U.S. patent number 3,808,628 [Application Number 05/263,126] was granted by the patent office on 1974-05-07 for floor mat.
This patent grant is currently assigned to Construction Specialties, Inc.. Invention is credited to Kenneth H. Betts.
United States Patent |
3,808,628 |
Betts |
May 7, 1974 |
**Please see images for:
( Certificate of Correction ) ** |
FLOOR MAT
Abstract
A floor mat comprises a multiplicity of substantially rigid
elongated rails joined together in closely spaced parallel relation
by spaced apart flexible strips that extend transversely across the
rails. Each rail has at least two matching slots spaced
longitudinally from each other. Each slot is open at the free edge
of the rib remote from the base and has an undercut portion spaced
from the free edge to leave a projection at the opening of the
slot. The connector strips are shaped in cross-section generally to
match the shapes of the slots in the rib and extend through the
slots. The projections are staked toward the rail bases to engage
and secure the connector strips to the rails.
Inventors: |
Betts; Kenneth H. (Mississauga,
Ontario, CA) |
Assignee: |
Construction Specialties, Inc.
(Cranford, NJ)
|
Family
ID: |
23000482 |
Appl.
No.: |
05/263,126 |
Filed: |
June 15, 1972 |
Current U.S.
Class: |
15/215; 15/238;
160/231.2; 52/669; 428/53 |
Current CPC
Class: |
A47L
23/26 (20130101); E04F 15/02166 (20130101); Y10T
428/17 (20150115) |
Current International
Class: |
A47L
23/00 (20060101); A47L 23/26 (20060101); A47l
023/24 () |
Field of
Search: |
;52/669,668,664
;15/215,216,217,238,239,240 ;160/231,231A |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Machlin; Leon G.
Attorney, Agent or Firm: Brumbaugh, Graves, Donohue &
Raymond
Claims
I claim:
1. A floor mat comprising a multiplicity of substantially rigid
elongated rails disposed generally parallel to each other in
closely spaced relation, each rail having a base portion supporting
a tread surface of the mat and at least one rib projecting from the
undersurface of the base portion, and at least two flexible
compressible connector strips extending transversely of the rails
and connecting them together, the rib of each rail having at least
two matching slots spaced longitudinally from each other, each slot
opening at the free edge of the rib remote from the base and having
an undercut portion spaced from the free edge and defining a
projection at the free edge of the rib, and the connector strips
being shaped in cross-section generally to match the shape of the
slots in the ribs and being received in the slots of the rails with
a portion thereof projecting slightly below the edge of each rib,
each connector strip including a portion extending into the
undercut portion of each slot and the projection defined at the
free edge of each rib being staked to engage, compress and grip the
portion of the connector strip extending into the undercut.
2. A floor mat according to claim 1 wherein each rail has two
transversely spaced longitudinally extending ribs, each of which
has a free edge spaced from the tread surface an equal distance so
that each strip is stably supported on a surface by the spaced
ribs.
3. A floor mat according to claim 2 wherein the ribs are located at
or close to the opposite lateral edges of the base portions.
4. A floor mat according to claim 1 wherein the connector strips
are of uniform cross-section throughout their length.
5. A floor mat according to claim 4 wherein the slots in the ribs
are generally T-shaped in cross-section, the cross of the T in each
slot defining two undercut portions spaced from the free edge of
the rib and defining projections on either side of the slot at the
free edge of the rib, the edges of the undercut portions remote
from the free edge of the rib being substantially coextensive with
the undersurface of the base portion of the rail, and wherein the
connector strips are substantially T-shaped in cross-section to
match generally the shape of the slots.
6. A floor mat according to claim 1 wherein the portion of each
connector strip corresponding to the vertical of the T (hereinafter
"vertical portion") is, in cross-section, substantially wider than
it is high.
7. A floor mat according to claim 6 wherein the said vertical
portion of the connector strip has, in cross-section, a varying
height across its width, the height in the region of the center
being less than the height adjacent the edges, thereby facilitating
bending the strip transversely into generally a U.
8. A floor mat according to claim 7 wherein a zone of the strip
corresponding to the crosspiece of a T is of a relatively hard,
rigid material and the remainder is of a relatively softer more
flexible material.
9. A floor mat according to claim 1 wherein the connector strips
are of a moderately compressible material and include a portion
normally projecting below the free edge of the rib but compressible
substantially to reduce the clearance between the rib edges and a
supporting surface.
10. A floor mat according to claim 1 and further comprising a
laterally adjacent longitudinally extending threshold portion
joined to at least one laterally outermost rail of the mat, the
threshold portion having an upper surface sloping laterally
downward from generally adjacent the tread surface of the mat
toward the surface on which the mat rests.
11. A floor mat according to claim 10 wherein the threshold portion
is integral with the said laterally outermost rail.
12. A floor mat according to claim 1 comprising a laterally
extending threshold portion joined to the ends of the rails at
least at one end of the mat, the laterally extending threshold
portion having an upper surface sloping laterally downward from
generally adjacent the outer surface of the mat toward the surface
on which the mat rests.
13. A floor mat according to claim 1 and further comprising a
peripheral frame having end members abutting the respective ends of
the rails and side members abutting the laterally outermost rails
of the mat.
14. A floor mat according to claim 13 wherein the end members and
side members of the frame have upper surfaces sloping laterally
downward from generally adjacent the tread surface of the mat
toward the surface on which the mat rests.
15. A floor mat according to claim 14 wherein the end members and
side members of the frame are secured to portions of the rails that
they abut.
16. A floor mat comprising two separate floor mat units, each of
said units including a multiplicity of substantially rigid
elongated rails disposed generally parallel to each other in
closely spaced relation, each rail having a base portion supporting
a tread surface of the mat and at least one rib projecting from the
undersurface of the base portion, and at least two flexible
connector strips extending transversely of the rails and connecting
them together, the rib of each rail having at least two matching
slots spaced longitudinally from each other, each slot opening at
the free edge of the rib remote from the base and having an
undercut portion spaced from the free edge, and the connector
strips being shaped in cross-section generally to match the shape
of the slots in the ribs, the units abutting each other with their
rails aligned end to end, and means for retaining the ends of the
rails of the respective mat units in axial alignment with each
other against relative lateral displacement.
17. A floor mat according to claim 16 wherein said retaining means
includes an elongated splice strip lapping end portions of the
rails of the respective units and having transverse ribs
dimensioned and spaced for coaction with the cross-sectional shapes
of the rails.
18. A floor mat comprising two separate mat units, each of said
units having a multiplicity of substantially rigid elongated rails
disposed generally parallel to each other in closely spaced
relation, each rail having a base portion supporting a tread
surface of the mat and at least one rib projecting from the
under-surface of the base portion, and at least two flexible
connector strips extending transversely of the rails and connecting
them together, the rib of each rail having at least two matching
slots spaced longitudinally from each other, each slot opening at
the free edge of the rib remote from the base and having an
undercut portion spaced from the free edge, and the connector
strips being shaped in cross-section generally to match the shape
of the slots in the ribs, the units abutting each other laterally
with a laterally outermost rail of one unit disposed adjacent a
laterally outermost rail of the other unit in closely spaced
parallel relation, and means for retaining said laterally outermost
rails in parallel, closely-spaced relation against relative lateral
displacement.
19. A floor mat according to claim 18 wherein said retaining means
includes at least one splice strip lapping the respective laterally
outermost adjacent rails of the two units and having ribs
dimensioned and spaced for coaction with the cross-sectional shapes
of the rails substantially to preclude relative lateral movement of
said laterally outermost rails.
20. A floor mat according to claim 1 wherein the rails are of
uniform cross-section along their length, each rail including in
cross-section a base portion having an essentially flat, shallow
channel defined by a flange portion along each side of and
extending upwardly from the base portion and a lip portion
extending inwardly from the upper edge of each flange portion and
defining with each flange portion an inwardly open slot extending
along each side of the base portion, and further comprising an
elongated strip of pile fabric material removably received in the
flat, shallow channel and anchor members on the base portion of
each rail adjacent opposite ends thereof and including teeth
penetrating into the overlying pile fabric material and securing
the pile fabric material against longitudinal movement in the
channel.
Description
BACKGROUND OF THE INVENTION
This invention relates to floor mats of the type used, for example,
in building entrances for dirt removal from the footwear of persons
entering the building.
Commonly, almost all types of buildings, including residential,
commercial and industrial, employ a grille, grating or mat, either
inside or outside (or both) of each entrance to the building, for
removal of dirt from the footwear of persons entering the building.
A wide variety of gratings and mats are available for this
purpose.
Among the attributes that a floor mat should have are effectiveness
in dislodging dirt from shoes and other footwear and retaining the
dirt dislodged, attractiveness, ease of cleaning, and a durability
that permits the grille or mat to withstand environmental
conditions, such as abrasions, water, substances present in the
dirt carried on the footwear, sunlight and temperature
conditions.
SUMMARY OF THE INVENTION
There is provided, in accordance with the invention, a floor mat
that very effectively meets the requirements set forth above. In
accordance with the invention, a floor mat comprises a multiplicity
of substantially rigid, elongated rails disposed generally parallel
to each other and in closely spaced relation. Each rail has a base
portion that supports a tread surface of the mat and at least one
rib, and preferably two, projecting down from the undersurface of
the base portion. The rails are connected together to form a mat by
at least two connector strips that extend transversely across the
rails and are located some distance apart longitudinally of the
rails. The ribs of each of the rails have slots that receive the
connector strips, the slots being shaped generally to match the
cross-section of the connector strip. Each slot is open at the free
edge of the rib and has an undercut portion spaced from the free
edge that defines a projection on either side of the opening. In a
preferred form, the slots are generally T-shaped and the connector
strips are correspondingly T-shaped in cross-section. The rails are
secured to the connector strips by staking the projections at the
slot opening so that they dig slightly into and thereby lock the
rails firmly in place at the proper spacing.
In a preferred embodiment of the floor mat, each rail has a rib
extending down from the base adjacent each lateral edge, and
aligned slots are formed in both ribs. The two spaced-apart ribs
strengthen the rail, provide stability for each rail, inasmuch as
the rails are supported on the ribs, and enhance the strength of
the attachment between the strips and the rails. The connecting
strips may extend a short distance below the bottoms of the ribs so
that the mat normally rests on the series of connector strips. The
bottoms of the connector strips may be roughened or otherwise
treated to provide a non-slip surface or may be of an inherently
non-slip material, such as a neoprene or some other type of rubber.
When the mat is walked upon, there will be a small deflection or
displacement of the rails so that the ribs are supported on the
floor. The magnitude of projection of the bottoms of the connector
strips and the compressibility of the strips are preferably such
that when the mat is walked upon, the strips will be compressed so
that the ribs, rather than the strips, carry a major part of the
load into the floor. In any instance, the degree of projection
should be less than that which would permit permanent deformation
of the rails.
The tread surface of the mat may be of various materials, including
the base material of the rails themselves, e.g., metal or plastic,
a grit material applied to the rail base, plastic tread pieces
appropriately installed on the rails or a pile fabric (e.g., a
carpet) permanently or removably installed on the rail bases. In
general, a removable carpet is preferred, inasmuch as carpet is an
excellent dirt remover, aesthetically pleasing, and reasonably
durable. The form of removable carpet strip and companion rail
construction described in U. S. Patent Application Ser. No. 200,372
entitled "Foot Grilles and Mats," filed Nov. 19, 1971, and assigned
to the assignee of the present application (also described below
and illustrated in some of the figures of the drawings) offers
significant advantages in the floor mats of the present
invention.
The effectiveness of dirt removal with a floor mat incorporating a
carpet as the tread surface is further enhanced by the dirt
capturing or storing ability of not only the carpet itself but the
inclusion of spaces between the carpet strips afforded in the strip
form of construction in the mat; dirt removed on the mat is
captured in the spaces in between the rails of the mat and, to some
extent, in the spaces under the base portions of the rails. Unlike
carpets, molded pieces and other types of continuous mats in which
dirt rapidly accumulates to the point that the ability of the tread
surface to capture and store additional dirt is virtually
eliminated, the dirt capturing and storage capability of a mat,
according to the invention, makes it particularly well suited for
high traffic areas, such as entrances to stores and commercial and
industrial buildings.
The flexibility of the connecting strips of the mats make it
possible for the mat to be rolled up, an advantage that is
particularly useful in cleaning the dirt storage area below the
mat. By rolling the mat away from its usual position on the floor,
cleaning of the space that it occupied is conveniently and quickly
accomplished. The mat may also be rolled up and stored when it is
not required, for example, in good weather.
When constructed of appropriate materials, for example, extruded
aluminum rails, highly durable carpet materials, connector strips
of neoprene, vinyl or any other durable rubber or plastic, the mat
has a very long, useful life, in contrast to the limited useful
life of various other types of mats. The use of replaceable carpet
strips in the mat further enhance its useful life in a good
condition; replacement of the carpet strips restores the mat to
"like-new." The mat may be manufactured at relatively low cost,
inasmuch as it employs a minimum number of different parts, i.e., a
uniform extruded rail, a uniform extruded or molded connector
strip, and a uniform tread material. When measured over the useful
life of the mat, the effective cost to the user is very low.
The manufacture of the grille is well adapted to mass production
techniques. For example, the rails, cut to appropriate lengths, are
assembled in a jig, the connector strips are readily pushed into
place in the open-ended slots, and an appropriate press with
appropriate tooling is employed to stake all of the projections
along each connector strip in a single operation.
DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention, reference may be made
to the following description of exemplary embodiments, taken in
conjunction with the figures of the accompanying drawings, in
which:
FIG. 1 is a plan view of the embodiment;
FIG. 2 is a cross-sectional view of the mat of FIG. 1 taken
generally along the lines 2--2 in FIG. 1 and in the direction of
the arrows;
FIG. 3 is a view in section of an end threshold member that may be
employed with the mat;
FIG. 4 is an end sectional view of a laterally outermost rail of a
mat fitted with a longitudinal threshold member;
FIG. 5 is an end cross-sectional view, on a larger scale than in
FIGS. 1 and 2, of a typical part of the mat of FIGS. 1 and 2;
FIG. 6 is a bottom view of a typical section of a mat, the view
being on a larger scale than FIGS. 1 and 2 and taken generally
along view lines 6--6 of FIG. 5;
FIG. 7 is a side sectional view taken generally through a connector
strip generally along the lines 7--7 of FIG. 5 and in the direction
of the arrows;
FIG. 8 is a cross-sectional view of an alternative embodiment of a
connector strip for use in the mat;
FIG. 9 is an end sectional view of the side portion of a mat having
an alternative form of longitudinal threshold;
FIGS. 10 and 11 are a top view and an end view, respectively, of a
splice between two abutting mat units, FIG. 11 being taken
generally along the lines 11--11 of FIG. 10 and in the direction of
the arrows;
FIG. 12 is a pictorial view of the end of a mat rail having a
carpet strip retainer;
FIG. 13 is a side elevational view of a modified form of rail for
use in the mat;
FIG. 14 is an end sectional view of another rail for the mat;
FIG. 15 is a pictorial view of an end portion of a modified form of
mat rail in which a group of pins for holding the carpet strip or
other tread member are formed integrally in the face of the
rail;
FIG. 16 is an end view of one rail of a mat according to the
invention having another form of tread member installed in the rail
channel; and
FIG. 17 is an end sectional view of a side portion of a mat
installed in a preformed and framed recess in a building floor.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
Referring first to FIGS. 1 and 2 of the drawings, an exemplary
embodiment of a floor mat, according to the invention, comprises a
multiplicity of rails 10 connected together in parallel
closely-spaced relation by connector strips 12 to form a unit that
is mounted within a peripheral frame 14. Although it is not
necessary, it will frequently be desirable for the mat to have a
frame or threshold around its perimeter, inasmuch as the tread
surface will inevitably be located some distance above a floor on
which the mat is used. In commercial installations, the building
will often be built with a floor recess at the entrance so that the
tread surface of the mat will be at about the same level as the
floor. In such a case, the peripheral frame may be a simple
rectangular frame having members that are rectangular in cross
section. The mat may, alternatively, be mounted within a frame that
is mounted directly on the floor of the building, in which case the
frame members will preferably be tapered in cross-section (see FIG.
2) to provide an inclined surface ascending from near the floor
surface up to approximately the level of the tread surface. Such a
threshold form of frame adds to the safety and attractive
appearance of the mat.
A threshold frame for the mat may be made of metal or plastic and
may be a separate unit or part of the mat. If a separate unit is
employed which may, for example, be a frame formed from aluminum
extrusions or from a relatively rigid plastic, the frame may be
either fastened to the floor or simply laid on the floor.
FIGS. 3 and 4 of the drawings illustrate a form of peripheral frame
that is a part of the mat. Inasmuch as it is usually desirable for
the mat to be susceptible of being rolled up, the members of the
frame, where the frame is part of the mat, are preferably formed of
a flexible material, such as rubber or plastic. An exemplary frame
14 (FIGS. 3 and 4) includes end members 16 that are united with the
ends of the rails 10 at each end of the mat and side members 17
that are united with the laterally outermost rails. Both the side
members and end members 16 and 17 include threshold portions 16a
and 17a, respectively, having upper surfaces that taper downwardly
from generally the tread surface level of the mat toward the floor.
The end members are joined to the ends of the rails by a mechanical
connection provided by slots 18 in the ends of the rail (as will be
described in more detail below) that receive a longitudinally
continuous tab 19 formed on the end threshold or frame member 16.
The side members 17 of the frame 14 (FIG. 4) include longitudinally
continuous legs 17b that are received under the bases of each of
the laterally outermost rails of the mat and are joined to them by
an adhesive, rivets, or other appropriate fastener. As mentioned
above, a peripheral frame or threshold is an optional, though
usually preferred, component of the mat.
Referring to FIGS. 5 to 7, an exemplary embodiment of the mat
includes identical parallel substantially rigid rails 10 made of
aluminum extrusions cut to appropriate lengths. Each rail 10 is of
uniform cross-section along its length and, in cross-section, is
generally H-shaped, though the cross of the H is greatly elongated.
In cross-section (FIG. 5) the rail is composed of a base portion
22, an upwardly extending flange 24 along each edge of the base, an
inwardly projecting lip 26 along the upper end of each flange 24
and a downwardly extending flange or rib 28, also extending along
each edge of the base 22. The flanges 24, lips 26 and base 22
define a channel that receives a replaceable carpet strip 30.
Reference may be made to U. S. Patent Application Ser. No. 200,372
(referred to above) for a complete description and illustration of
appropriate replaceable carpet strips for the mat. Although
replaceable carpet strips constitute a preferred form of tread
surface for the mat, it will be readily apparent to those skilled
in the art that various other forms of tread surface may be
used.
The connector strips 12 that join the rails 10 together extend
continuously across the mat and extend through aligned slots 32
punched or otherwise formed in both ribs 28 of each rail (see FIG.
7). The slots 32 are generally T-shaped and are open at the lower
edge of each rib, the opening being of a substantially lesser
dimension longitudinally of each rib than the upper portion (or
cross of the T) 33 of the slot. The cross portion 33 of the slot is
generally contiguous with the bottom surface of the base portion 22
of the rail. Thus, the configuration of the slot is such as to
provide a pair of inwardly extending projections 34 at the lower
edge of the rib 28. As originally formed, the projections extend
straight along the bottoms of the ribs 28.
The connector strips 12 are made of a flexible material, such as
rubber or a flexible plastic. Ninety Durometer neoprene provides
excellent results and has the advantage of being more durable under
various environmental conditions than are most plastics. Each
connector strip 12 is of uniform cross-section along its length
and, in cross-section, has a shape substantially matching the
original shape of the slots 32 in the ribs, i.e., generally
T-shaped in cross-section. The ends of the upper or cross portion
35 of the connector strip 12 are tapered (see FIG. 7), and the base
36 is formed with a continuous lengthwise slot 38. The slot 38
facilitates bending the cross part 35 into a generally U-shape in
cross-section and permits the strip 12 to be installed in the
aligned slots of the mat rails by bringing the extremities of the
top portion of the strip inwardly to clear the inner ends of the
projections 34 on the ribs and then pushing the strip into place.
The tapered ends at the extremities of the cross part of the strip
facilitate acceptance of the end portions of the cross part 35 in
the extremities of the slots. The projections 34 on either side of
the slots in all ribs of all rails of the mats are staked toward
the base into engagement with the strips to anchor the rails in
place on the strips. Thus the mat is united into a unit that can be
rolled laterally because of the flexibility of the strips 12.
FIG. 8 of the drawings illustrates a modified form of connector
strip for the mat. The general cross-sectional shape of the
modified form, which is designated by the reference numeral 12a, is
the same as the embodiment of FIG. 7. The principal difference
between the two forms of strips 12 and 12a is that instead of
having a slot extending along the base portion, as in the
embodiment of FIG. 7, the embodiment of FIG. 8 is formed of
neoprene rubbers of two different hardnesses. The upper or cross
part 35a is made of relatively hard, though flexible, neoprene,
whereas the bottom or base portion 36a is made of a relatively
softer neoprene. In addition, the bottom surface of the base
portion 36a is concave, rather than grooved. The softer material in
the base portion 36a, permits the connector strip 12a to be bent
into a U shape in the manner described above without the groove.
The concave shape of the base 36a and the use of a softer rubber in
the base portion also enhances the non-slip characteristics
provided by the connector strip in the mat; the concavity at the
bottom of the base 36a in the embodiment of FIG. 8 is relatively
easily compressed under load and in the process forces air out from
under the strip to provide a suction-cup effect.
It will be observed in the drawings that the bottom of the
connector strips 12 project slightly below the bottom edges of the
ribs 28 of the rails. Accordingly, the mat is supported on a floor
by the connector strips, and the rubber or other material of the
strips provides non-slip characteristics. The extent to which the
bottoms of the connector base portions 36 extend below the bottoms
of the ribs should not be so great to permit a large flexure or
possible permanent deformation of the rails. When the mat is walked
upon, the connector strips will deform or displace slightly to
allow the ribs to engage and be supported on the floor. It will
sometimes be advantageous to roughen or otherwise treat the bottom
surfaces of the connector strips to enhance their non-slip
properties.
FIG. 9 shows a mat similar to the embodiment of FIGS. 1 and 2
except that the laterally outermost rail 10a has an integral
threshold portion 40. The rail 10a is formed of extruded aluminum,
though it may be made of plastic or some other metal. The threshold
portion 40 has an inclined leg that extends continuously along the
length of the laterally outermost rail 10a and has teeth or some
other uneven surface to increase its non-slip properties.
FIG. 9 also shows that the connector strips terminate inside of the
laterally outermost bottom rib 28 of the rail 10a. For aesthetic
reasons, it is usually desirable so to end the connector strip so
that the laterally outermost side surfaces of the mat present a
clean appearance. The upper portion of the ends of the connector
strips may be secured to the underside of the base of the rail by
an adhesive, rivets or other appropriate connector. It may be
mentioned at this point that an adhesive may be employed to provide
further securement of the connector strips 12 to the rails 10 in
grilles constructed according to the invention.
A floor mat having an integral threshold (as in FIG. 9) along each
lateral edge is particularly well suited for use in corridors or
entrance ways to buildings in which the mat runs the entire width
from wall to wall. In such an installation, the ends of the rails
abut the wall or baseboard so no threshold or frame portion is
required at the ends.
An important feature of a mat according to the invention is that it
can be rolled up for storage or for cleaning of the space below it.
Accordingly, it is desirable not to produce a mat of a size so
large as to make it difficult or inconvenient to roll it up.
Nonetheless, many installations, such as large entrance ways to
commercial and industrial buildings, will utilize very large mats,
larger than can conveniently be rolled up. Accordingly, a further
feature of the invention, as illustrated in FIGS. 10 and 11 of the
drawings, involves providing for butting mat units end to end or
side by side, as may be warranted by particular design
requirements, so that large areas may be covered but separate
convenient-sized units of the mat can be rolled up separately.
FIGS. 10 and 11 illustrate portions of two mat units, designated by
the reference numerals 50 and 52, that are placed end to end at a
joint 54. The rails of the two units are held in axial alignment
with each other and at proper spacing by a splice strip 56. The
splice strip, which may be made of metal or plastic, is an
elongated member that laps the end portions of the rails of the two
mat units 50 and 52 and is formed with upwardly extending ribs 58
having a width equal to the spacing between the sides of the rails
and spaced-apart along the length of the strip a distance equal to
the pitch distance of the rails. As illustrated in FIGS. 10 and 11,
the ribs extend somewhat above the bottoms of the bases of the
rails so that the rails nest between the ribs 58 and the bases of
the rails rest on the splice strip 56. It should be evident from
FIGS. 10 and 11 that the end portions of the ribs 28 along the
bottoms of the rails are cut away to an extent sufficient to
accommodate the splice strip 56.
FIGS. 10 and 11 should also make readily evident the form of a
similar splice strip that can be used to maintain proper spacing
and alignment between mat units that are placed side by side.
Several splice strips that are substantially the same in general
configuration as the splice strip 56 are used at intervals along
the lengths of the two laterally abutting units. Each splice strip
has three ribs, the outermost two of which are at the end
extremities of the splice strips. The center of the three ribs is
received at the joint between the two mat units and each of the
outermost pair of ribs is received between the laterally outermost
pair of rails of the two mat units. The ribs on the underside of
the outermost rails of the two units that are laterally abutting
are cut away to accept the splice strip. In some installations, it
may be desirable to employ metal splice strips that are secured to
the floor so that the mat is replaced in its proper position after
cleaning. In other instances it may be desirable to employ flexible
splice strips and to join the splice strip to one of the two units
that abut, using an adhesive, rivets or other appropriate
connectors. Splice strips can also be secured to the respective
members by forming matching slots and ribs on the splice strip and
using the staking principle employed in the basic construction of
the mat. For example, referring (briefly) to FIG. 3, a splice strip
could be secured to the ends of one of two adjacent mat units by
forming slots in the bottom ribs of the rails of the mat to accept
a projecting tongue on a splice strip and then staking a projection
defined by the slot to anchor the splice strip to the ends of the
rails. In FIG. 3, the slot 18 previously described, accepts the
continuous tongue 19, and a projection 20 defined by the slot 18 in
each rib 28 of each rail is staked to anchor the end frame member
16 to the end of each rail.
The removable carpet strips 30 in a mat of the type of the present
invention may be secured to the rails against longitudinal movement
by small anchor pieces 60 shown in FIG. 12 that are installed at
each end of each rail. Each piece 60 is a thin sheet of metal that
has been punched in a manner to create small pointed projections 62
constituted by the metal cut out in the punching operation. The
under surface of the piece 60 is coated with a pressure-sensitive
adhesive and is adhered to the upper surface of the base of each
rail. The projections 62 dig into the base of the carpet strips and
retain the carpet strips against longitudinal movement.
FIG. 13 shows an advantageous modification of the rails in which
the ribs along one or both sides of each rail are cut away at
intervals. As mentioned above, one of the important advantages of a
mat according to the invention is the provision of a substantial
storage space for dirt dislodged from the footwear of people who
tread upon it. The size of the storage space can be further
increased by the cut-aways or slots 66 in the ribs, inasmuch as
dirt falling between the rails of the mat can readily pass through
the slots 66 and into regions directly underneath the rails. The
slots 66 should not be of such a length as to materially weaken the
rails and permit permanent deformation of the rails in regions
between portions 68 of the rails that are left after cutting away
to form the slots 66. In other words, a sufficient number of rib
portions 68 at a relatively close spacing should be left to support
the rails on the floor.
FIG. 14 is exemplary of a modified form of rail for the mat, in
this case, a rail 70 formed entirely of plastic and having a
toothed or grooved upper surface that provides for dirt removal and
enhances the slip resistance properties of the mat. As mentioned
previously, various forms of tread surfaces may be employed and
FIG. 14 is included to illustrate one of them. Although not
illustrated in FIG. 14, all-plastic (or all-rubber) rails may have
material of two hardnesses, a soft material as the tread portion
and a hard material as the base portion. If the rails 70 are of a
thermoplastic material, the connector strip may be united to the
rails by heat-staking the projections at either side of the slots.
If the connector strips are made of a flexible thermoplastic
material, rather than a thermosetting material, the connector
strips can readily be glued to the bottoms of the rails, rather
than or in addition to being mechanically connected, or they may be
ultrasonically or otherwise heat-welded to each other. The ability,
according to the invention, to interconnect flexible connector
strips with relatively rigid mat rails, even in an all plastic
grille, offers advantages over a molded type of mat in that the
relatively rigid, spaced-apart, longitudinal rails, coupled with
the flexible strips, provides the combined advantages of large dirt
storage capability and the capability of being readily rolled up
for storage or cleaning. Moreover, extrusion of thermoplastic
members for a grille according to the invention will usually
provide economical advantages over molding techniques, and the
sizes of the units that can be constructed in accordance with the
present invention are much greater than those that are conveniently
or practically produced by molding.
FIG. 15 illustrates a modified form of retainer arrangement on a
rail for holding tread surface elements installed on the rail
against longitudinal slipping. A rail 72 substantially identical to
the rails 10 of the embodiment illustrated in other figures and
described previously is punched with small triagular pins 74
adjacent opposite ends and projecting up from the base 76 of the
rail. The pins 74 are constituted by a material punched out of the
base portion 76 and, upon installation of a tread element, such as
a carpet strip (not shown in the figure), the pins 74 will dig into
the bottom of the tread member and hold it against longitudinal
movement.
In FIG. 16 of the drawings, another form of tread element 78,
namely one extruded from rubber or plastic, is employed in
association with a mat that otherwise is identical to the mat
illustrated, for example, in FIGS. 5 to 7 of the drawings and
described above. Preferably, the plastic or rubber tread elements
78 are of a relatively compressible material and have an upper
surface constituted by alternating ribs 80 and slots, the upper
ends of the ribs assisting in dirt removal and contributing to the
non-slip characteristics of the tread surface and the slots 82
providing dirt storage and, of course, being involved in creating
the ribs. The lateral edges of the tread element 78 are formed with
longitudinally continuous projecting portions 84 that are received
in the side slots of the rail 12. It will usually be desirable to
secure the tread elements 78, and similar forms of rubber of
plastic tread elements, to the rails 12 by an adhesive, such as a
pressure sensitive adhesive. Excellent results have been obtained
by applying a strip of double-faced pressure sensitive tape to the
rail prior to installing the element 78.
FIG. 17 illustrates the installation of a mat, according to the
invention, in a frame 86 built into the building floor 88, in this
instance a poured concrete floor. In the illustrated construction,
the floor 88 includes a surfacing 90 of stone, terrazzo, or any
other appropriate surface material, separated from the frame by a
grouting 92. The frame is constituted by continuous extrusions that
are generally H-shaped in cross-section, the legs 94 and 96 of the
extrusion having inwardly projecting ribs 98 and 100. Masonry
anchors 102 having leg portions of appropriate shape are installed
at intervals along each member of the frame by clamping the leg 104
on the anchor and an anchor retainer piece 106 together using a
screw 108 to produce a firm engagement with the lower ones of the
ribs 98 and 100. The horizontal part 110 of the H is located at the
elevation of the recessed surface 112 of the concrete floor 88 upon
which the mat is supported. The upstanding leg 114 of the extrusion
constitutes a peripheral wall within which the mat is fitted within
the floor recess.
The mat illustrated in FIG. 17 is identical to the mat illustrated
in FIGS. 5 to 7 of the drawings, except that the sides and ends of
the mat receive extruded spacers 116 of plastic or rubber that,
preferably, are field cut to conform the overall mat size and shape
to the field dimensions and shape of the floor recess. The spacers
116 are quite similar to the threshold elements 114 shown in FIGS.
3 and 4 of the drawings and may be installed in a manner identical
to the manner in which the threshold elements of FIGS. 3 and 4 are
installed on the mat. The upper part of each spacer 116 is formed
with longitudinal slots or grooves 118 located, say, one-eighth or
one-fourth inch apart, the grooves providing a guideway for field
cutting with a knife of the spacers to the desired width for
properly fitting the mat. Accordingly, it is desirable initially to
make the spacers 116 somewhat wider than the final required
dimension; for example, the spacers may have an exposed width
extending beyond the sides and ends of the grille rails
approximately equal to the width of one rail.
Many other variations and modifications of the invention will be
apparent to those skilled in the art without departing from the
spirit and scope of the invention. The above described embodiments
are, therefore, intended to be merely exemplary, and all such
variations and modifications are intended to be included within the
scope of the invention as defined in the appended claims.
* * * * *