U.S. patent application number 12/931944 was filed with the patent office on 2011-06-16 for foldable and flexible laminated mat.
Invention is credited to Darryl S. Gold.
Application Number | 20110143615 12/931944 |
Document ID | / |
Family ID | 44143451 |
Filed Date | 2011-06-16 |
United States Patent
Application |
20110143615 |
Kind Code |
A1 |
Gold; Darryl S. |
June 16, 2011 |
Foldable and flexible laminated mat
Abstract
A chair pad or a roll up mat that can be manufactured from
medium density fiberboard with a laminate surface decorative layer
applied thereon. The laminate is treated with various protective
coatings, to add resistance to natural deleterious factors
including water and dirt. The chair mat includes a series of
planks, held together by tape, with an under layer of a mesh, all
applied by resin together, and having a bottom layer of a felt or
rubber to provide cushioning when the mat is applied upon a floor
or surface, and to function as a living hinge, when it is rolled up
or folded for storage or shipment.
Inventors: |
Gold; Darryl S.;
(Chesterfield, MO) |
Family ID: |
44143451 |
Appl. No.: |
12/931944 |
Filed: |
February 15, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12214007 |
Jun 16, 2008 |
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12931944 |
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10905827 |
Jan 21, 2005 |
7402536 |
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12214007 |
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12460841 |
Jul 23, 2009 |
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10905827 |
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11468290 |
Aug 29, 2006 |
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12460841 |
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60741990 |
Dec 2, 2005 |
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Current U.S.
Class: |
442/1 |
Current CPC
Class: |
B32B 5/02 20130101; Y10T
442/10 20150401; B32B 3/18 20130101; B32B 21/06 20130101; A47G
27/0206 20130101; B32B 21/10 20130101; B32B 21/02 20130101 |
Class at
Publication: |
442/1 |
International
Class: |
D03D 9/00 20060101
D03D009/00 |
Claims
1. A mat or pad for use for supporting a chair, other item of
furniture, or other equipment, and comprised of a plurality of
elongated flat laminated planks arranged lengthwise in adjacency,
with each plank being arranged contiguously in a substantially
abutting relationship with respect to the adjacent planks, each
said plank comprising a length of fiberboard composite, each plank
having a covering thereon, laminated onto the fiberboard to add to
the aesthetics and appearance of each plank, said plurality of
adjacently arranged planks having a series of fiberous tape strips
connected orthogonally to the underside of said planks for forming
a formed mat or pad, a fibrous mesh sheet applied on the underside
of said laminated planks and said tape strips, a resin material
layer applied to the fiber mesh sheet underside for bonding the
mesh sheet to the underside of the laminated planks and the fibrous
tape strips of the formed mat, and a high density layer made of one
of matted felt, rubber and polymer matting bonded onto the resin
layer material, for adhering the layer to the underside of the
formed mat, and wherein said planks, tape, mesh sheet, and high
density layer being subjected to pressure and rolled to enhanced
the bonding of the laminated planks together.
2. The mat of claim 1 wherein the fiberboard comprises medium
density fiberboard.
3. The mat of claim 1 wherein the resin layer is a mastic resin
layer.
4. The mat of claim 3 wherein the laminated planks are formed of
medium density fiberboard, and the laminated covering is applied by
glue, said covering comprising decorative paper as applied to the
top of the fiberboard planks during fabrication.
5. The mat of claim 4 wherein a plurality of layers of urethane
coating are applied to the laminated paper covering of the
planks.
6. The mat of claim 5 wherein the high density layer is made of
sisal.
7. The mat of claim 6 wherein the fibrous tape strip is a polymeric
fiber tape strip.
8. The mat of claim 7 wherein the fiber mesh sheet is a nylon mesh
sheet.
9. The mat of claim 8 wherein the peripheral shape of the mat is
substantially rectangular and having its front corners cutaway to
provide for its accommodation during usage.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This is a continuation-in-part of the patent application and
claims priority to the provisional patent application having Ser.
No. 12/214,007, filed on Jun. 16, 2008, which claims priority and
is a continuation of the patent application having Ser. No.
10/905,827, filed on Jan. 21, 2005; this application also claims
priority as a continuation-in-part of the application having the
Ser. No. 12/460,841, filed on Jul. 23, 2009, which is a
continuation-in-part of patent application having Ser. No.
11/468,290, filed on Aug. 29, 2006, which claims priority to the
provisional patent application having Ser. No. 60/741,990, filed on
Dec. 2, 2005.
FIELD OF THE INVENTION
[0002] This development relates to a laminated roll up or foldable
mat that may be manufactured from medium density fiberboard, and
having a surface layer of a laminated decorative paper, or a wood
veneer, with a protective coating applied thereon, to furnish a
strengthened mat of slats that can be subjected to roll up, or
folding, as when not in usage.
BACKGROUND OF THE INVENTION
[0003] This invention primarily relates generally to chair mats,
and more particularly, to medium density fiberboard laminated chair
mats.
[0004] Chair mats have long been used as a protective covering for
a floor area on which a chair rest or some other furniture item
locates. The chair mat is utilized to protect the underlying floor,
or even a rug, from damage due to wear and tear caused by the chair
and its constant movement, and/or from the occupant of the chair
moving about within the floor area on which the furniture rest. A
typical chair mat is made of plastic, or other appropriate
material, that is semi flexible, but resilient enough such that
when the chair mat is placed on the floor area a semi ridged
surface is provided by the chair mat. The semi ridged surface makes
it easier to move about in the floor area, while occupying a chair
with wheels.
[0005] Most chair mats are of a unitary one piece flattened body.
Some chair mats as indicated are made of plastic. However, others
are made of a hardwood material to provide a better aesthetic
appeal. Hardwood chair mats, however, are not flexible, are very
expensive, and do tend to crush down on any underlying rugs, due to
their weight. Such chair mats, particularly the larger ones, are
difficult to move about and very difficult to ship because of the
special packaging required. Obviously, cost can be an excessive
factor. Also, one alternative to a hardwood pad would be the
subject matter of this invention, to utilize a medium density
fiberboard (MDF) laminate, which can also be used for a chair mat
if processed like hardwood.
[0006] Thus, the concept of the current invention is to provide a
much lesser expensive woodlike material, of reduced weight, and
more easier to work with, type of plank or slats of such MDF that
can be applied in adjacency, and then affixed together in the
manner as described in this invention, and in co-pending prior
applications, into a roll up or foldable type of chair mat, yet one
having the aesthetic appeal of a treated or stained hardwood pad as
known in the prior art.
SUMMARY OF THE INVENTION
[0007] This invention contemplates the formation of a MDF/laminate
chair mat formed from multiple elongated MDF/laminate planks that
have been processed like hardwood flooring. The chair mat provides
a substantially hardwood ridged surface, but the mat can be rolled
up like a chair mat for ease of transport, storage, or shipment.
The fiberboard planks have sufficient thickness such that when they
are bonded to a backing in an adjacent side by side manner, a
substantially ridged surface is provided. The planks are not
adjacent connected along their side edges, and therefore, the mat
can be rolled for ease of transport and storage.
[0008] Medium density fiberboard is an engineered wood product
formed by breaking down hardwood or softwood residuals into wood
fibers, often in a defibrator, and combining it with a wax and a
resin binder, forming panels by applying high temperature and
pressure to compress them into a woodlike product of significant
density. MDF is denser than plywood. It is made up of separate
fibers, not wood veneers, but can be used as a building material
similar in application to plywood. It is stronger and much denser
than normal particle board. The name derives from the distinction
and densities of fiberboard. Large scale production of medium
density fiberboard began many decades ago, and such fiberboard has
now been perfected where it can be used in the manufacture of
furniture, such as the chair pad or mat of this invention.
[0009] There are various types of MDF/laminate flooring including
tongue and groove type, and the type that needs to be butted
together. The lacquered flooring panels are finished using wear
resistant UV lacquer and the unlacquered flooring panels need to be
coated/waxed and polished after installation. The strength of
MDF/laminate boards can be better than common wood boards due to
the high pressure and high temperature of their manufacturing
process.
[0010] Furthermore, wood is subject to deterioration, splintering,
and cracking when subjected to too much drying, which the
fiberboard of this invention avoids.
[0011] It has been found that the MDF/laminate material used in
this invention is very durable for a chair mat application,
however, the construction of many MDF/laminate mats are ridged,
lacking the capability to flex or bend. A novel MDF/laminate chair
mat construction is needed in the industry, and it is believed that
this current invention may satisfy that requirement.
[0012] In the formation of the mat of this invention, the formed
planks have a paper laminate applied over their surface, and such
paper may have aesthetics related to that as providing a wood
appearance, or it may have almost any appearance that may be
desired for the chair mat when employed. Or, there is the potential
that veneer may be applied upon the surface of the planks, to give
a natural wood appearance.
[0013] The planks of this invention are then coated with UV
coatings, which are applied onto the surface of the MDF/laminate
planks. One embodiment of the invention can have up to seven coats
of UV protection. The MDF/laminate can be arranged with a series of
planks lying next to one another, and then assembled into the chair
mat. The chair mat can then be rolled or pressed thereby
compressing all of the layers of the chair mat simultaneously.
[0014] During the assembly process, a mesh sheet is placed on the
bottom side of the chair mat. The mesh sheet can be made of nylon
fibers, or other polymers. A mastic layer is then placed over the
nylon mesh sheet, thereby adhering it to the undersurface of the
aligned planks, and then a final layer of high density felt or
sisal can be applied under the mesh sheet. Such a high density
layer can be preferably of about approximately 2 mm in thickness.
The chair mats can then be cut to the desired dimensions. This
bottom high density layer can be made of the matted felt, rubber,
or polymer padding, bonding over and to the resin material layer,
and this layer can function as a type of living hinge, for the
aligned slats, when they are rolled up, or folded into closures
when used as a chair pad, thereby eliminating the need for usage of
any metal hardware, for hinge purposes, in the construction,
manufacture, and usage of this current invention.
[0015] It is, therefore, the principal object of this invention to
use medium density fiberboard planks in the construction of a chair
pad or mat, and which may be laminated with a surface coating of
paper, or veneer, to add to its attractiveness.
[0016] A further object of this invention is to provide for the use
of lower cost materials in the fabrication of a high strength chair
mat or pad, when employed for those purposes.
[0017] Another object of this invention is to provide a mat or pad
that can be rolled up or folded, as during nonusage, or during
shipment, during its usage.
[0018] Another object of this invention is to provide a laminated
structure for a pad or mat, one fabricated of fiberboard, but which
in its final processing, after all of its laminated layers have
been brought together, and may be subjected to pressure compressing
to assure its integrity even after prolonged usage.
[0019] These and other objects may become more apparent to those
skilled in the art upon review of the summary of the invention as
provided herein, and upon undertaking a study of the description of
its preferred embodiment, in view of the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] For a better understanding of the present invention,
reference may be made to the accompanying drawings, in which:
[0021] FIG. 1 is a perspective view of the foldable and flexible
laminated mat or pad of this invention; and
[0022] FIG. 2 is a perspective partial cutaway view of the pad or
mat of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] According to the present invention, various views of the
foldable and flexible laminated mat or pad of this invention are
shown in FIGS. 1 and 2. In the embodiment of the present invention,
comprising medium density fiberboard laminated planks, these are
laid in adjacency and a felt or sisal backing provides both the
adherence of the planks in adjacency, and furnishes a backing for
resting upon the floor, in addition to functioning as a living
hinge when the mat or pad is to be rolled up, or folded, for
storage or shipment. The details of the invention can be better
understood by referring to FIG. 1. This is a perspective of the
present pad or mat 100, and the pad is constructed including a
plurality of elongated medium density fiberboard planks 102,
arranged lengthwise in a side by side manner where the long side
edge of each plank can be abutted against the adjacent long side
edge of the adjacent planks. The abutting relationship between the
planks can form a mat, as at 114. The adjacent long side edges of
the planks can be unattached. The laminated chair pad as shown is
cut into a typical chair pad pattern outline that is substantially
rectangular in design, with adjacent corner sections cutaway. See
the notched cutaway areas 104 and 108.
[0024] The certain MDF/laminate that can be used in the manufacture
of the present chair mat is oxidize and gives it an extra step in
making the MDF/Laminate more impermeable to water and dirt. Once
the elongated planks have been processed, they can be laminated,
with a paper overcoating, which may be to any design as desired.
For example, it may have a wood grain finish, or some other
appearance, depending upon the desires of any purchaser.
Furthermore, once the planks have been processed, they are
adjacently aligned lengthwise, and in a side-by-side relationship.
A fibrous strip, or multiple threads and/or a fibrous tape
material, as at 210, can be applied to the underside to connect the
MDF/laminate planks. A fiber mesh sheet 206 can then be applied and
bonded to the underside to hold these strips together. A resin
material layer is then applied to the fiber mesh sheet 206, bonding
the mesh sheet to the underside of the MDF/laminate layer portion
of the planks, in addition to the tape material, to form a means
for holding the adjacent planks together, in their assembly.
[0025] Applied to the bottom of the pad is a layer 212, which is
adhered by the resin material layer to the undersurface of the mesh
sheet, and the strips 210, and this particular layer for the mat is
formed of a high density layer made of matted felt rubber, or
polymer matting bonded by the resin layer and thereby functions not
only as a cushion for the mat when applied upon the floor, but
further functions as a living hinge for the slats when the mat is
rolled up, or if formed as a chair pad, when the sections of the
pad are folded over into closure. After application of the layer
212, the entire mat can then be pressed thereby compressing all of
the layers of the chair mat into almost an integrated structure,
may even have some heat applied, in order to provide for the
bonding by the resin material into an integrated structure. The
pressure rolling achieves a bonding of all of the components
together, into the desired formation of the floor mat or chair pad
of this invention.
[0026] From the aforementioned description, a foldable chair mat
has been described. The foldable chair pad, or roll up mat, is
uniquely capable of folding wooden panels into a light compact form
for shipping and eventual placement at its final location. The
foldable chair pad may be manufactured from many materials,
including but not limited to wood, laminated wood, fiberboard, and
other wood composites.
[0027] In addition, the resin layer of the formed mat may be of a
mastic resin layer.
[0028] Furthermore, the laminated planks of the medium density
fiberboard may be of higher or lower densities of fiberboard,
depending upon their intended usage. The planks are made of a
laminated surface, and have applied thereto by gluing decorative
paper to the top of the plank for enhanced appearance. The planks
will also have several layers of urethane coating applied thereon.
As many as seven layers of coating have been applied, to attain the
quality appearance for the mats, as marketed.
[0029] The fibrous tape strip that is used to hold the planks
initially in adjacency may be made of a polymeric fiber. The fiber
mesh sheet that is used to bond the entire planks, and tape,
together, in addition to holding the felt, rubber or polymer high
density under layer may be a nylon fiber mesh sheet.
[0030] Obviously, the final peripheral shape of the chair pad may
be substantially rectangular, and wherein adjacent corners may be
notched away, for convenience of location, particularly when
partially arranged under a desk.
[0031] Variations or modifications to the subject matter of this
invention may occur to those skilled in the art upon review of the
mat or pad as described herein. Such variations, if within the
spirit of this invention, are intended to be encompassed within the
scope of any claims to patent protection issuing hereon. The review
of the preferred embodiment of the invention, and its depiction in
the drawings, are [0032] set forth for illustrative purposes
only.
* * * * *