WO2016144851A1

WO2016144851A1 - Improved floor mats

Info

Publication number: WO2016144851A1
Application number: PCT/US2016/021133
Authority: WO
Inventors: Chia-Hung Lin; Shih Wei Chen; Shih-Ying Huang
Original assignee: 3M Innovative Properties Company
Priority date: 2015-03-09
Filing date: 2016-03-07
Publication date: 2016-09-15
Also published as: KR20170126951A; TW201637865A

Abstract

The present disclosure relates generally to multilayer articles for potential use as floor mats and to methods of making the same. In some embodiments, the multilayer articles include a first layer including a closed cell foam; a second layer directly adjacent to the first layer and including an open cell foam, and a third layer directly adjacent to the second layer and including a closed cell foam.

Description

IMPROVED FLOOR MATS

Technical Field

[0001] The present disclosure relates generally to multilayer articles for potential use as floor mats and methods of making the same. The present disclosure relates generally to articles including two closed cell foam layers between which is an open cell foam layer and methods of making the same.

Background

[0002] Many conventional floor mats require some degree of water resistance. For example, floor mats for use in gyms, exercise centers, or kitchens are repeatedly exposed to liquid substances. Floor mats used in these locations often include closed cell foams which prevent water or air from passing through the floor mat. Some exemplary such floor mats include 100% closed cell foam either in a single or multiple layers. Chinese Publication No. 202237005, for example, describes such a floor mat.

[0003] Other conventional floor mats require some degree of sound proofing. In Chinese Publication No. 103774833, a floor mat having excellent sound proofing is achieved by arranging a closed cell foam layer directly adjacent to an open cell foam layer.

[0004] Other conventional floor mats include a layer of open cell polyurethane with a foam or film on either side thereof. Patent Publication No. TW M 275955, for example, describes such a floor mat.

Summary

[0005] The inventors of the present disclosure recognized that conventional floor mats exhibit inadequate compression deformation resistance and/or shock absorption. The inventors of the present disclosure recognized that at least one of compression deformation resistance and/or shock absorption in floor mats could be improved while maintaining at least one of water resistance and/or sound resistance.

[0006] The inventors of the present disclosure recognized that at least one of these features could be improved in some floor mat embodiments by positioning a layer of closed cell foam on either side of a layer of open cell foam. The resulting floor mat exhibits excellent shock absorption (due to the presence of the open cell foam) as well as water resistance (due to the presence of close cell foam on either side of the open cell foam). The inventors recognized that these embodiments would have applicability in all floor mats, and especially in safety floor mats for children.

[0007] In some embodiments, the present disclosure relates to a floor mat, comprising: a first layer including a closed cell foam; a second layer including an open cell foam; and a third layer including a closed cell foam; wherein the first layer is directly adjacent to the second layer, and wherein the second layer is directly adjacent to the third layer. [0008] In some embodiments, at least one of the first layer or the third layer includes at least one of a polyolefin or an ethylene vinyl acetate. Either may also include an elastomer or other additive. In some embodiments, the polyolefin is at least one of polyethylene and/or polypropylene.

[0009] In some embodiments, at least one of the first layer or the third layer has a thickness of between about 0.5 mm and about 3.0 mm. In some embodiments, at least one of the first layer or the third layer has a thickness of between about 1 mm and about 2 mm.

[0010] In some embodiments, at least one of the first layer or third layer include at least 50% of closed cell foam as measured by testing under ASTM D6226-14. In some embodiments, at least one of the first layer or third layer include at least 60% of closed cell foam as measured by testing under ASTM D6226- 14. In some embodiments, at least one of the first layer or third layer include at least 70% of closed cell foam as measured by testing under ASTM D6226-14. In some embodiments, at least one of the first layer or third layer include at least 80% of closed cell foam as measured by testing under ASTM D6226-14.

[0011] In some embodiments, the second layer includes at least one of a polyolefin, a polyurethane, or an ethylene vinyl acetate. In some embodiments, the second layer includes a polyethylene. In some embodiments, the second layer has a thickness of between about 10 mm and about 30 mm. In some embodiments, the second layer has a thickness of between about 15 mm and about 22 mm. In some embodiments, the second layer includes at least 80% of open cell foam as measured by testing under ASTM D6226-14. In some embodiments, the second layer includes at least 90% of open cell foam as measured by testing under ASTM D6226-14. In some embodiments, the second layer is at least 50% of the total floor mat thickness. In some embodiments, the second layer has an expansion ratio that is less than the expansion ratio of either the first layer or the third layer.

[0012] In some embodiments, the floor mat has a compression deformation of less than 40% after 40 minutes of recovery time as measured when tested under ASTM D3575-14 (Suffix B). In some embodiments, the floor mat has a compression deformation of less than 5% after 240 hours of recovery time as measured when tested under ASTM D3575-14 (Suffix B).

[0013] In some embodiments, the floor mat further includes at least one of an anti-slip coating formulation, treatment, or coating or an anti-scratch formulation, treatment, or coating.

[0014] In some embodiments, the floor mat has a shock absorption of less than 200 m/s² at an initial state when measured under the SATRA TM142 test method; and a shock absorption of less than 300 m/s² after 40 hours of recovery time when measured under the ASTM D3575- 14 compression deformation test method; and a shock absorption of less than 250 m/s² after 240 hours of recovery time when measured under the ASTM D3575-14 compression deformation test method.

[0015] Some embodiments relate to a method of forming a floor mat, comprising: providing a first layer including a closed cell foam; providing a second layer including an open cell foam; and providing a third layer including a closed cell foam; bonding the first, second, and third layers so that the first layer is directly adjacent to the second layer and the second layer is directly adjacent to the third layer. In some embodiments, the bonding step involves thermal hot melting. Brief Description of Drawings

[0016] Fig. 1 shows a side view of an exemplary embodiment of the present disclosure in which a layer of closed cell foam on either side of a layer of open cell foam.

Detailed Description

[0017] Various embodiments and implementations will be described in detail. These embodiments should not be construed as limiting the scope of the present application in any manner, and changes and modifications may be made without departing from the spirit and scope of the inventions. For example, many of the embodiments, implementations, and examples are discussed with specific reference to floor mats, but these should not be construed to limit the application scope to this one exemplary

implementation. Further, only some end uses have been discussed herein, but end uses not specifically described herein are included within the scope of the present disclosure. As such, the scope of the present disclosure should be determined by the claims.

[0018] The inventors of the present disclosure recognized that a floor mat having excellent compression deformation resistance and/or shock absorption and/or water resistance and/or sound proofing could be made by forming a floor mat including a layer of closed cell foam directly on either side of a layer of open cell foam. [0019] In general, foam structures include a solid material that is filled with voids or bubbles. Foams are typically generated by forming gas bubbles in a liquid base as the liquid hardens into a solid. The properties of the liquid and the gas determine the final structure of the foam. Two of the primary categories of foam materials are (1) open cell foam and (2) closed cell foam.

[0020] In open cell foams, the voids intersect each other, forming paths through the solid. As a result, open cell foams are generally soft and compressible. Open cell foams also typically act as good insulators because they trap air or other gases within the cells. Open cell foams can absorb liquid into their cells (and are thus often used as, for example, sponges). Open cell foam has a generally low cost per R value making its use in various applications such as sound dampening, shock absorbers, cushioning and pillows, cost-effective.

[0021] In contrast, closed cell foams include individual closed spheres. The presence of individual, closed spheres results in an inability of most gases (eg: air) or fluids to permeate this type closed cell foam, making them generally waterproof and/or water-resistant. Closed cell foams also generally provide greater structural stiffness than open cell foams. In some embodiments, the individual, closed cells are filled with gasses (e.g., often gases other than air) during fabrication. Closed cell foams can be used to prevent water or air from passing from one area to another. Closed cell foam is denser than open cell foam, and is thus generally more expensive to manufacture [0022] "Memory foam" can be either closed cell foam or open cell foam. It is typically a polyurethane including additives that increase its viscosity and density. It is often referred to as "viscoelastic" polyurethane foam, or low-resilience polyurethane foam. [0023] In some embodiments, the present disclosure relates to a floor mat, comprising: a first layer including a closed cell foam; a second layer including an open cell foam; and a third layer including a closed cell foam; wherein the first layer is directly adjacent to the second layer, and wherein the second layer is directly adjacent to the third layer. One exemplary embodiment of such a floor mat 10 is shown in Fig. 1. Floor mat 10 of Fig. 1 includes a first layer 20 including closed cell foam. First layer 20 is directly adjacent to a second layer 30 including open cell foam. Second layer 30 is directly adjacent to a third layer 40 including closed cell foam.

[0024] Closed Cell Foam Layers. In some embodiments, the first and third layers of the floor mat of the present disclosure include closed cell foam. In some embodiments, at least one of the first layer or the third layer includes at least one of a polyolefin, an ethylene vinyl acetate, and/or an elastomer. In some embodiments, the polyolefin is at least one of polyethylene and/or polypropylene. In some embodiments, the first and third layers include the same materials. In some embodiments, the first and third layers include different materials. In some embodiments, the elastomer is ethene-l-octene copolymer. In some embodiments, the first and third layers have the same composition; in some embodiments, the first and third layer have different compositions.

[0025] In some embodiments, at least one of the first layer or the third layer has a thickness of between about 0.5 mm and about 3.0 mm. In some embodiments, at least one of the first layer or the third layer has a thickness of between about 1 mm and about 2 mm. In some embodiments, the first and third layers have the same thickness; in some embodiments, the first and third layer have different thicknesses.

[0026] In some embodiments, at least one of the first layer or third layer include at least 50% of closed cell foam as measured by testing under ASTM D6226-14. In some embodiments, at least one of the first layer or third layer include at least 60% of closed cell foam as measured by testing under ASTM D6226- 14. In some embodiments, at least one of the first layer or third layer include at least 70% of closed cell foam as measured by testing under ASTM D6226-14. In some embodiments, at least one of the first layer or third layer include at least 80% of closed cell foam as measured by testing under ASTM D6226-14. In some embodiments, the first and third layers have the same closed cell foam content; in some

embodiments, the first and third layer have different closed cell foam content.

[0027] In some embodiments, at least one of the first and third layers have an expansion ratio of greater than 20x. In some embodiments, the first and third layers have the same expansion ratio; in some embodiments, the first and third layer have different expansion ratio. [0028] In some embodiments, at least one of the first and third layers may include within or be coated with at least one of an anti-slip coating formulation, treatment, or coating or an anti-scratch formulation, treatment, or coating. [0029] Open Cell Foam Layers. In some embodiments, the second layer of the floor mat of the present disclosure includes open cell foam. In some embodiments, the second layer includes at least one of a polyolefin, polyurethane, or an ethylene vinyl acetate. In some embodiments, the polyolefin is polyethylene or polypropylene.

[0030] In some embodiments, the second layer has a thickness of between about 10 mm and about 30 mm. In some embodiments, the second layer has a thickness of between about 15 mm and about 22 mm.

In some embodiments, the second layer is at least 50% of the total floor mat thickness.

[0031] In some embodiments, the second layer includes at least 80% of open cell foam as measured by testing under ASTM D6226-14. In some embodiments, the second layer includes at least 90% of open cell foam as measured by testing under ASTM D6226-14.

[0032] In some embodiments, the second layer has an expansion ratio that is less than the expansion ratio of at least one of the first layer or the third layer. In some embodiments, the expansion ratio of the second layer is between lOx and 3 Ox.

[0033] Floor Mats. In some embodiments, the floor mat has a compression deformation of less than 40% after 40 minutes of recovery time as measured when tested under ASTM D3575-14 (Suffix B). In some embodiments, the floor mat has a compression deformation of less than 5% after 240 hours of recovery time as measured when tested under ASTM D3575-14 (Suffix B).

[0034] In some embodiments, the floor mat further includes at least one of an anti-slip coating formulation, treatment, or coating or an anti-scratch formulation, treatment, or coating.

[0035] In some embodiments, the floor mat has a shock absorption of less than 200 m/s² at an initial state when measured under the SATRA TM142 test method; and/or a shock absorption of less than 300 m/s² after 40 hours of recovery time when measured under the ASTM D3575-14 compression deformation test method; and/or a shock absorption of less than 250 m/s² after 240 hours of recovery time when measured under the ASTM D3575-14 compression deformation test method.

[0036] Methods of Making. Some embodiments relate to a method of making or forming a floor mat, comprising: providing a first layer including a closed cell foam; providing a second layer including an open cell foam; and providing a third layer including a closed cell foam; bonding the first, second, and third layers so that the first layer is directly adjacent to the second layer and the second layer is directly adjacent to the third layer. In some embodiments, the bonding step involves thermal hot melting. In some embodiments, there is no adhesive present between the first and second layers and/or between the second and third layers. The elimination of adhesive in the floor mat eliminates or reduces some of the toxicity in the floor mat, which is especially beneficial for floor mats used in, for example, safety or kitchen applications.

[0037] The following examples describe some exemplary constructions of various embodiments of layers, methods, and articles of the present disclosure. The following examples describe some exemplary constructions and methods of constructing various embodiments within the scope of the present disclosure. The following examples are intended to be illustrative, but are not intended to limit the scope of the present disclosure.

Examples

[0038] Example 1

[0039] A floor mat having three layers as shown in Figure 1 was prepared having first and third, closed cell foam outer layers and a second, open cell foam inner layer positioned between the first and third outer layers. The foam material used for the first and third outer layers was obtained from Holyfoam Chemical Industry Group, Taipei, Taiwan (Holyfoam product number YR1502). Each of the first and third layers was a 2 mm thick, closed cell foam material that included ethylene vinyl acetate and an ethene-l-octene copolymer elastomer (closed cell content >50%). The second, open cell foam inner layer was also obtained from Holyfoam Chemical Industry Group. The inner layer included two 8 mm thick, polyethylene/ethylene vinyl acetate open cell foam materials (Holyfoam product number OP2508) that had been thermally laminated together to provide a 16 mm, thick open cell foam layer (Holyfoam product number OP2516). The open cell content of the second layer was 99% based on ASTM D6226. The three foam layers were thermally bonded together using conventional calendering equipment with the calender rolls maintained at a temperature of about 210 - 250°C.

[0040] The floor mat of Example 1 was tested for compression deformation resistance using ASTM test method "Standard Test Methods for Flexible Cellular Materials Made From Olefin Polymers" (ASTM D3575-14, Suffix B-Compression Set Under Constant Deflection). Competitive floor mat products Cl- C5 were also tested. CI was an EVA Alphabet Mat sold by Dau Cheng Enterprise Co., Ltd., in Taipei, Taiwan. C2 was a Baby Great Puzzle Mat sold by Great Ball Enterprise Co., Ltd., in Taichung, Taiwan. C3 was an EVA Circle Traction Heart Mat sold by Dau Cheng Enterprise Co., Ltd., Taipei, Taiwan. C4 was a Skip Hop PlaySpot Interlocking Foam Tile sold by Skip Hop, Inc., New York City, NY

(www . skipho . com) . C5 was a LOG® Puzzle Mat sold by Echain Tech. Corporation

(www.lQgtoy.corn.tw).

[0041] Data is provided in Table 1. Thickness measurements were obtained at 23°C. The initial thickness (Tl) was the thickness of the floor mat measured prior to any compression. After having been compressed 50% for 22 hours, the thickness (T2) was measured after 30-40 minutes recovery time, and then the thickness (T3) was measured again after 240 hours recovery time. Deformation #1 was calculated as Tl - T2 /Tl x 100. Deformation #2 was calculated as Tl - T3 /Tl x 100. [0042] Table 1. Thickness and Deformation Results for Example 1 and Comparative Products.

[0043] The data indicates that the Example 1 floor mat exhibits improved compression deformation resistance compared to the competitive floor mat products (approximately 22% compared to

approximately 44-62% after 30-40 minutes recovery time, and approximately 1% compared to approximately 8-43% after 240 hours recovery time).

[0044] The Example 1 floor mat was also tested for shock absorption performance according to the SATRA test method "Falling Mass Shock Absorption Test - May 1992" (SATRA TM142, SATRA Test Methods Catalogue - September 2104, SATRA Technology Center, United Kingdom). Prior to testing for shock absorption the floor mat samples were subjected to compression deformation as described above. Competitive floor mat products C1-C5 were similarly tested for comparison. The initial shock absorption data was obtained prior to any compression. Shock absorption data was then obtained after 30- 40 minutes recovery time and then again after 240 hours recovery time. The shock absorption data is summarized in Tables 2 and 3, and is reported as peak deceleration (Gmax).

[0045] Table 2. Shock Absorption Results for Example 1 and Comparative Products

[0046] Table 3. Shock Absorption Results for Example 1 and Comparative Products - Thickness Adjusted

[0047] A low Gmax value indicates good shock absorption characteristics. The data indicates that the Example 1 floor mat had improved shock absorption after compression deformation compared to the competitive floor mat products. Compared to the Gmax values for the competitive floor mat products, the Gmax values for the Example 1 floor mat were at least 50% lower after 30-40 minutes recovery time and at least 45% lower after 240 hours recovery time.

[0048] The recitation of all numerical ranges by endpoint is meant to include all numbers subsumed within the range (i.e., the range 1 to 10 includes, for example, 1, 1.5, 3.33, and 10).

[0049] The terms first, second, third and the like in this disclosure, including in the claims, are used for distinguishing between elements / layers and not necessarily for describing a sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other sequences than described or illustrated herein.

[0050] Those having skill in the art will appreciate that many changes may be made to the details of the above-described embodiments and implementations without departing from the underlying principles thereof. Further, various modifications and alterations of the present disclosure will become apparent to those skilled in the art without departing from the spirit and scope of the disclosure. The scope of the present disclosure should, therefore, be determined only by the following claims.

Claims

What is claimed is:

1. A floor mat, comprising:

a first layer including a closed cell foam;

a second layer including an open cell foam; and

a third layer including a closed cell foam;

wherein the first layer is directly adjacent to the second layer, and wherein the second layer is directly adjacent to the third layer.

2. The floor mat of claim 1, wherein at least one of the first layer or the third layer includes at least one of a polyolefin, an ethylene vinyl acetate, or an elastomer.

3. The floor mat of claim 1 or claim 2, wherein at least one of the first layer or the third layer has a thickness of between about 0.5 mm and about 3.0 mm.

4. The floor mat of claim 1 or claim 2, wherein at least one of the first layer or the third layer has a thickness of between about 1 mm and about 2 mm.

5. The floor mat of any of the preceding claims, wherein at least one of the first layer or third layer include at least 50% of closed cell foam as measured by testing under ASTM D6226-14.

6. The floor mat of any of the preceding claims, wherein at least one of the first layer or third layer include at least 60% of closed cell foam as measured by testing under ASTM D6226-14.

7. The floor mat of any of the preceding claims, wherein at least one of the first layer or third layer include at least 70% of closed cell foam as measured by testing under ASTM D6226-14.

8. The floor mat of any of the preceding claims, wherein at least one of the first layer or third layer include at least 80% of closed cell foam as measured by testing under ASTM D6226-14.

9. The floor mat of any of the preceding claims, wherein the second layer includes at least one of a polyolefin, a polyurethane, or an ethylene vinyl acetate.

10. The floor mat of claim 9, wherein the second layer includes at least one of a polyethylene or a polypropylene .

11. The floor mat of any of the preceding claims, wherein the second layer has a thickness of between about 10 mm and about 30 mm.

12. The floor mat of any of the preceding claims, wherein the second layer has a thickness of between about 15 mm and about 22 mm.

13. The floor mat of any of the preceding claims, wherein the second layer includes at least 80% of open cell foam as measured by testing under ASTM D6226-14.

14. The floor mat of any of the preceding claims, wherein the second layer includes at least

90% of open cell foam as measured by testing under ASTM D6226-14.

15. The floor mat of any of the preceding claims, wherein the second layer is at least 50% of the total floor mat thickness.

16. The floor mat of any of the preceding claims, wherein the second layer has an expansion ratio that is less than the expansion ratio of either the first layer or the third layer.

17. The floor mat of any of the preceding claims, wherein the floor mat has a compression deformation of less than 40% after 40 minutes of recovery time as measured when tested under ASTM

D3575-14 (Suffix B).

18. The floor mat of any of the preceding claims, wherein the floor mat has a compression deformation of less than 5% after 240 hours of recovery time as measured when tested under ASTM D3575-14 (Suffix B).

19. The floor mat of any of the preceding claims, further including at least one of an anti-slip coating formulation, treatment, or coating or an anti-scratch formulation, treatment, or coating.

20. The floor mat of any of the preceding claims, wherein

the floor mat has a shock absorption of less than 200 m/s² at an initial state when measured under the SATRA TM142 test method; and

a shock absorption of less than 300 m/s² after 40 hours of recovery time when measured under the ASTM D3575-14 compression deformation test method; and

a shock absorption of less than 250 m/s² after 240 hours of recovery time when measured under the ASTM D3575-14 compression deformation test method.

21. A method of forming a floor mat, comprising:

providing a first layer including a closed cell foam;

providing a second layer including an open cell foam; and

providing a third layer including a closed cell foam;

bonding the first, second, and third layers so that the first layer is directly adjacent to the second and the second layer is directly adjacent to the third layer.

22. The method of claim 16, wherein the bonding step involves thermal hot melting.