing a new clean layer.
These "peel off mats have several disadvantages. Firstly, and most importantly, the peel off mats do not work very well in comparison to polymeric matting. The surface tack is not as good as polymeric matting and does not retain nearly as many contaminants. Second, adhesive can be removed from the uppermost layer to adjacent floor surfaces by feet and wheels which can itself attract contaminants, meaning that peel off mats can be counterproductive by actually encouraging contaminants into the controlled area. Third, when an upper layer is removed from the mat it creates a considerable volume of waste which is difficult to recycle. Fourth, when removing an upper layer, contaminate particles can be released which may be hazardous to a user who may breath them in.
It is an object of the invention to overcome, or at least to mitigate, the disadvantages of prior art products.
Summary of the Invention
According to one aspect of the invention there is provided a contamination control mat comprising a core layer which is a non-woven substrate, wherein the core layer is coated on one surface with a contamination control polymeric top layer, and coated on the opposing surface with a polymeric backing layer. In use, the top layer is uppermost and attracts, and at least substantially retains, contaminants.
Contamination control mats in accordance with the invention, with a three-layer structure having a non-woven substrate as a core layer, a contamination control polymeric coating as the top layer, and a polymeric coating as the backing layer, have several advantages over known contamination control mats. Falling
between polymeric matting and peel off mats they are, in particular, inexpensive and easy to fit, requiring low capital investment by the user. The contamination control mats may be easily movable, allowing maximum flexibility for users in contamination control situations.
The flexibility and light weight of the mats according to the present invention is achievable because of the new three-layered structure (Tri-Layer Technology), which is in contrast to the peel off mats, and to the traditional polymeric mats which contain a single polymer material all the way through. In particular, using a non-woven substrate core layer gives rigidity and cross dimensional stability to the mat which means that a much thinner product can be used than when using polymers alone.
A further advantage of using a non-woven substrate as the core layer, is that it can be printed as described below, to allow for a pattern to be visible to the user.
The contamination control mat may not need cleaning, before replacement, on a regular, say weekly, basis. Additionally, the contamination control mat is unlikely to be deployed in the wrong orientation because the two outer surfaces, i.e. the top layer, and the backing layer can be visibly different to a user.
Accordingly, the present invention provides a mat which is better suited to short term contamination control than existing polymeric products, and is much more effective in controlling contamination than peel off disposable mat products.
The top layer provides the contamination control properties to the mat. By contamination control polymeric top layer, we mean that this layer must be made from a material that attracts, and at least substantially retains, contaminants. The top layer is preferably formed from a blended polymer comprising polyester plasticisers. Suitable materials are known to those skilled in the art. Suitable materials are described in WO2006/1 14599, GB1399191 , GB1475366, GB2025319, and GB2144139. Permanent versions of the contamination control floor coverings are available from Dycem, under the "CleanZone" and "WorkZone" trade names. The same materials can be used
in the polymeric layer of the present invention, but in a much thinner layer than in the permanent version, and in combination with the non-woven substrate.
The top layer may be dyed, and can be translucent, transparent, or solid in colour, but is preferably translucent or transparent. This is advantageous, as it allows any printing on the non-woven substrate to be visible from the surface.
The contamination control mat may have antimicrobial properties. For example, the top layer may include an antimicrobial ingredient. A preferred antimicrobial ingredient is silver ions which inhibit the growth of microorganisms, preferably derived from silver nitrate.
Similar to the top layer, the backing layer is a polymeric coating on the non- woven substrate. It can also be a blended polymeric formulation comprising polyester plasticisers. It may be the same as, or different from, the top layer in composition. In a preferred embodiment, the backing layer looks different from the top layer, so that consumers do not use the backing layer to try to provide contamination control. The backing layer preferably has non-slip properties, for example may be textured. The backing layer often has a black appearance, which can be through the polymer coating on the non-woven substrate being black in colour, or having an additional coating which is black.
The top layer and backing layer are added onto the core layers as coatings on opposing surfaces of the core layer. Where they are coated directly onto the core layer, they can impregnate the non-woven substrate and encapsulate the core layer. This is preferable. Alternatively, there may be one or more other layers between the core layer and the top and/or backing layers. In this case the top and/or backing layers are coated onto the core layer indirectly, on top of any other layers that are present.
As mentioned above, the core layer is advantageous in that it adds rigidity and cross-dimensional stability to the mat. The core layer is formed from a non- woven substrate such as a fabric, for example, non-woven spun bond polyester. This is typically the type of material that is used in cleaning products, where
cross-dimensional strength is important. The non-woven substrate is typically 0.5 to 3mm, preferably 1 to 2mm thick.
The material of the core layer is preferably printed before the contamination control mat is formed. For example, the outer edges of the core layer can be printed with a set pattern. Usually the substrate is light in colour, often white, and the printed areas are darker. In this way, the printed area is relatively dark compared to the centre of the core layer, thus visually defining a border around the core layer. In a preferred embodiment, the print on the core layer is visible through the top layer. In contrast, the backing layer is usually solid in colour, so the print on the core layer is not visible through the backing layer. The backing layer is typically a darker colour than the core layer and/or the top layer. The backing layer is often black.
Further layers may be interposed between the top layer and core layer, and/or between the core layer and backing layer. For example, where the core layer is white, an additional white polymeric layer may be interposed between the core layer and the backing layer which can, for example, be black.
Typically, a contamination control mat in accordance with the invention will be relatively thin compared to conventional polymeric contamination control mats, preferably 0.5 to 3mm thick, more preferably 1 to 2 mm thick, most preferably, contamination control mats in accordance with the invention are about 1 .2 mm thick. This is substantially thinner than previous contamination control flooring. The use of the non-woven substrate core layer allows for the product to be this thin. The top and backing layers are very thin, with the core layer typically making up the majority (more than 50%) of the thickness of the mat.
In a preferred embodiment, the contamination control mat includes or is supplied with means for indicating the length of use of the mat. For example, the contamination control mat may include an area, preferably a strip, on which can be indicated the date of first deployment of the contamination control mat, or may include an indicator that changes with time and/or use. Alternatively, a
separate indicator can be supplied, that can be displayed close to the mat, for example a chart on a piece of paper or card, which can be pinned to a wall adjacent the mat.
According to another aspect of the invention there is provided a method of contamination control, the method comprising deploying a contamination control mat in accordance with the first aspect of the invention in an environment where contamination is to be controlled, such that the top layer is uppermost.
The contamination control mat may have double sided adhesive applied to the perimeter of the backing layer to allow it to be adhered to surfaces such as vinyl or a smooth epoxy resin.
The top layer may be cleaned on an occasional basis, with water and a gentle surfactant product.
In contrast to the top layer, the backing layer is preferably solid in colour, meaning that it is not transparent or translucent. This means that any print on the core layer would not be visible through the backing layer. The backing layer is often black.
According to a third aspect of the invention, a contamination control mat is made by providing a) non-woven substrate as a core layer, b) coating one surface of the core layer with a contamination control polymeric material to provide a top layer, and c) coating the opposing surface of the core layer with a polymeric backing layer.
The top layer is translucent or transparent and the core layer is printed, so that the print on the core layer is visible to the user through the top layer, whereas the backing layer is preferably solid in colour, so that the print on the core layer is not visible through the backing layer.
Brief Description of the Drawings
Contamination control mats in accordance with the invention will now be described, by way of example only, with reference to the accompanying drawing, Figure 1 , which is a cross-section through a mat in accordance with the invention.
Description
The mat 10 comprises a top layer 12, a backing layer 14 and a core layer 16 which is coated on opposing surfaces by the top layer 12 and the backing layer 14.
The top layer 12 is formed from a blend of polymers comprising polyester plasticisers. The top layer is tinted blue, and is substantially translucent so that the core layer 16 is visible to a user. An area 13 is provided on the upper surface of the top layer 12 for a user to mark the date of first deployment of the contamination control mat. Alternatively, an indicator can be a separate item, which can be mounted on an adjacent wall, such as a sheet of paper specifically designed to allow use of the mat to be monitored.
The backing layer 14 is formed from black polymeric material and has surface adhesive qualities to allow a temporary bond to the subfloor.
The core layer 16 is formed from a nonwoven substrate which is a spun bond polyester of the type used in cleaning products where cross-dimensional strength is important. In this embodiment the core layer is white. A black awareness border 17 is printed around the perimeter of the core layer 16 and is visible to a user through the top layer 12. The awareness border 17 visually defines the periphery of the mat to a user.
The top layer 12, the backing layer 14 and the core layer 16 are thermally bonded together.
In use, the contamination control mat 10 is deployed in an environment where contamination is to be controlled. The contamination control mat 10, is deployed with the backing layer 14 lowermost and the top layer 12 uppermost. Typically, the contamination control mat may be changed on a regular basis. For example weekly. The contamination control mat may be cleaned, for example with water and a cleaning product.
Claims
1 . A contamination control mat comprising a core layer which is a non-woven substrate, wherein the core layer is coated on one surface with a contamination control polymeric top layer, and coated on the opposing surface with a polymeric backing layer.
2. A contamination control mat according to claim 1 , which is 0.5 to 3mm thick.
3. A contamination control mat according to claim 2, which is 1 to 2mm thick, preferably about 1 .2mm thick.
4. A contamination control mat according to any preceding claim, in which the top layer is formed from a blended polymer comprising polyester plasticisers.
5. A contamination control mat according to any preceding claim, in which the top layer is translucent or transparent in colour.
6. A contamination control mat according to any preceding claim, which has antimicrobial properties.
7. A contamination control mat according to claim 6, in which the top layer includes at least one antimicrobial ingredient.
8. A contamination control mat according to claim 7, in which the antimicrobial ingredient is silver nitrate.
9. A contamination control mat according to any preceding claim, in which the backing layer has nonslip properties.
10. A contamination control mat according to any preceding claim, in which the backing layer is solid in colour, preferably wherein the backing layer is black.
1 1 . A contamination control mat according to any preceding claim, in which the core layer is printed, preferably wherein the core layer is printed with a border around the edges.
12. A contamination control mat according to any preceding claim, in which the core layer is visible to a user through the top layer.
13. A contamination control mat according to any preceding claim, including at least one further layer interposed between the top layer and core layer.
14. A contamination control mat according to any preceding claim, including at least one further layer interposed between the core layer and backing layer.
15. A method of contamination control, the method comprising deploying a contamination control mat in accordance with any of claims 1 to 14 in an environment where contamination is to be controlled, such that the top layer is uppermost.
16. A method of contamination control according to claim 16, in which the contamination control mat is stuck down using a double sided adhesive.
17. A method of making a contamination control mat according to any of claim 1 to 14, the method comprising the steps of providing a) non-woven substrate as a core layer, b) coating one surface of the core layer with a contamination control polymeric material to provide a top layer, and c) coating the opposing surface of the core layer with a polymeric backing layer.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB1404988.6A GB2524306B (en) | 2014-03-20 | 2014-03-20 | Contamination control mat |
GB1404988.6 | 2014-03-20 |
Publications (1)
Publication Number | Publication Date |
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WO2015140558A1 true WO2015140558A1 (en) | 2015-09-24 |
Family
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/GB2015/050806 WO2015140558A1 (en) | 2014-03-20 | 2015-03-19 | Flooring |
Country Status (2)
Country | Link |
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GB (1) | GB2524306B (en) |
WO (1) | WO2015140558A1 (en) |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
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BE1026249B1 (en) * | 2018-10-04 | 2019-12-02 | C Rm Ind Bvba | FLOOR COVERING AND RELATED METHOD |
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JPS60234629A (en) * | 1984-05-07 | 1985-11-21 | ダスキンフランチヤイズ株式会社 | Stickiness treated mat |
EP0188005A2 (en) * | 1985-01-07 | 1986-07-23 | Kimberly-Clark Corporation | Absorbent floor mat |
US20060286334A1 (en) * | 2005-06-17 | 2006-12-21 | Batam, Llc | Absorbent non-woven mat having perforations or scoring |
US20070048356A1 (en) * | 2005-08-31 | 2007-03-01 | Schorr Phillip A | Antimicrobial treatment of nonwoven materials for infection control |
EP1793032A1 (en) * | 2004-08-25 | 2007-06-06 | Takiron Co., Ltd. | Flooring material |
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GB2025319B (en) * | 1978-06-19 | 1982-06-30 | Dycem Ltd | Composite sheet material |
US4324824A (en) * | 1978-08-24 | 1982-04-13 | The Akro Corporation | Tufted pile floor covering with piling of coated fibrous material |
GB0130607D0 (en) * | 2001-12-21 | 2002-02-06 | Millikem Ind Limiyed | Printed or printable mat |
MX2011009424A (en) * | 2010-09-14 | 2012-03-22 | 3M Innovative Properties Co | Floor mat article. |
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2014
- 2014-03-20 GB GB1404988.6A patent/GB2524306B/en active Active
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2015
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JPS60234629A (en) * | 1984-05-07 | 1985-11-21 | ダスキンフランチヤイズ株式会社 | Stickiness treated mat |
EP0188005A2 (en) * | 1985-01-07 | 1986-07-23 | Kimberly-Clark Corporation | Absorbent floor mat |
EP1793032A1 (en) * | 2004-08-25 | 2007-06-06 | Takiron Co., Ltd. | Flooring material |
US20060286334A1 (en) * | 2005-06-17 | 2006-12-21 | Batam, Llc | Absorbent non-woven mat having perforations or scoring |
US20070048356A1 (en) * | 2005-08-31 | 2007-03-01 | Schorr Phillip A | Antimicrobial treatment of nonwoven materials for infection control |
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Also Published As
Publication number | Publication date |
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GB2524306B (en) | 2016-03-16 |
GB201404988D0 (en) | 2014-05-07 |
GB2524306A (en) | 2015-09-23 |
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