U.S. patent application number 16/283618 was filed with the patent office on 2019-06-20 for foam mat.
The applicant listed for this patent is Parallax Group International, LLC. Invention is credited to Bruce A. Thrush.
Application Number | 20190183273 16/283618 |
Document ID | / |
Family ID | 37074276 |
Filed Date | 2019-06-20 |
![](/patent/app/20190183273/US20190183273A1-20190620-D00000.png)
![](/patent/app/20190183273/US20190183273A1-20190620-D00001.png)
![](/patent/app/20190183273/US20190183273A1-20190620-D00002.png)
United States Patent
Application |
20190183273 |
Kind Code |
A1 |
Thrush; Bruce A. |
June 20, 2019 |
FOAM MAT
Abstract
A two layer foam mat is described. The raw materials for each
layer are separately mixed and heated in different batches, and
separately pressed through heated rollers to form a plurality of
sheets. One or more sheets from each batch are stacked together in
a press and heated above a foaming temperature to permit the
stacked sheets to foam and expand. The press restricts the sheets
from vertical expansion while allowing horizontal expansion. Once
the sheets are foamed, a series of alternating teeth and receiving
slots can be cut around the boundary of the mat to form an
interlocking peripheral wall. The layers preferably have the same
chemical composition after foaming, even though the layers are
formed from different batches and may have different colors and/or
textures.
Inventors: |
Thrush; Bruce A.; (San Juan
Capistrano, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Parallax Group International, LLC |
San Juan Capistrano |
CA |
US |
|
|
Family ID: |
37074276 |
Appl. No.: |
16/283618 |
Filed: |
February 22, 2019 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
15642078 |
Jul 5, 2017 |
10258179 |
|
|
16283618 |
|
|
|
|
15052788 |
Feb 24, 2016 |
10172491 |
|
|
15642078 |
|
|
|
|
14630232 |
Feb 24, 2015 |
9289085 |
|
|
15052788 |
|
|
|
|
11105182 |
Apr 13, 2005 |
|
|
|
14630232 |
|
|
|
|
29203027 |
Apr 8, 2004 |
D532238 |
|
|
11105182 |
|
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 25/14 20130101;
B32B 2250/22 20130101; B32B 2266/025 20130101; B32B 2266/0221
20130101; B32B 2471/04 20130101; E01C 13/045 20130101; B32B 5/32
20130101; A47G 27/0206 20130101; B32B 3/263 20130101; E04F 2201/095
20130101; B32B 3/06 20130101; B32B 25/04 20130101; Y10T 428/24612
20150115; B32B 5/18 20130101; A47G 27/0293 20130101; B32B 2250/02
20130101; B32B 3/30 20130101; B32B 2307/402 20130101; B32B 3/10
20130101; B32B 3/02 20130101; E01C 2201/14 20130101; E04F 15/105
20130101; B32B 2266/0278 20130101; E04F 15/10 20130101; A47G
27/0218 20130101; B32B 2307/404 20130101; A47G 27/0275
20130101 |
International
Class: |
A47G 27/02 20060101
A47G027/02; E04F 15/10 20060101 E04F015/10; B32B 3/02 20060101
B32B003/02; B32B 3/06 20060101 B32B003/06; B32B 3/26 20060101
B32B003/26; B32B 3/30 20060101 B32B003/30; B32B 5/18 20060101
B32B005/18; B32B 5/32 20060101 B32B005/32; B32B 25/04 20060101
B32B025/04; B32B 25/14 20060101 B32B025/14; E01C 13/04 20060101
E01C013/04; B32B 3/10 20060101 B32B003/10 |
Claims
1. A foam mat comprising a body bounded by an interlocking
peripheral wall, the body comprising: a first layer made from a
first batch of raw materials comprising a first polymer and a
second polymer; a second layer made from a second batch of raw
materials comprising the first polymer and the second polymer;
wherein the first layer and second layer are made by (i) separately
heating and mixing the first batch of raw materials and the second
batch at a temperature that is below a foaming temperature of the
first batch of raw materials and the second batch of raw materials,
respectively; (ii) separately heating and pressing the first batch
of raw materials and the second batch of raw materials through
rollers that are maintained within uniform temperatures of a range
of 5.degree. C. to form a first plurality of sheets and a second
plurality of sheets, respectively; and (iii) stacking, pressing,
and heating one or more of the first plurality of sheets and one or
more of the second plurality of sheets to a temperature that
permits the sheets to foam and expand; and wherein, after foaming
and expansion, the first layer comprises a first chemical
composition and the second layer comprises a second chemical
composition that is substantially similar to the first chemical
composition so that the first layer and second layer respond
similarly when subject to temperature changes and forces.
2. The foam mat of claim 1 wherein the first polymer comprises
ethylene vinyl acetate (EVA) and the second polymer comprises
polyethylene (PE).
3. The foam mat of claim 2 wherein the EVA is recycled EVA, and the
PE is virgin PE.
4. The foam mat of claim 2 wherein the EVA is virgin EVA, and the
PE is recycled PE.
5. The foam mat of claim 2 wherein the EVA is virgin EVA, and the
PE is virgin PE.
6. The foam mat of claim 1 wherein the second batch of raw
materials comprising the same amount of the first polymer and the
second polymer as the first batch of raw materials.
7. The foam mat of claim 1 wherein the first layer and the second
layer have the same coefficient of thermal expansion and the same
elastomeric properties.
8. The foam mat of claim 1, wherein the first batch of raw
materials comprises a first colorant and the second batch of raw
materials comprises a second colorant that is different that the
first colorant.
9. The foam mat of claim 1, wherein the first layer comprises a
first texture and the second layer comprises a second texture that
is different than the first texture.
10. The foam mat of claim 1 wherein the interlocking peripheral
wall comprises a plurality of alternating teeth and receiving
slots.
11. A method of manufacturing a foam mat comprising a first layer
and a second layer, the method comprising the steps of: (i)
separately heating and mixing a first batch of raw materials and a
second batch of raw materials at a temperature that is below a
foaming temperature of the first batch of raw materials and the
second batch of raw materials, respectively; wherein the first
batch of raw materials comprises a first polymer, a second polymer,
and a colorant; and wherein the second batch of raw materials
comprises the first polymer, the second polymer, and a second
colorant; (ii) separately heating and pressing the first batch of
raw materials and the second batch of raw materials through rollers
that are maintained within uniform temperatures of a range of
5.degree. C. to form a first plurality of sheets and a second
plurality of sheets, respectively; and (iii) stacking, pressing,
and heating one or more of the first plurality of sheets and one or
more of the second plurality of sheets to a temperature that
permits the sheets to foam and expand; and (iv) cutting a plurality
of alternating teeth and receiving slots around a peripheral wall
of the mat.
12. The method of claim 11 wherein the first polymer has a first
rate of foaming and the second polymer has a second rate of foaming
that is different than the first rate of foaming.
13. The method of claim 11 wherein the first polymer has a first
rate of expansion and the second polymer has a second rate of
expansion that is different than the first rate of expansion.
14. The method of claim 11 wherein the step of stacking, pressing,
and heating one or more of the first plurality of sheets and one or
more of the second plurality of sheets comprises stacking the
sheets in a press.
15. The method of claim 14 wherein the press comprises a top plate
and a bottom tray.
16. The method of claim 15 wherein the bottom tray comprises a
first die having a first texture.
17. The method of claim 16 wherein the top place comprises a second
die having a second texture that is different than the first
texture.
18. The method of claim 11 wherein the step of stacking, pressing,
and heating one or more of the first plurality of sheets and one or
more of the second plurality of sheets comprises stacking three or
more of the first plurality of sheets and three or more of the
second plurality of sheets.
19. The method of claim 11 wherein the first plurality of sheets
and the second plurality of sheets have a uniform thickness.
20. The method of claim 11 wherein the first plurality of sheets
and the second plurality of sheets have a thickness between 5 to 10
millimeters.
Description
[0001] This application is a continuation of U.S. patent
application Ser. No. 15/642,078, filed Jul. 5, 2017, which is a
continuation of U.S. patent application Ser. No. 15/052,788, filed
Feb. 24, 2016, which is a continuation of U.S. patent application
Ser. No. 14/630,232, filed Feb. 24, 2015, now issued U.S. Pat. No.
9,289,085, which is a continuation of U.S. patent application Ser.
No. 11/105,182, filed Apr. 13, 2005, which is a
continuation-in-part of U.S. patent application Ser. No.
29/203,027, filed Apr. 8, 2004, now issued U.S. Pat. No. D532,238,
all of which are incorporated herein by reference in their
entirety.
FIELD OF THE INVENTION
[0002] The present invention is directed to floor matting. More
specifically, the present invention is directed to resilient floor
matting which can be used in playroom environments, athletic
environments such as for gymnastics or tumbling, and for
environments where cushioning from the hard undersurface is
desirable, such as a studio, or workplace where people are standing
for prolonged periods. Artists, draftsmen, wood workers, printers,
surgeons, dentists, retail sales people, and the like, are subject
to standing on hard surfaces for prolonged periods.
BACKGROUND
[0003] Resilient floor matting has been used extensively for
thousands of years. Fiber matting was first used, then came
carpeting. Between the 1900's and 1960's, canvas mats filled with
batting were commonly used for gymnastics and tumbling. In the last
two centuries, floor matting of cork has been extensively used to
absorb the pounding forces of the feet on hard surfaces. In the
last 30 years mats prepared from polymeric foam has become common.
For purposes of convenience, such as retail sale, packaging,
transportation, and the like, the mats are sold in roll form, such
a 4'.times.8' sheets, or as tiles measuring anywhere from
6''.times.6'' up to 3'.times.4'. Some floor matting tiles,
especially large dimension tiles, are merely laid down with
adjacent tiles butting up against one another. For smaller tiles,
there is an interlocking arrangement. Some tiles have a periphery
of interlocking teeth which dovetail with the peripheral teeth of
adjoining tiles. Prior art tiles are one color and/or have a
textured surface on one side only. The bottom surface is normally
smooth and flat, and the top surface is smooth and flat or
textured, depending upon the taste of the user. The prior art has
attempted to make matting with one color on one side and another
color on the other side, but without success. Delamination of two
or more mat layers can be a problem especially with use or when
there are temperature changes, such as from ambient temperature to
below freezing or from ambient temperature to an elevated
temperature. In addition, delamination can occur when the mats are
subject to physical forces, such as with tumbling, or gymnastics,
or the dropping of articles, such as weights, on the matting. In
addition, running and stopping or quick turns on matting, applies
shear forces to each of the layers which can lead to delamination
of the layers.
[0004] With use, the working surface or top surface of the floor
matting can become disfigured with stains from dirt, paint, ink,
and the like, physically disfigured can cause cuts, abrasions, and
indentions in the floor matting. The floor matting can be reversed
but this can be unsatisfactory if the bottom surface of the matting
is smooth and the top surface of the matting is textured, or vice
versa. When it is reversed, the textured side becomes the base
surface and the original base surface becomes the top working
surface. The new working surface will not be textured.
[0005] Resilient matting, such as foam elastomeric matting, is
normally anywhere from 3/8'' to 3/4'' in thickness and around
2'.times.2' square. To cover a room 10'.times.10', 25 mat tiles are
normally required.
[0006] Solid resilient matting can be quite heavy and voluminous
when stacked. Polymeric foam elastomeric resilient matting is
relatively light, but it is also voluminous when stacked. For
example, matting (2'.times.2'.times.1/2'') for 12'.times.12'
coverage when stacked forms a cube 2'.times.2'.times.11/2'. For
retail sales, matting can take up a great deal of retail space
especially when several textures and several colors are being
offered. For example, if four colors are available and four
textures are available, the retail outlet has to carry sixteen
varieties of floor matting. The number of varieties could be cut in
half by having both surfaces of the matting textured in different
textures and/or different colors. Thus, if four colors are offered
in four textures for polymeric foam matting, the matting on one
surface having one color and one texture and the other surface
having another color and another texture, only eight varieties of
matting would be required at the retail outlet.
SUMMARY OF THE INVENTION
[0007] The floor matting of the present invention comprises a body
having first and second layers, each layer having an outer surface
and an inner surface, the inner surfaces of the first and second
layers are bound together to form an inner boundary, the outer
surfaces constituting a first and second surfaces of the body, the
first and second surfaces being generally parallel to one another
but not generally parallel to the boundary; the first and second
surfaces having different surface textures or design and/or
different colors, the body bounded by an interlocking peripheral
wall.
[0008] The body is a planar structure and from a plan view, it can
have a rectangular shape, triangular shape, square shape or
hexagonal shape. The interlocking peripheral wall has a series of
teeth and receiving slots in alternating positions. The teeth
dovetail with the receiving slots of adjacent floor mats to lock
the floor mats together.
[0009] The thickness of the body is generally constant over its
width and length. This is important because it permits a plurality
of floor mats to be joined together to form a continuous planar
surface. Although the thickness of the body is generally constant,
the thickness of the first and second layers is preferably not
constant. The reason for this is that the boundary between the
first layer and the second layer is undulating. If one layer was
peeled away to show the boundary which follows the inner surface of
the remaining layer, the topography of the boundary would look
similar to rolling hills and valleys.
[0010] The undulating nonplanar boundary resists delamination of
the two layers. By having an undulating boundary between the two
layers, shear forces and compressive forces applied to one layer
are partially converted to compressive forces and tension forces.
For example, if one layer is placed in shear with respect to the
other layer with an undulating boundary, in certain areas of the
undulating boundary shear forces are going to be partially
converted to compressive forces, and in other areas, the shear
forces are going to be converted into tension forces. This helps to
minimize delamination between the two layers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a top plan view of the floor mat of the present
invention;
[0012] FIG. 2 shows an embossed design on the top surface of the
floor mat of FIG. 1;
[0013] FIG. 2a shows an alternative embodiment of an embossed
design on the top surface of the floor mat of FIG. 1;
[0014] FIG. 2b is another embodiment of a design embossed in the
top surface of the floor mat of FIG. 1;
[0015] FIG. 3 is a bottom plan view of the floor mat of FIG. 1;
[0016] FIG. 4 shows another design embossed in the surface of the
floor mat of FIG. 3;
[0017] FIG. 5 shows a side view of the floor mat of FIG. 1; and
[0018] FIG. 6 is an enlargement of the side view of FIG. 5 in the
encircled area labeled FIG. 6.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Referring to FIGS. 1 and 3, the floor mat 10 is a large,
planar, flat, body 12 which has a first surface 16A and a second
opposing parallel surface 16B. The two surfaces 16A and 16B are
parallel to one another. The periphery of the floor mat is bounded
by an interlocking perimeter 26, which comprises a series of teeth
28A and receiving slots 30A in alternating positions. Interlocking
perimeter 26 also comprises four corners each having a smaller
tooth 28B and a smaller receiving slot 30B. The surface 16A has a
texture or three dimensional design 18' and the second surface 16B
has a texture or three dimensional design 18'', the two textures or
designs can be the same or different. For purposes of this
invention, texture means a three dimensional texture or design
embossed in or embossed out of the mat surface. One or both
surfaces 16A and 16B can also be smooth. The body is made up of two
layers 14A and 14B (see FIG. 6). The two layers are bound together
either by heat welding and/or an adhesive. Preferably, the two
layers have the same chemical composition so that the two layers
have the same coefficient of thermal expansion and the same
elastomeric properties so that the two layers work together and
respond similarly when subject to temperature changes and forces.
The two layers have an outer surface 16A and 16B, respectively, and
two inner surfaces 17A and 17B which preferably form an undulating
boundary 20 between the two layers. Preferably, the inner surfaces
17A and 17B are not parallel to the first and second surfaces.
Rather, the two inner surfaces 17A and 17B in the preferred
embodiment meet to form undulating boundary 20 which has a
topography of rolling hills and vales. The two outer surfaces 16A
and 16B are parallel, or generally parallel. In the preferred
embodiment, the inner surfaces 17A and 17B are generally not
parallel to either of the outer surfaces. Thus, the thickness 22 of
the body is generally constant across the entire length and width
of the body. In contrast, in the preferred embodiment, the
thicknesses of the first layer and second layer vary as the
boundary undulates. Thus, the thickness of the first and second
layers vary from point to point. The thickness 24A of the first
layer 14A at a given point, together with the thickness 24B of the
second layer at the same point are equivalent to the thickness 22
of the body. Thus, thickness 24C of the first layer 14A, at a
second point, is less than the thickness 24A at the first point and
the thickness 24D of the second layer 14B at the second point is
greater than the thickness 24B of the second layer at the first
point. The undulating boundary between the first layer and the
second layer resists delamination of the two layers making the mats
more robust as explained supra. However, the two layers 14A and 14B
can be flat planar layers of the same or different thickness, each
having a generally uniform thickness.
[0020] As described above, the texture of the first surface 16A can
be different than the texture of the second surface 16B (see FIGS.
2, 2a, 2b, and 4 showing textures 18A, 18B, 18C and 18D,
respectively). Similarly, the color of the first layer and the
first surface 16A can be different than the color of the second
layer 14B. Thus, the present mats give the purchaser the
opportunity to have a selection of colors and/or a selection of
textures. In addition, it permits the purchaser to form a
checkerboard pattern or other pattern, assuming enough tiles are
utilized, utilizing the different textures and/or colors of the mat
tiles.
[0021] Preferably, the mats are made from resilient polymeric
materials, such as natural or synthetic rubber, and most preferably
from foam elastomeric material, such as polyethylene foam,
polyurethane foam, EVA-PE foam (ethylene vinyl acetate-polyethylene
foam elastomer), and EVA foam (ethylene vinyl acetate foam).
[0022] Preferably, the elastomeric mats are made from a combination
of virgin polymer and recycle polymer, such as virgin EVA polymer
and a mix of virgin and recycle PE (polyethylene) polymer. The
blend of EVA and virgin and recycle PE are compounded together and
heated to a temperature below the polymer foaming temperature and
pressed into thin sheets through rollers of uniform thickness
within uniform temperatures of a range of 5.degree. C.; preferably
within a range of 1.degree. C. The sheets are 5 to 10 millimeters
in thickness. Other thicknesses can be employed. The sheets are
sandwiched together, normally about six sheets to each mat and
placed in trays having a bottom surface with a die or mold for the
texture and a top plate. The top plate may also have a die or mold
for the texture for the other surface. The tray with the sandwich
of layers of the raw composition and the top plate are pressed in a
press and heated to a temperature to permit the elastomer to foam
and expand. The press is required to keep the distance between the
tray and the top plate constant to yield elastomeric foam mat of a
predetermined thickness. Preferably, the three like sheets have
virtually identical compositions and blend together to form one
layer of the mat. The two mat layers may have slightly different
compositions because their respective sheets are made from
different raw compositions (the differences can be slight) at
different times (e.g., in different batches).
[0023] The virgin PE and the recycle PE have different rates of
thermal expansion and different rates of foaming. The raw
compositions of the sheets are restricted in vertical movement and
unrestricted in horizontal movement between the tray and the top
plate in the press when heated. In the preferred embodiment, three
layers of the raw composition will have one color and the other
three layers of composition will have another color. Thus, one side
of the mat may be red and the other side may be black, etc. The die
in the bottom of the tray places one texture on one surface of the
mat, and if the top plate has a die, it places a texture on the
other surface of the mat. Preferably, the two textures are
different although they can be the same. After the foaming reaction
is completed by the heating in the press, the tray and the top
plate are removed from the press and the unfinished mat is removed
from the tray. The mat is allowed to cool and then it is passed to
a cutting machine wherein the mat with the interlocking periphery
is cut out of the unfinished mat. The mat is now complete.
[0024] In those cases where the top plate does not have a die for
the texture, the mat comes out of the press with a texture only on
one surface and a smooth planar other surface. The mat can be sent
to a roller mill having a cool roller and a heated roller with a
die attached thereto. The heated roller with die only heats the
surface not having a texture permitting the heated roller with die
to texture the other surface of the mat. The textured surface is
kept cool by the cool roller. The mat is passed between two rollers
and the roller that touches the texture surface is cool, whereas
the roller with the die to give texture to the other surface is
hot. The cooling roller prevents destruction or damage to the
textured surface created in the press.
[0025] The above invention is not restricted to the specific
embodiments disclosed herein; modifications and other embodiments
of the invention are within the scope of the invention.
* * * * *