U.S. patent application number 15/869985 was filed with the patent office on 2018-07-19 for spacer mesh mat base.
The applicant listed for this patent is MindsInSync, Inc.. Invention is credited to Iain SCORGIE.
Application Number | 20180202084 15/869985 |
Document ID | / |
Family ID | 54067562 |
Filed Date | 2018-07-19 |
United States Patent
Application |
20180202084 |
Kind Code |
A1 |
SCORGIE; Iain |
July 19, 2018 |
SPACER MESH MAT BASE
Abstract
A mat includes a base portion having a spacer mesh fabric. The
mat includes a cover, an optional filler material and a base. The
cover may be any type of fabric and/or carpet material and the
filler may be a foam or other cushioning material. The spacer mesh
base includes a plurality of sets of lands and grooves.
Inventors: |
SCORGIE; Iain; (New York,
NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MindsInSync, Inc. |
New York |
NY |
US |
|
|
Family ID: |
54067562 |
Appl. No.: |
15/869985 |
Filed: |
January 12, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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14216974 |
Mar 17, 2014 |
9873963 |
|
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15869985 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 2255/02 20130101;
B32B 5/028 20130101; D04B 21/16 20130101; A47G 27/0206 20130101;
B32B 5/245 20130101; B32B 5/026 20130101; D10B 2403/0112 20130101;
B32B 2266/0278 20130101; Y10T 428/24612 20150115; B32B 2262/0276
20130101; B32B 5/26 20130101; B32B 2255/26 20130101; B32B 2471/04
20130101; D10B 2403/0221 20130101; B32B 2266/06 20130101 |
International
Class: |
D04B 21/16 20060101
D04B021/16; B32B 5/02 20060101 B32B005/02; B32B 5/26 20060101
B32B005/26; A47G 27/02 20060101 A47G027/02; B32B 5/24 20060101
B32B005/24 |
Claims
1-13. (canceled)
14. A mat, comprising: a base including a top surface and a bottom
surface, the top and bottom surfaces being separated at least by a
spacer mesh core layer and wherein the bottom surface and core
layer each include at least one channel, wherein the bottom surface
includes a plurality of ground-engaging surfaces and a plurality of
channels between at least some adjacent ground-engaging surfaces,
each channel extending from a first edge of the base layer to a
second edge of the base layer, and the core layer includes a
plurality of channels, each channel of the core being aligned with
a corresponding bottom surface channel extending from the first
edge of the base layer to the second edge of the base layer and
wherein the spacer mesh core comprises monofilament yarn extending
between the top and bottom surfaces of the base.
15. A mat as in claim 14, wherein the plurality of ground-engaging
surfaces and channels comprise a repeating pattern of
ground-engaging surfaces and channels.
16. A mat as in claim 14, wherein the monofilament is knit together
with the top and bottom surfaces of the core.
17. A mat as in claim 14, wherein the monofilament has a thickness
between about 0.10 mm and about 0.30 mm.
18. A mat as in claim 14, wherein the monofilament has a thickness
between about 0.10 mm and about 0.14 mm.
19. A mat as in claim 14, wherein the monofilament, top and bottom
surfaces are heat set after being knit together to stabilize a
separation between the top and bottom surfaces.
20. A mat as in claim 14, further comprising a fabric cover layer,
secured to the base.
21. A mat as in claim 14, wherein the fabric cover layer is
directly secured to the base.
22. A mat as in claim 14, further comprising a cushioning layer
between the fabric cover layer and the base.
23. A mat as in claim 14, wherein the bottom surface further
comprises a slip-resistant coating.
24. A mat as in claim 23, wherein the slip-resistant coating
comprises a rubber material.
25. A mat as in claim 23, wherein the slip-resistant coating
comprises a material selected from the group consisting of: latex,
rubber, SBR and combinations thereof.
26. A mat as in claim 15, wherein the pattern of ground-engaging
surfaces comprises a first ground-engaging surface having a first
width and a second ground-engaging surface having a second width,
wider than the first width, separated by a channel.
27. A mat, comprising: a base including a top surface and a bottom
surface, the top and bottom surfaces being separated at least by a
spacer mesh core layer and wherein the bottom surface and core
layer each include at least one channel, wherein the bottom surface
includes a plurality of ground-engaging surfaces and a plurality of
channels between at least some adjacent ground-engaging surfaces
and said channels extending from a first edge of the base layer to
a second edge of the base layer and into the core layer, and
wherein the spacer mesh core comprises monofilament yarn extending
between the top and bottom surfaces of the base.
28. A mat, comprising: a base including a top surface and a bottom
surface, the top and bottom surfaces being separated at least by a
spacer mesh core layer and wherein the bottom surface and core
layer each include at least one channel, wherein the bottom surface
includes a plurality of ground-engaging surfaces and a plurality of
channels between at least some adjacent ground-engaging surfaces
and said channels extending from a first edge of the base layer to
a second edge of the base layer and into the core layer, and
wherein the spacer mesh core comprises monofilament yarn extending
into the bottom surface of the base.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent
application Ser. No. 14/216,974, filed on Mar. 17, 2014, the entire
contents of which is incorporated herein in its entirety by
reference.
FIELD OF THE INVENTION
[0002] The invention relates generally to mats for use in home
environments and more particularly to mats incorporating spacer
mesh material.
BACKGROUND OF THE INVENTION
[0003] Spacer mesh is a knitted fabric material that may be used to
separate layers of a textile product. An example of a three
dimensional spacer mesh is shown in Chinese Utility Model
CN203174270, herein incorporated by reference in its entirety.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 schematically shows a mat in accordance with an
embodiment;
[0005] FIG. 2A shows a cross sectional view of a base portion of
the mat of FIG. 1, FIG. 2B shows a top plan view and FIG. 2C shows
a bottom plan view of the base of FIG. 2A;
[0006] FIG. 3A is an isometric view of a mat in accordance with an
embodiment, FIG. 3B is a detail view of a portion of the mat of
FIG. 3A;
[0007] FIG. 4 shows an embodiment illustrating a leaning issue as
described below; and,
[0008] FIG. 5A shows a bottom plan view of a lean-resistant
embodiment, and FIG. 5B shows a cross sectional view of the
embodiment of FIG. 5A.
DETAILED DESCRIPTION
[0009] These and other aspects of various embodiments of the
present invention, as well as the methods of operation and
functions of the related elements of structure and the combination
of parts and economies of manufacture, will become more apparent
upon consideration of the following description and the appended
claims with reference to the accompanying drawings, all of which
form a part of this specification, wherein like reference numerals
designate corresponding parts in the various figures. In one
embodiment of the invention, the structural components illustrated
herein are drawn to scale. It is to be expressly understood,
however, that the drawings are for the purpose of illustration and
description only and are not intended as a definition of the limits
of the invention. In addition, it should be appreciated that
structural features shown or described in any one embodiment herein
can be used in other embodiments as well. As used in the
specification and in the claims, the singular form of "a", "an",
and "the" include plural referents unless the context clearly
dictates otherwise.
[0010] A mat in accordance with an embodiment is schematically
illustrated in FIG. 1 and includes a cover 10, an optional filler
material 12 and a base 14. The cover 10 may include any type of
carpeting, including woven, needlefelt, tufted and knitted, and may
have a pile. Materials may include polypropylene, polyamide,
polyester, nylon, cotton, wool, acrylic and combinations thereof.
The yarn may be draw textured and/or fully drawn yarn, according to
the selected use for the final product. In an embodiment, the
material may be a microfiber material which may be, for example, a
material including from 60-90% polyester by weight with the
remainder polyamide. In a selected embodiment, the material may be
75%-85% polyester and 15 to 25% polyamide and in a specific
embodiment, the material may be 80% polyester and 20% polyamide.
Filler materials may include batting or padding, foam, memory foam,
or other cushioning materials as known in the art. The filler
material may be from 1 cm to 5 cm thick, and in the memory foam
embodiment, may include a viscoelastic open cell polyurethane
having a density of between 2.6 and 3 lbs/ft.sup.3 and in a
specific embodiment, of approximately 2.8 lbs/ft.sup.3.
[0011] Layers may be glued together, or, when suitable,
flame-bonded. In certain embodiments, stitching may be used to
secure the layers, either alone or in combination with glue and/or
flame-bonding.
[0012] The base 14 is a three-dimensional spacer mesh which is
itself made up of a top surface 20, a plurality of bottom surfaces
22, and a core 24. In an embodiment, the core 24 comprises a single
extruded polyester monofilament composed that is knit together with
the top 20 and bottom surfaces 22, which may also be formed by
knitting. As will be appreciated, in principle the core need not be
formed from a single filament, but may, depending on the knitting
process, include multiple such filaments. The bottom surfaces 22
are separated by channels 26 forming a series of lands and
grooves.
[0013] FIG. 2A shows the base 14 in greater detail, while FIG. 2B
shows the top 20 and FIG. 2C shows the bottom 22. Note that the
"eyes" of the top and bottom fabric are of differing sizes in the
illustrated embodiment. The eye size may be selected in accordance
with the specific desired end product.
[0014] The mat may include an optional border 26, around the outer
edge of the base. Typically, this border will be made from the same
material as the cover and/or be a continuation/fold of the cover
material. In an alternate approach, the border may be an additional
piece such as piping or the like. The border may be glued or sewn
as desired.
[0015] The polyester monofilament is sufficiently strong to act as
a support, separating the top surface from the bottom surface, and
maintaining an air gap therebetween. The monofilament is knitted in
a less dense pattern such that fluid may flow through gaps in the
core layer. In particular, both air and water can freely flow
though the core such that a mat having a base in accordance with an
embodiment will tend to allow water to flow out from the mat,
discouraging it from becoming waterlogged, and further, will tend
to allow air to flow, encouraging drying of a wet mat.
[0016] The characteristics of the monofilament fiber may be
selected to optimize different aspects, such as strength,
resilience, durability, and/or cost. Typically, thicker
monofilament will provide for greater supporting force. The
characteristics of the core act, in addition to the fluid
characteristics described above, to provide a selected amount of
cushioning, providing a comfortable support to a person standing or
walking on the mat.
[0017] As shown in FIGS. 3A and 3B, the core 24, and the
monofilament which comprises it, is visible in the channels 26
between each adjacent pair of bottom surfaces 22.
[0018] In a particular embodiment, a yarn thickness of between 0.08
and 0.16 mm and more particularly between 0.10 and 0.14 mm. In a
specific embodiment, the yarn thickness is 0.12 mm. In an
embodiment, the bottom surfaces 22 include a slip-reducing surface
which may be, for example, a latex and/or styrene-butadiene rubber
(SBR) coating. For stronger, more resilient embodiments, thicker
yarns may be used, including 0.15 mm, 0.16 mm, 0.18 mm, 0.25 mm, or
0.30 mm yarn.
[0019] The thickness of the three-dimensional layer 14 may be, for
example, between about 4 mm and about 20 mm, though certain
embodiments may make use of a thinner sandwich having a thickness
between about 2 mm and about 4 mm
[0020] The configuration of strips and grooves may be formed during
the knitting process by selection of the parameters for the
knitting. In particular, the skilled artisan understands that the
yarn feeder is adjustable to control the yarn knit according to a
particular design selection. Likewise, the size of the eyes, as
shown in FIGS. 2A and 2B is adjustable by adjusting the knitting
machine. As shown in FIG. 1, the strips and grooves may simply
alternate and have similar widths. Likewise, either the strips or
the grooves may be relatively larger than the other. For example,
the strips may be half the width of the grooves or twice the width
of the grooves. As will be appreciated, other ratios may be
selected.
[0021] In an embodiment, the base may be made in accordance with a
method including, obtaining selected yarns, warping the yarns to a
pan head of a knitting machine, knitting the yarns to obtain a
knitted fabric, heat setting the raw (griege) fabric at a
temperature selected to obtain a size stable fabric, optionally
dying the fabric, washing and drying, and finally, heat setting the
fabric again. In the stabilizing step, the selected heat may be,
for example, in a range between about 180 C and 200 C, and more
particularly, about 190 C.
[0022] In a specific embodiment, the base fabric has a base fabric
weight of 450 g.+-.30 g/m.sup.2, a thickness of 6 mm.+-.0.5 mm, a
rib width of 6 mm.+-.0.5 mm, a stripe to space duty cycle of
33.3%/66.6%, a fully drawn top yarn of 300D/96F, a monofilament
diameter of 0.12 mm, and a bottom yarn similar to the top yarn. In
an alternate embodiment, the base fabric is thinner and has a base
fabric weight of 230 g.+-.10 g/m.sup.2, a thickness of 3 mm, a rib
width of 3 mm, a stripe to space duty cycle of 50%/50%, a fully
drawn top yarn of 100D/48F, a monofilament diameter of 0.12 mm, and
a bottom yarn of 75D/48F. As will be appreciated, the top and
bottom yarns may be selected to vary in accordance with the desired
final fabric weight and stiffness.
[0023] In certain cases, it is possible that the strips of spacer
mesh material may be susceptible to "leaning" when the mat is
stepped on, as shown in FIG. 4. While this is not believed to be
hazardous, it may feel disconcerting or otherwise undesirable to a
person stepping on a mat so configured. In this case, it may be
useful to include a combination of narrow bottom surfaces 22 and
wide bottom surfaces 30 to help offset the leaning phenomenon while
providing sufficient channels/grooves 26 for funneling water away.
In this alternate embodiment the base profile alternates a pair of
narrow strips with a wider strip, as shown in FIGS. 5A and 5B. In
this approach, the wide strips provide greater stability to help
reduce "collapsing", while the narrow strips provide channels for
water to flow.
[0024] The skilled artisan will appreciate that configurations
other than that illustrated may be used, such as varying the number
of strips and their width and depth. It is also appreciated that
the mixture of wide and narrow strips can be irregular. Likewise,
though the embodiment shown involves several separated base
segments, a channel may be used that does not separate all regions
of the base. For example, a single channel in an s-shape or a
zig-zag shape could provide an appropriate flow path for water
without separating the base into unconnected regions.
[0025] In each of the foregoing embodiments, a coating may be
applied to the bottom surfaces to increase the coefficient of
friction between the bottom surfaces and the floor in both dry and
wet environments. This coating may be applied by spraying or by
other known methods.
[0026] The foregoing illustrated embodiments are provided to
illustrate the structural and functional principles of embodiments
of the present invention and are not intended to be limiting. To
the contrary, the principles of the present invention are intended
to encompass any and all changes, alterations and/or substitutions
within the spirit and scope of the following claims. Where
approximate measurements are provided, the skilled artisan will
appreciate that typically variations of approximately plus or minus
10% will, in general, provide similar functionality.
* * * * *