GB1605028A

GB1605028A - Mats

Info

Publication number: GB1605028A
Application number: GB1862777A
Authority: GB
Original assignee: Nuway Manufacturing Co Ltd
Current assignee: Nuway Manufacturing Co Ltd
Priority date: 1978-04-21
Filing date: 1978-04-21
Publication date: 1981-12-16

Description

(54) MATS (71) We, NUWAY MANUFACTUR ING COMPANY LIMITED, a British Company of Coalport, Ironbridge, in the County of Salop, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed to be particularly described in and by the following statement: This invention relates to mats. In our prior patent specification No. 1,055,960 there is described a mat comprising strips or bars of rubber or similar flexible material and strips or bars of metal arranged side by side and held together by wires passing through transverse apertures in the strips or bars.

Mats made according to the prior specification have embodied rubber material having fabric reinforcement embedded therein.

When the surfaces of the fabric reinforced rubber strips are buffed as described in said specification, the fabric stands proud of the rubber surface and provides a foot-wiping material.

The increasing cost of fabric-reinforced rubber is necessitating the provision of a less expensive construction.

It is an object of one aspect of the invention to provide a mat similar to that described in our prior specification but made of less costly materials. It is an object of preferred embodiments of the invention to provide a mat construction which can be made in a variety of colours.

According to one aspect of the invention we provide a mat comprising a plurality of bars of resilient material arranged in sideby-side spaced parallel relationship with spacer elements between adjacent resilient bars and held together by wires passing through apertures in the bars and spacer elements the bars of resilient material each having secured to at least one face thereof a strip of carpet material.

The spacer elements may comprise a separate element associated with each wire between each pair of adjacent resilient bars.

Alternatively the spacer elements may comprise a plurality of bars of material more rigid than said resilient material, a said more rigid bar being provided between the bars of at least some of the pairs of resilient bars.

A said more rigid bar may be provided between each pair of adjacent resilient bars.

Alternatively a said more rigid bar may be provided between the bars of only some of the pairs of the resilient bars of the pairs of adjacent resilient bars, for example, between the resilient bars of every other pair, with separate spacer elements for each wire being provided between the resilient bars of each of the pairs of bars not having a said more rigid bar therebetween.

If the resilient bars each have carpet material only on one face thereof then in the finished mat the "carpeted" faces may all be on the same side of the mat. Alternatively half the "carpeted" faces may be on one side of the mat and half on the other so that the "uncarpeted" faces would provide scraper bars and the "carpeted" faces drying bars.

The use of resilient bars to support the carpet material has a number of advantages.

The combination of the resilient bar and the carpet material gives a soft feel underfoot and the carpet material provides an efficient foot-wiping material. The provision of the resilient support for the carpet material ensures that the latter has a long life.

Flexible and resilient bars enable mats to be made of, for example, curved form in which case of course the rigid bars will be similarly curved. It is preferred that the resilient material has a Shore hardness of between 10 and 60 on scale D.

Although pile carpet is the preferred foot-wiping material, the resilient bars could carry a strip of other material such as a harder or softer material than the resilient bar or a strip of abrasive material to provide a non-slip surface or a strip of rubber. In this specification, therefore, the reference to "carpet material" is to be taken to include these other materials whilst reference to "pile carpet" is intended to refer only to carpet having a pile.

Preferably the or each face of the bar of resilient material having carpet material thereon is provided with a channel in which the strip of carpet material is secured. The resilient bars may be of generally square section with channels in two opposite faces thereof to receive the strips of carpet material. The resilient bar may be of hollow section to save material.

The resilient bar may be of a composite construction. Thus in one composite construction each resilient bar comprises a supporting portion and one or two carpet material-carrying portions of resilient material the or each of which is detachably secured to the supporting portion. There may be a longitudinal dovetail joint between the supporting portion and the or each carpet material-carrying portion. As before, the carpet material-carrying portion may have a channel to take the length of carpet material.

In another composite form a resilient bar comprises a supporting portion of channel section and a carpet material carrying portion of resilient material and of T section, the stem of the carpet material carrying portion being received in the channel of the supporting portion and the cross-member of the carpet material carrying portion supporting the strips of carpet material. The cross-member may be provided with a channel to receive the carpet material strip as described above. The stem of the T may have L-shaped slots therein so that the carpet material carrying portion can be pushed into the channel with the wires joining the resilient and rigid bars entering the one limbs of the slots. The carpet material carrying portion can then be moved longitudinally of the channel to an assembled position so that the wires enter the other limbs of the slots and the carpet material carrying portion is prevented from moving out of the channel. The carPet material carrying portion may be locked in said assembled position by a locking pin passing through the walls of the channel and the stem of the T-section.

We prefer to use pile carpet of a type in which the pile is trapped in a thermoplastic backing. If the resilient bars are also made of thermoplastic material it is then possible to weld the pile carpet strips to the resilient bars. If other carpet material having a thermoplastic back surface is used then these may also be welded to thermoplastic resilient bars. However, although welding is preferred, it is possible also to adhere the pile carpet or other carpet material in position.

According to another aspect of the invention we provide a method of making a mat according to the first aspect of the invention including the steps of extruding plastics material to form a resilient bar, securing strip carpet material to the resilient bar, cutting the resilient bar into desired lengths, and then arranging the resilient bars formed by said lengths in side-by-side spaced parallel relationship with spacer elements between adjacent resilient bars and introducing wires into apertures formed in the resilient bars and spacer elements to hold together the resilient bars and spacer elements to provide said mat.

The resilient bar may be cut into said lengths and then the strip carpet material secured thereto.

Alternatively the strip carpet material can be secured to the resilient bar as it is extruded or thereafter and then the combined carpet and resilient bar cut into said lengths.

The resilient bar may be pierced, to receive the wires to hold together said resilient bars and spacer elements, by hollow cutters which may be mounted in a power press for this purpose.

The invention will now be described in detail by way of example with reference to the accompanying drawings in which: Figure 1 is a perspective view of a mat constituting a first embodiment of the invention, Figure 2 is a part end elevation of an alternative form of mat to that shown in Figure 1 Figure 3 is part end elevation of a further alternative form of mat to that shown in Figure 1, Figure 4 is a section through an alternative form of resilient bar for use in the mat of Figure 1, Figure 5 is a section through a further alternative form of resilient bar for use in the mat of Figure 1, and Figure 6 and 7 are a section and a side view of a still further form of resilient bar for use in the mat of Figure 1.

Referring now to Figure 1, the mat shown comprises a plurality of resilient bars 10 and between each resilient bar is interposed a rigid bar 11 of generally H-cross section.

Along each edge of the mat is a rigid bar 12 of generally C-section and the bars are held together by wires, not shown in Figure 1, which pass through transverse apertures in the rigid and flexible bars, some of such apertures being shown at 13.

Each resilient bar 10 is formed as an extrusion of plastics material and has a central bore 14 which is provided to save material. The resilient bar is of generally square-section and formed in its upper and lower faces are channels 15. Secured in each channel 15 is a strip 16 of pile carpet. The carpet is of the form in which the pile 17 is secured in a thermoplastic backing 18 which is secured to the base of the channel 15. The thermoplastic backing is preferably welded to the base of the channel or alternatively may be adhered to the base of the channel.

It will be seen that the pile extends from the channel to provide foot-wiping material while the thermoplastic backing is received within the channel.

The mat is constructed in the general manner described in specification 1,055,960 to which reference should be had.

Although Figure 1 shows a rigid bar between each adjacent pair of resilient bars, if desired and as shown in Figure 2, at least alternate rigid bars 11 could be omitted and individual spacers 1 la inserted between adjacent resilient bars, one spacer 11a being threaded on each wire 9 passing through the bars.

If desired, no rigid bars 11 may be provided as shown in Figure 3. In this case individual spacer elements 11a (of metal or plastics material and preferably more rigid material than the bars 11) are provided one for each wire between each pair of adjacent resilient bars. Also the rigid strips 12 may not be provided.

Preferably the bars 10 of resilient material are made from a thermoplastic having a Shore hardness of between 10 and 60 on scale D. The use of a resilient backing to support the pile carpet strips has the advantages referred to above. The pile carpet strips may be replaced by strips of plastic material which are harder or softer than the bars themselves or by rubber strip or by an strip of abrasive material especially where the mat is to be used in the wet.

Referring now to Figure 4, this shows a modified form of resilient bar for use in the mats of Figures 1 to 3. The bar 10 is similar to those shown in Figure 1 except that pile carpet material 16 is provided on only the upper surface, the lower surface 19 being longitudinally serrated.

Referring now to Figure 5, this shows a further modified form of resilient bar for use in the mats of Figures 1 to 3. The bar comprises a central supporting portion 20 and two carpet material-supporting portions 21. A longitudinal dovetailed joint 22 is provided between the central supporting portion 20 and the carpet material supporting portions 21. Each carpet material supporting portion 21 is provided with a channel 23 in which is received a strip of pile carpet 24 which is of the same construction and secured in the same way as described in relation to Figure 1. The portions 21 may be secured to the central portion 20 by one or more vertical pins. When it is desired to replace the portions 21 the pins are removed, the portions 21 are slid off the portion 20 and are replaced by fresh portions 21. The central portion 20 will contain the apertures such as 25 for the wires to hold the bars in position in the mat. Both the portions 20 and 21 may be made of flexible polyvinylchloride.

Referring now to Figures 6 and 7 these show a further modified form of resilient bar. The bar comprises a supporting portion 26 of channel section having sides 27 and a base 28. There is a carpet material carrying portion 29 of T-section having a stem part 30 and a cross member 31. The part 31 has a channel 32 in which is welded or adhered to a strip of pile carpet 33 in the manner described in relation to Figure 1. As shown in Figure 7, the stem part 30 has a plurality of L-shaped slots 34 therein, each slot having a vertical portion 35 and a horizontal portion 36.The portion 29 can be inserted into the portion 26 by engaging the wires 37 which hold the strips together with the vertical parts 35 of the slots 34. When the wires 36 reach the tops of the vertical portion 35 then the portion 29 can be slid in the direction of the arrow 38 in Figure 7 thus bringing the wires to the positions shown in that Figure at the ends of the horizontal parts 36. When the portion 29 is in the position shown in Figure 4, a locking pin 39 Is passed through the sides 27 and the stem portion 30 thus holding the portion 29 in position.

Different parts of the mat may be made from material of different colours if desired thereby providing a mat having a variety of colours.

WHAT WE CLAIM IS: 1. A mat comprising a plurality of bars of resilient material arranged in side-by-side spaced parallel relationship with spacer elements between adjacent resilient bars and held together by wires passing through apertures in the bars and spacer elements the bars of resilient material each having secured to at least one face thereof a strip of carpet material.

2. A mat according to Claim 1 wherein the spacer elements comprise a separate element associated with each wire between each pair of adjacent resilient bars.

3. A mat according to Claim 1 wherein the spacer elements comprise a plurality of bars of material more rigid than said resilient material, one a said more rigid bar being provided between the bars of at least some of the pairs of resilient bars.

4. A mat according to Claim 3 wherein a said more rigid bar is provided between each pair of adjacent resilient bars.

**WARNING** end of DESC field may overlap start of CLMS **.

Claims

**WARNING** start of CLMS field may overlap end of DESC **. central bore 14 which is provided to save material. The resilient bar is of generally square-section and formed in its upper and lower faces are channels 15. Secured in each channel 15 is a strip 16 of pile carpet. The carpet is of the form in which the pile 17 is secured in a thermoplastic backing 18 which is secured to the base of the channel 15. The thermoplastic backing is preferably welded to the base of the channel or alternatively may be adhered to the base of the channel. It will be seen that the pile extends from the channel to provide foot-wiping material while the thermoplastic backing is received within the channel. The mat is constructed in the general manner described in specification 1,055,960 to which reference should be had. Although Figure 1 shows a rigid bar between each adjacent pair of resilient bars, if desired and as shown in Figure 2, at least alternate rigid bars 11 could be omitted and individual spacers 1 la inserted between adjacent resilient bars, one spacer 11a being threaded on each wire 9 passing through the bars. If desired, no rigid bars 11 may be provided as shown in Figure 3. In this case individual spacer elements 11a (of metal or plastics material and preferably more rigid material than the bars 11) are provided one for each wire between each pair of adjacent resilient bars. Also the rigid strips 12 may not be provided. Preferably the bars 10 of resilient material are made from a thermoplastic having a Shore hardness of between 10 and 60 on scale D. The use of a resilient backing to support the pile carpet strips has the advantages referred to above. The pile carpet strips may be replaced by strips of plastic material which are harder or softer than the bars themselves or by rubber strip or by an strip of abrasive material especially where the mat is to be used in the wet. Referring now to Figure 4, this shows a modified form of resilient bar for use in the mats of Figures 1 to 3. The bar 10 is similar to those shown in Figure 1 except that pile carpet material 16 is provided on only the upper surface, the lower surface 19 being longitudinally serrated. Referring now to Figure 5, this shows a further modified form of resilient bar for use in the mats of Figures 1 to 3. The bar comprises a central supporting portion 20 and two carpet material-supporting portions 21. A longitudinal dovetailed joint 22 is provided between the central supporting portion 20 and the carpet material supporting portions 21. Each carpet material supporting portion 21 is provided with a channel 23 in which is received a strip of pile carpet 24 which is of the same construction and secured in the same way as described in relation to Figure 1. The portions 21 may be secured to the central portion 20 by one or more vertical pins. When it is desired to replace the portions 21 the pins are removed, the portions 21 are slid off the portion 20 and are replaced by fresh portions 21. The central portion 20 will contain the apertures such as 25 for the wires to hold the bars in position in the mat. Both the portions 20 and 21 may be made of flexible polyvinylchloride. Referring now to Figures 6 and 7 these show a further modified form of resilient bar. The bar comprises a supporting portion 26 of channel section having sides 27 and a base 28. There is a carpet material carrying portion 29 of T-section having a stem part 30 and a cross member 31. The part 31 has a channel 32 in which is welded or adhered to a strip of pile carpet 33 in the manner described in relation to Figure 1. As shown in Figure 7, the stem part 30 has a plurality of L-shaped slots 34 therein, each slot having a vertical portion 35 and a horizontal portion 36.The portion 29 can be inserted into the portion 26 by engaging the wires 37 which hold the strips together with the vertical parts 35 of the slots 34. When the wires 36 reach the tops of the vertical portion 35 then the portion 29 can be slid in the direction of the arrow 38 in Figure 7 thus bringing the wires to the positions shown in that Figure at the ends of the horizontal parts 36. When the portion 29 is in the position shown in Figure 4, a locking pin 39 Is passed through the sides 27 and the stem portion 30 thus holding the portion 29 in position. Different parts of the mat may be made from material of different colours if desired thereby providing a mat having a variety of colours. WHAT WE CLAIM IS:

1. A mat comprising a plurality of bars of resilient material arranged in side-by-side spaced parallel relationship with spacer elements between adjacent resilient bars and held together by wires passing through apertures in the bars and spacer elements the bars of resilient material each having secured to at least one face thereof a strip of carpet material.

5. A mat according to Claim 3 wherein a

said more rigid bar is provided between the bars of only some of the pairs of resilient bars of the pairs of adjacent resilient bars with separate spacer elements for each wire being provided between the resilient bars of each of the pairs of resilient bars not having a said more rigid bar therebetween.

6. A mat according to any one of the preceding claims wherein the resilient bars each have pile carpet material only on one face thereof and in the finished mat the "carpeted" faces are all on the same side of the mat.

7. A mat according to any one of Claims 1 to 5 wherein the resilient bars each have pile carpet material on only one face thereof and in the finished mat half of the "carpeted" faces are on one side of the mat and half on the other so that the "uncarpeted" faces provide scraper bars and the "carpeted" faces drying bars.

8. A mat according to any one of the preceding claims wherein the resilient material has a Shore hardness of between 10 and 60 on scale D.

9. A mat according to any one of the preceding claims wherein the carpet material comprises a carpet having a pile.

10. A mat according to any one of Claims 1 to 8 wherein the carpet material comprises a strip of material harder than the resilient bar.

11. A mat according to any one of Claims 1 to 8 wherein the carpet material comprises a strip of material softer than that of the resilient bar.

12. A mat according to any one of Claims 1 to 8 wherein the carpet material comprises a strip of abrasive material to provide a non-slip surface.

13. A mat according to any one of Claims 1 to 8 wherein the carpet material comprises a rubber strip.

14. A mat according to any one of the preceding claims wherein the or each face of the bar of resilient material having carpet material thereon is provided with a channel in which the strip of carpet material is secured.

15. A mat according to Claim 14 wherein the resilient bars are of generally square section with channels in two opposite faces thereof to receive the strips of carpet material.

16. A mat according to any one of the preceding claims wherein the resilient bars are of hollow section.

17. A mat according to any one of the preceding claims wherein the resilient bars are of a composite construction.

18. A mat according to Claim 17 wherein each resilient bar comprises a supporting portion and at least one carpet material carrying portion of resilient material the or each of which is detachably secured to the supporting portion.

19. A mat according to Claim 18 wherein there is a longitudinal dovetail joint between the supporting portion and the or each carpet material carrying portion.

20. A mat according to Claim 18 or 19 wherein the carpet material carrying portion has a channel in which the strip of carpet material is secured.

21. A mat according to Claim 17 or 18 wherein each resilient bar comprises a supporting portion of channel section and a carpet material carrying portion of resilient material and of T-section, the stem of the carpet material carrying portion being received in the channel of the supporting portion and the cross member of the carpet material carrying portion supporting the carpet.

22. A mat according to Claim 21 wherein the cross member is provided with a channel in which the carpet material is secured.

23. A mat according to Claim 21 or 22 wherein the stem of the T has L-shaped slots therein so that, on assembly, the carpet material carrying portion can be pushed into the channel with the wires Joining the resilient and rigid bars entering the one limbs of the slots, and so that the carpet material carrying portion can be moved longitudinally of the channel to an assembled position so that the wires enter the other limbs of the slots and the carpet material carrying portion is prevented from moving out of the channel.

24. A mat according to Claim 23 wherein the carpet material carrying portion is locked in said assembled position by a locking pin passing through the walls of the channel and of the stem of the T-section.

25. A mat according to any one of the preceding claims wherein said resilient strips comprise thermoplastic material and the carpet material has a thermoplastic back surface welded to said resilient bars.

26. A mat according to Claim 25 wherein the carpet material is a pile carpet of the type in which the pile is trapped in a thermoplastic backing.

27. A mat according to any one of Claims 1 to 26 wherein the carpet material is secured by an adhesive.

28. A mat substantially as hereinbefore described with reference to and as shown in Figure 1, or Figure 2 or Figure 3, or Figure 4, or Figure 5, or Figures 6 and 7 of the accompanying drawings.

29. A method of making a mat according to any one of the preceding claims including the steps of extruding plastics material to form a resilient bar, securing strip carpet material to the resilient bar, cutting the resilient bar into desired lengths, and then arranging the resilient bars formed by said length in side-by-side spaced parallel relationship with spacer elements between adjacent resilient bars and introducing wires into apertures formed in the resilient bars and spacer elements to hold together the resilient bars and spacer elements to provide said mat.

30. A method according to Claim 29 wherein the resilient bar is cut into said lengths and then the strip carpet material secured thereto.

31. A method according to Claim 29 wherein the strip carpet material is secured to the resilient bar as it is extruded or thereafter and then the combined carpet and resilient bar cut in to said lengths.

32. A method according to any one of Claims 29 to 31 wherein the resilient bars are pierced to receive said wires to hold together said resilient bars and spacer elements by hollow cutters mounted in a power press.

33. A method of making a mat accord-ing to any one of Claims 1 to 28 substantially as hereinbefore described with reference to the accompanying drawings.