RU239671U1 - MULTILAYER TEXTILE RUG - Google Patents

Abstract

This utility model relates to multilayer textile products, specifically soft floor mats. The technical result of the claimed utility model is to prevent the migration of elastic layer fibers through the mat's face layer. This technical result is achieved by a multilayer textile mat comprising a decorative face layer, an elastic layer of synthetic fiber filler, a backing, and at least one barrier layer, all of which are joined by segmented thermal stitching.

Description

This utility model relates to multilayer textile products, specifically soft floor mats (e.g., children's play mats or home floor mats) with synthetic filler. These mats are designed to provide a comfortable, soft surface, thermal insulation, and safety when used on the floor. The utility model addresses the problem of preventing filler fibers from migrating through the mat's top textile layer, which is especially important for products with synthetic filler. Furthermore, the mat offers improved durability, retains its shape and properties after repeated use and washing, and has anti-slip properties for safe operation.

Multilayer mats are known to contain a decorative textile face layer, a synthetic elastic filler layer (such as non-woven polyester insulation such as synthetic padding), and a backing with an anti-slip coating. These mats are typically made with three layers: a polyester outer layer, a synthetic padding inner layer, and a polyvinyl chloride (PVC) base with a textured or dotted anti-slip layer. An example is the children's plush mat, selected as the closest analogue, presented on the manufacturer's website (Topodrom, https://topodrom.ru/catalog/plyushevye_kovriki/1038/), consisting of a polyester face fabric, a synthetic padding layer, and a PVC backing with an anti-slip coating. These layers are joined by segmented stitching (usually thermal), creating a textured pattern across the surface of the mat.

However, the prototype lacks a special barrier layer to prevent fiber migration. As a result, with prolonged use and repeated deformation of the filler, individual fibers of the synthetic padding may gradually penetrate through the pores of the face fabric onto the surface of the rug (the so-called fiber "bleeding" effect or migration). Fiber migration in nonwoven insulation is known to manifest itself as protruding fibers or fluff pellets on the surface of the product, which spoil the appearance and reduce its performance. Furthermore, protruding fibers may pose a hazard to small children (for example, the risk of inhalation or ingestion). The prototype rug without a barrier layer is also less stable: over time, the filler may shift and clump, especially if not quilted frequently, reducing comfort and uniform cushioning.

Thus, the closest analogue solves the problem of creating a soft, insulated mat, but the problem of preventing the migration of the filler fibers remains unresolved. This necessitates the development of an improved multilayer mat with an additional barrier layer to retain the synthetic fibers, which is achieved by the proposed product.

The technical result of the claimed utility model is the prevention of the exit (migration) of the elastic layer fibers through the top layer of the mat.

The proposed technical result is achieved in that the multilayer textile mat contains a decorative facing layer, an elastic layer of synthetic fibrous filler, a backing, at least one barrier layer, wherein all said layers are connected by segmented thermal stitching, and the barrier layer can be made from a calendered non-woven fabric, or from a polyurethane membrane, or from a polyethylene membrane, or from calendered holofiber, or from a combination of the above materials, or any other material with similar characteristics.

As a result of the introduction of the said barrier layer, fastened to the remaining components by segmental thermal stitching, the migration of the elastic layer fibers outward is excluded, which is further detailed in the description of the design and materials of the product layers:

1. The top layer is decorative and made of a wear-resistant textile material. Knitted or pile fabric with a density of 120-400 g/m² is preferred. The top layer can have a pleasant texture (such as plush or fleece) and can be printed, for example, with a children's or zoological theme, to give the rug an attractive appearance.

2. The elastic filler layer is a synthetic fibrous material such as padding polyester or hollow fiber, which serves as a soft lining and thermal insulation. The filler is made from hollow polyester fibers with the addition of bicomponent fibers with a low melting point (for example, polyester fibers with a core and a low-melting sheath). These bicomponent fibers make up approximately 10-30% of the filler's mass and serve as a thermal bonding component, allowing the fibers to bond together during heat treatment without the use of adhesives. The hollow spiral fibers impart high elasticity, volume, and thermal insulation properties to the filler. The filler is formed using aerodynamic web formation (aeroforming), in which the fibers are mixed with an air stream and deposited onto a moving mesh to form a uniform, loose web. The resulting canvas then undergoes heat treatment: it's heated in an oven or passed between heated rollers to fuse the bicomponent fibers, giving the synthetic padding strength and elasticity without significantly losing porosity. The padding thickness in the rug is selected from 5-70 mm (for example, 25-50 mm for a children's rug), ensuring a soft feel and adequate thermal insulation from the floor.

3. The barrier layer is a key element of the proposed model, at least one layer located between the filler and the face layer and/or between the filler and the backing, depending on the mat's design. The barrier layer can be made of a thin, solid or microporous material with an average pore size of no more than 80 µm. Its purpose is to block the migration of filler fibers through the face fabric while maintaining the overall breathability of the product. Various materials or combinations thereof can be used as the barrier layer:

- Calendered nonwoven fabric with a density of 10-80 g/m² - thin spunbond or other nonwoven fabric that has been calendered (rolled between heated smooth rollers). Calendering fuses the fabric's surfaces, forming a virtually continuous layer that reduces pore diameter and prevents filler fibers from escaping. This material is lightweight, fairly durable, and easy to manufacture.

- A microporous membrane made of thermoplastic polyurethane (TPU) or polyethylene (PE) with a thickness of ≤ 25 µm—an elastic film with a structure of microscopic pores that are permeable to air and water vapor but retain fibers. The membrane thickness is selected to be very thin (fractions of a millimeter) so as not to affect the flexibility of the mat.

- Calendered hollow fiber made from bicomponent fibers is the same synthetic padding fabric (canvas) made from hollow fibers with a BCF, but additionally processed by calendering to form a thin, compacted layer on the surface. In this version, the barrier can be integrated with the filler itself: the top layer of synthetic padding is melted during heat treatment, forming a continuous film of fused, low-melting components. Alternatively, a thin, heat-bonded spunbond (e.g., with a density of ~30 g/m²) is laminated over the filler, followed by heat pressing. Both methods reduce migration by forming a thin barrier directly at the filler boundary.

- Combinations of the above materials—for example, a layered structure of spunbond and microporous film, or two different barrier layers on top and bottom of the filler for maximum protection. A double-sided polymer coating can be used on the filler (similar to well-known insulation materials like Isosoft, where both sides are coated with a polymer coating to prevent fiber migration).

4. The mat's backing (base) is the bottom layer, designed to provide structural strength and perform the opposite function to the front surface (contact with the floor, wear resistance, moisture protection, etc.). The backing can be made from the following materials:

- Woven or non-woven polyester fabric - a durable synthetic fabric (e.g., Oxford, Taft, etc.) with an optional polymer coating. This type of backing provides wear resistance, resistance to washing and tearing. It can be equipped with anti-slip elements (dots, geometric patterns, etc.) or have an integrated coating.

Thermoplastic rubber (TPR) is an elastic polymer material that combines the properties of rubber and thermoplastic. The TPR backing is a molded or foamed layer that adheres to the floor. It is non-slip, waterproof, and flexible. It is often used in bathroom rugs and children's mats due to its grip and non-marking properties.

Polyvinyl chloride (PVC) is a polymer material widely used for rugs. The PVC backing can be a solid film or a foam layer. It gives the rug its shape and rigidity, completely preventing moisture from penetrating from below. To prevent slipping, PVC is usually embossed or enhanced with special elements.

Multi-component bases are also possible, for example: woven polyester with a dotted layer of silicone, or a combined backing - textile laminated with thin rubber, etc. The choice of backing material is determined by the required balance between the flexibility of the mat, its thickness, and the degree of adhesion to the floor surface.

Anti-slip elements, which can be distributed across the outer surface of the mat, are designed to increase friction with the floor, preventing the mat from slipping during use. These elements can be small raised dots (droplets) made of an elastic material such as silicone or latex. The dots range in diameter from 1 to 10 mm and are 0.1 to 2.5 mm above the mat surface. The dots are applied at a uniform interval of 5 to 50 mm across the entire underside of the mat. When the mat is pressed against the floor, the soft silicone dots deform slightly, holding the mat firmly in place. Silicone anti-slip dots are widely used in textiles (e.g., socks, bath mats, etc.) – after polymerization, the silicone firmly bonds to the fabric, forming non-slip anchor points. In alternative designs, if the backing itself is made of a non-slip material (TPR, ribbed PVC), individual dots may be optional; however, in the proposed solution, their presence is preferable for enhanced safety. Alternatively, the dots can alternate with various geometric shapes and can be designed in any possible form while maintaining the spatial parameters described by the dots.

Thus, anti-slip elements can be discrete elements of any shape required by the technology—squares, diamonds, triangles, or abstract geometric figures. Their characteristic transverse dimensions (diameter, side length, or maximum diagonal) can vary widely, for example, from 0.5 to 20 mm, the protrusion height above the surface can range from 0.05 to 5 mm, and the placement pitch can range from 2 to 100 mm, allowing the design to be adapted to various operating conditions and flooring types.

All of the layers listed are connected using segmented thermal stitching—meaning the mat is quilted (fastened) over an area into segments of a specific shape without the use of threads, using spot thermal welding of the layers. Segmented stitching can be achieved using ultrasonic welding or hot embossing in a specified pattern. With ultrasonic quilting, layers of material are pressed against a shaped mandrel and locally heated by ultrasonic vibrations, causing the synthetic components (such as polyester in the fabric and filler) to melt at the contact points, bonding the layers without threads. This method leaves no through holes (punctures), unlike needle stitching, preserving the integrity of the barrier layer and improving the hygienic properties of the mat. Hot embossing is also possible: a "sandwich" of mat layers is passed between heating rollers or molds with a relief pattern; the layers are fused at the raised areas of the pattern. Segmented thermal quilting patterns can take various geometric shapes, such as honeycomb, diamond, brick, and circle. Specifically, the honeycomb pattern consists of adjacent hexagons, diamonds of intersecting lines forming a diamond-shaped lattice, bricks of checkerboard-patterned rectangular blocks, and circles of repeating circles. The segment size (pattern repeat) can vary from 30 mm to 300 mm in diameter. A fine stitch ensures very close bonding—the filling is secured as tightly as possible, eliminating even the slightest fiber displacement. However, too close a stitch can reduce the softness of the rug. A coarser stitch creates a textured, plump pattern and a softer feel, while the filling segments are small enough to prevent fiber migration. All layers of the rug, as a result of segmented thermal quilting, form a single, multi-layered package that maintains its integrity even under intensive use.

Thus, the essence of the technical solution lies in the addition of a special barrier layer of solid or microporous material to the rug's structure. This layer is positioned between the textile face layer and the filler (and/or backing), preventing the migration of synthetic filler fibers through the face layer. All layers are joined by segmental heat-stitching (ultrasonic welding or equivalent thermal bonding). This design preserves the decorative and functional properties of the face layer without fiber shedding, while simultaneously ensuring the necessary softness, breathability, and durability of the rug.

Fig. 1 shows a cross-section of a multilayer mat (in schematic form), illustrating the composition and relative position of the layers, where:

1 - face layer;

2 - intermediate elastic layer;

3 - barrier layer;

4 - bottom layer (substrate)

5 - anti-slip ledges;

6 - edging tape along the edge of the rug (the picture shows a fragment of the edge with edging).

The face layer 1 is connected to the backing 4 by means of an interlayer of intermediate elastic layer 2. A barrier layer 3, shown by a conventional thin line, is introduced between the face layer 1 and the intermediate elastic layer 2. Anti-slip protrusions 5 in the form of raised dots are located on the lower surface of the backing 4. The layered structure of the mat and the anti-slip protrusions 5 are shown to scale for clarity. All layers over the entire area of the mat are fastened together by segmental thermal welding spots (not shown in the cross-section). In Fig. 1, it is evident that the barrier layer 3 separates the intermediate elastic layer 2 from the face layer 1, creating a barrier for any individual fibers attempting to penetrate upward. The anti-slip protrusions 5 protrude under the mat, preventing slipping on the floor. The thickness of the layers and the distances between the dots may vary in specific designs; however, the basic arrangement corresponds to that shown.

Examples of implementation

Example 1. A prototype of a 150x100 cm rug for a child's room was made. Construction: face layer - knitted polyester fabric (plush "Minky") with a density of 200 g / m² with a printed pattern "Forest Animals". Filler - synthetic padding with a thickness of ~ 20 mm, a weight of 200 g / m², consisting of 85% hollow polyester fibers (length 45 mm, thickness. 6 den) and 15% bi-component fibers (PET core, PE shell). Barrier layer - polypropylene spunbond with a density of 40 g / m², calendered on one side (pores ~ 30-50 μm). This spunbond is pre-laminated onto synthetic padding from the front side by passing it through a calender press (temperature 140°C, speed 5 m/min) - as a result, the smooth calendered side of the spunbond is firmly welded to the upper filler fibers. The bottom backing is Oxford fabric (100% polyester) with a density of 180 g/m² with an internal PVC coating. Silicone dots with a diameter of 2 mm, a pitch of 10 mm (a matrix of 100 × 150 dots over the entire area) are applied to the backing, followed by vulcanization at 150°C for 2 minutes. The layers are assembled into a package in the following order: front (on top), barrier (calendered layer up, i.e. between the filler and the front), filler, backing (bottom). The package is subjected to heat-stitching in a "diamond" pattern with a side of 180 mm. Heat-stitching parameters are specified by the manufacturer. Along the perimeter of the rug, there is a 25 mm wide edging tape made of wear-resistant polyester material (twill), stitched with a double seam.

The finished rug was approximately 15 mm thick, with a soft surface and no visible defects. Aesthetically, the front side features a neat quilted pattern; the fabric pattern is unaffected by the fusible stitching (no thread snags or needle holes). The barrier layer is invisible both visually and to the touch—the rug is breathable when pressed.

The sample was tested for durability:

- Repeated folding test. The mat was folded in half and unfolded 50 times in a row (simulating repeated folding during cleaning/transportation). After 50 cycles, the mat was inspected: no creases or cracks were found in either the face fabric or the barrier layer. The heat-sealed seams were intact, and there was no delamination of the layers. No filler fibers had penetrated the face layer—the surface was clean and lint-free.

- Repeated washing test. The sample was machine washed 10 times (delicate cycle, 30°C, spin speed, 400 rpm), with drying at room temperature in between. After 10 washes, the rug retained its shape, the quilting did not unravel, and the color of the face print was vibrant. Important observation: no fiber migration was detected, either visually (no protruding fibers or clumps) or by palpating the surface. For testing, a 15 cm long section of the edging was ripped open: the inner filling remained intact, the barrier spunbond was in place, and there were no dead fibers between it and the face fabric. The thickness of the rug changed only slightly after washing: it decreased by only ~5% due to natural fiber shrinkage, but the filling did not bunch up or felt—the quilting segments kept it evenly distributed. The product's breathability was assessed qualitatively: when pressing with the palm of the hand, air flowed through the mat, and no film formed (the mat "breathes"). Thus, the tests confirmed the claimed advantages of the design.

Example 2. A round mat with a diameter of 1.2 m was made (intended for playing on the floor).

The outer layer is made of polyester fleece with a full-color printed pattern "City Roads" (approximately 200 g/m², soft short pile up to 3 mm high). The filling is 30 mm thick hollow fiber (300 g/m²) containing 20% low-melting fibers. The barrier layer is a 20 µm thick TPU membrane laminated to a non-woven base. In this case, a breathable polyurethane membrane (vapor permeability index of 3000 g/m²/day) was used, welded to a thin polyester spunbond of 15 g/m². The result is a two-layer barrier: one side is woven for convenience, the other is a solid film. This barrier is cut in a circle and inserted between the filler and the outer layer (membrane to the filler, woven side to the outer fabric). The bottom backing is a thermoplastic rubber (TPR) ~1.5 mm thick, circular in shape, with a honeycomb-like ribbing. The TPR base is inherently non-slip, so individual dots were not applied. The layers are assembled using a hot-pressing process: the layers are fixed in a press frame and dot-embossed with a honeycomb pattern with a honeycomb cross-section of 70 mm. The mold temperature is 160°C, with a 3-second hold for each zone, then the mold is repositioned (a 30 cm diameter matrix was used; the entire circle is covered by repositioning). After quilting, the edge is edged with a 30 mm wide velvet binding—a decorative feature that also covers the end face.

Tests showed that the mat withstands intensive use: it was trampled and children ran around—the filling does not bunch up thanks to its fine honeycomb structure. An inspection of the face after some time of use confirmed the absence of protruding fibers. The polyurethane membrane inside does not crack when folded (the mat was rolled up for storage). When placed on a cold floor, the mat feels well insulated from the cold (the air in the filling and the TPU film act as a barrier to heat loss). At the same time, when lying on the mat, the child does not sweat—the membrane allows water vapor to pass through, making the mat breathable. Thus, example 2 demonstrates the effectiveness of the membrane and spunbond combination as a barrier.

Both examples illustrate that the proposed technical solution can be implemented with a variety of materials and methods, while achieving the main effect: the synthetic fibers are securely held within the mat, and the product lasts a long time without losing its shape or appearance.

The utility model is industrially applicable in the light industry, particularly in the production of children's goods, tourist and sports equipment, and household goods. The technology for producing a multilayer mat with a barrier layer is based on widely used processes: synthetic padding molding (aerodynamic or carded web formation), thermal bonding, calendering, lamination, ultrasonic welding, etc. All the necessary equipment—calenders, ultrasonic machines, and heat presses—is readily available at textile factories. The materials (polyester fibers, spunbond, polyurethane membranes, Oxford fabrics, and silicone) are mass-produced and inexpensive. This means that mat production using the proposed model is possible without significant capital investment: simply add the barrier layer and adjust the stitch settings.

The finished product—a multilayer children's mat—is in high demand. Modern consumers have high expectations for the quality of children's products, including durability and safety. This mat meets these requirements, surpassing similar products. It can be used as a soft developmental floor for infants (for their first attempts at crawling and walking), as a play mat for preschoolers (it cushions falls and insulates against cold floors), as a gymnastics mat for home use, or simply as an interior accessory. Machine washability makes it hygienic. A barrier layer helps maintain the mat's appearance, enhancing its consumer value and competitiveness.

The utility model can be implemented in various modifications (sizes, patterns, barrier materials) without deviating from its essence, giving the manufacturer product flexibility. Therefore, the proposed technical solution is suitable for widespread implementation in the textile industry and has significant commercial potential.

Claims (6)

1. A multilayer textile mat comprising a decorative facing layer connected to a backing by means of an intermediate elastic layer made of synthetic fibrous filler, with a barrier layer located between the decorative facing layer and the intermediate elastic layer, and all said layers connected by segmental thermal stitching. 2. A multilayer textile mat according to claim 1, in which the barrier layer is made of calendered non-woven fabric. 3. A multilayer textile mat according to claim 1, wherein the barrier layer is made of a polyurethane membrane. 4. A multilayer textile mat according to claim 1, wherein the barrier layer is made of a polyethylene membrane. 5. A multilayer textile mat according to claim 1, in which the barrier layer is made of calendered holofiber. 6. A multilayer textile mat according to claim 1, in which the barrier layer is made from a combination of materials according to claims 2-5.