WO2007122399A1

WO2007122399A1 - Mat

Info

Publication number: WO2007122399A1
Application number: PCT/GB2007/001441
Authority: WO
Inventors: Thomas Langley Sutherland; William Burns
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-04-20
Filing date: 2007-04-20
Publication date: 2007-11-01
Anticipated expiration: 2008-10-20
Also published as: GB0607800D0

Abstract

This invention relates to mat (10). More particularly, the invention relates to entrance mat suitable for use in applications where water and dirt are likely to be deposited on the mat. Wherein the mat comprises a mani body (16) and at least one elongate member (12, 14) partly embedded and/or inserted in the man body.

Description

MAT

FIELD OF THE INVENTION

This invention relates to mat. More particularly, the invention relates to entrance mat suitable for use in applications where water and dirt are likely to be deposited on the mat.

BACKGROUND OF THE INVENTION In order to minimise the amount of dirt and water carried into a building on the feet of people entering the building, entrance mats may be placed just inside or outside doorways. For domestic or other light use applications, coir type or throw-down mat may be used. However, coir type or throw-down mat has only a limited lifespan .

The majority of high traffic applications require the use of mats formed of plastics or plastics extrusion, or aluminium alloy or PVC extrusions or strips, pieced together by wire or other forms of couplings. Such mats are hardwearing but tend to be expensive and, due to the nature of their construction, are commonly supplied in standard sizes or must be made to order. A further type of entrance mat uses a series of metal retaining wires with carpet material fitted between the wires. Such systems require the wires to be fixed and secured in place under tension. If these systems are removed for cleaning, they must be retensioned on fitting. These types of systems have a tendency to 'rock' when people walk over the mat. This form of mat will often move under the feet, which may be unsettling, and the gaps between the wires provide traps for heels and the points of walking-sticks . WO-A-9307789, which is incorporated herein by reference, describes entrance mat including a flexible rubber base layer and a flexible rubber upper layer comprising spaced upstanding strips having slots therebetween. Strips of carpet are fixed in the slots such that the strips collectively define a substantially continuous tread surface. The mat is located at a building entrance with the strips perpendicular to the direction of traffic over the mat. The rubber strips have ribbed upper surfaces and serve as scrapers to remove larger particles of dirt. The carpet strips are useful for removing finer particles of dirt and will also retain moisture. Other forms of entrance mat are described in GB-A-2256584, GB-A-2010087 , GB-A-2153668 , FR-A-852638, US-A-4587148 and US-A-4408365, which are incorporated herein by reference.

Additionally, WO-A-9636268 which is incorporated herein by reference, describes entrance mat comprising a flexible rubber base layer including spaced upstanding strips having slots therebetween. Carpet strips are fitted into the slots. The entrance, mat on its bottom surface comprises a series of spaced slots to permit water to drain therethrough.

WO-A-2005/087078, which is incorporated herein by reference, describes entrance mat which uses retaining clips to hold carpet strips in place.

It is an object of at least one embodiment of the present invention to obviate or mitigate one or more of the aforementioned problems. It is a further object of at least one embodiment of the present invention to provide an improved entrance mat . SUMMARY OF THE INVENTION

According to a first aspect of the present invention there is provided a mat, said mat comprising: a main body; and at least one elongate member partly embedded and/or inserted in the main body.

Typically, the at least one elongate member may define a series of slots adapted to receive and engage carpet strips. The at least one elongate member may be formed from a single or multi-component member. Multi-component members may provide the advantage of improved flexibility in the mat.

The at least one elongate member may be upstanding and may function as a scraper element to remove dirt, dust and snow from any person walking over the mat.

The at least one elongate member may be upstanding and extend from an upper surface of the. main body of the mat and may comprise an upper portion and a lower portion. The upper and lower portions may be substantially planar in construction. The upper and lower portions may be provided substantially horizontal on the at least one elongate member. The upper and lower portions may be connected with a web member. The upper and lower portions may be substantially centrally located on the web member . The web member may have a substantially planar construction. The web member may be provided substantially vertical on the at least one elongate member. A cross-section of the at least one elongate member may therefore show that the upper and lower portions are wider than the web member. In particular, a cross-section of the at least one elongate member may be substantially 'I '-shaped or 'T '-shaped. Elongate members located along the sides of the mat may have a different construction to that of elongate members located away from the sides of the mat. Although the elongate members located along the sides of the mat may have an upper and lower portion connected by a web, the upper and lower portions may extend out from only one side of the elongate member. These types of elongate members may be substantially ¹C -shaped or 'U' -shaped.

The lower portion of the at least one elongate member may be embedded in the main body of the mat. The lower portion may function as an anchor to securely retain the at least one elongate member in place in the main body of the mat.

A top surface of the upper portion of the at least one elongate member may be profiled or textured. The top surface of the upper portion may therefore be substantially corrugated or may comprise channels or grooves. For example, the top surface of the at least one elongate member may comprise parallel elongate grooves, chevron-like grooves, or any combination thereof. This may facilitate the removal of debris such as loose dirt, dust or snow from people walking over the mat. The profiling or texturing may also help to disperse any water deposited from the feet of users. The profiling or texturing may also help to prevent people from slipping when they walk over the mat.

Typically, about 20%, about 40%, about 60%, or about 80% of the at least one elongate member may be embedded in the main body of the mat. In a particular embodiment, the lower portion and about half of the web may be embedded in the main body of the mat. The at least one elongate mat may extend into the main body of the mat by about 1 to 10 mm or about 2 to 5. mm. In particular embodiments, the at least one elongate member may be embedded in the main body of the mat by about 3 mm.

The at least one elongate member may have a height of about 5 to 50 mm, the upper portion may have a width of about 5 to 50 mm and the lower portion may have a width of about 1 to 30 mm. ^'Typically, the width of the upper portion is greater than that of the lower portion. In particular embodiments, the at least one elongate member may have a height of about 30 mm, the width of the upper portion may be about 30 mm and the width of the lower portion may be about 10 mm. The elongate member may be of any appropriate length and may be easily cut to size. The elongate member may extend continuously from one side of the mat to another. The at least one elongate member may be manufactured from any suitable metal, plastics, composite or alloy using, for example, an extrusion process. In particular embodiments, the at least one elongate member may be manufactured from aluminium or aluminium alloy. The at least one elongate member may comprise at least one aperture (i.e. an opening) in the form of a through-hole which may have the function of helping to securely embed and fix the at least one elongate member in the main body of the mat. Settable material which may be used to form the main body of the mat may flow through and therefore harden around the at least one aperture. The at least one aperture may function as a keying hole. This may provide additional mechanical bonding strength for the at least one elongate member in the main body of the mat.

The at least one elongate member may comprise a plurality of apertures. The apertures may be provided in a bottom half of the at least one elongate member. In particular embodiments, a plurality of apertures forming keying holes may be provided along the web of the at least one elongate member. Alternatively, or in addition, apertures may be provided in the bottom portion of the at least one elongate member. The apertures in the bottom portion of the at least one elongate member may be provided on both sides of the web. Elongate members located along the sides of the mat may only comprise apertures in the bottom portion. Any suitable pattern and shape of apertures (e.g. circular, oval, slot-like, triangular, square or rectangular) maybe used which may have the function of additionally securing the at least one elongate member in the main body of the mat. The apertures may be formed by punching through the elongate members. Typically, the apertures may have a diameter of about 0.1 to 2 cms, about 0.2 to 1 cm or about 0.5 cm.

Alternatively, the at least on elongate member may comprise any form of protruding members or depressions such as grooves, barbs, flanges which help in securely engaging the at least one elongate member in the main body of the mat .

Typically, the main body of the mat may comprise a series of elongate channels within which the at least one elongate member may be inserted into such as using a snap-fit mechanism (e.g. a 'nap' lock) . In these embodiments, the at least one elongate member may simply be fitted into the elongate channels using a small amount of force such as from a hammer to force the at least one elongate member into the channels. To further enhance the bonding of the at least one elongate member to the main body of the mat, chemical bonding technology may be used. For example, prior to pouring a settable material around at least part of the at least one elongate member, the at least one elongate member may be coated in an appropriate chemical which provides a chemical bond to the settable material. Therefore, in particular embodiments, the at least one elongate member may be bound by both mechanical and chemical means .

In the mat, there may be provided a plurality of elongate members situated substantially parallel to one another extending continuously along a length of the mat. The elongate members may be spaced apart by about 3 to 10 cms or preferably by about 5 cms.

The mat may be provided in any suitable size such as of about 2 metres by about 0.5 metres and thereafter cut to size. The mat may be cut to any suitable size using any appropriate cutting means such as a jigsaw. The main body of the mat may be of a unitary structure and may be formed from a single material or may be formed from a mixture of different materials . Any suitable plastics or rubber-like material may be used. In particular embodiments polyurethane may be used. Alternatively, the main body of the mat may comprise two or a plurality of different types of layers in a sandwich-type structure. For example, a heavier/harder material may be used for the upper surface of the main body to prolong the life of the mat. The bottom surface of the mat may also comprise a patterned surface such as a plurality of protrusions . The patterned surface may allow a reduced amount of material to be used to form the main body. Additionally, the pattern in the form of protrusions may provide additional cushioning and comfort to a person walking over the mat and may also allow collected water to drain away.

The bottom surface of the mat may also be profiled to prevent the mat from slipping and also allowing the mat to dry more freely if it becomes wet. The lower surface of the mat may also comprise channels which may allow any water to drain away.

The mat may also comprise fire retardant materials. The mat is intended to exceed Euro Class Bl fire regulations .

Carpet strips may be inserted into slots formed between two elongate members. Typically, the carpet strips may fit snugly into the slots, thereby preventing any unnecessary slippage when a person walks over the mat. The carpet strips may therefore be fitted in to the slots formed between the upper and lower portions of the elongate members . The carpet strips may abut and engage against the elongate members thereby securing them in place. The carpet strips may have a width slightly greater than the distance between different elongate, members to ensure that the carpet strips are securely engaged. If necessary, mechanical fastening means such as tack's may be used to provide additional fixing for the carpet strips. The carpet strips may also be mechanically bonded to the mat. Alternatively, or in addition, adhesive means such as glue may be used. However, adhesive means is not preferred as this prevents easy removal and replacement of the carpet strips . Conveniently, the carpet strips may form a substantially concave configuration in the slots. The function of the carpet strips may be to remove dirt, dust and snow from any person walking over the mat.

Typically, the mat may be removed from its place of use and the carpet strips may be removed and either cleaned or replaced. The mat with the cleaned or replaced carpet strips may then be returned to its place of use.

Moreover, any number of different mat sections may be used together. The different mat sections may be in direct contact (i.e. side to side) with one another to prevent the different mat sections from moving. Alternatively, the different mat sections may be attached to one another using any suitable type of interconnecting mechanism.

According to a second aspect of the present invention there is provided an elongate member intended to form part of a mat, said elongate member comprising: an upper portion and a lower portion; said lower portion capable of being embedded in a main body of a mat .

The embedded elongate member may define a series of slots for receiving and engaging carpet strips.

The elongate member may comprise at least one aperture or a plurality of apertures capable of allowing a settable material to flow through and set the elongate member in the main body of the mat .

According to a third aspect of the present invention there is provided a method of forming a mat comprising: providing at least one elongate member, said elongate member comprising an upper and lower portion; providing a settable material around at least the lower portion of the at least one elongate member; said settable material setting to form a main body of the mat; and wherein on the setting of the settable material, the at least one elongate member is fixed to the main body of the mat .

Typically, the settable material may initially be in a liquid form and may be poured at room temperature, commonly known as a cold pour. For example, polyurethane may be poured at room temperature into a mould in the shape of the mat. The at least one elongate member may be located in the mould prior to the pouring of the settable material.

As the settable material is poured into the mould, the settable material extends around the lower portion of the at least one elongate member. The at least one elongate member may also comprise at least one aperture or a plurality of apertures which allows the settable material to extend therethrough. As the settable material sets, the settable material extending through the apertures may further securely attach the at least one elongate member in the main body of the mat . The apertures in the at least one elongate member may be provided in a substantially vertical portion, the lower portion, or a combination thereof. The settable material may set in any appropriate time such as about less than 1 hour or • more typically about 10 minutes . The setting may occur at room temperature or at an elevated temperature if necessary.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will now be shown, by way of example only, with reference to the accompanying drawings in which:

Figure 1 is a side view of a mat according to a first embodiment of the present invention;

Figure 2 is a plan view of the mat shown in Figure 1;

Figure 3 is a side view of the mat shown in Figures 1 and 2 wherein carpet strips have been inserted; Figure 4 is a side view of an elongate member in the mat shown in Figures 1 to 3;

Figure 5 is a perspective view of the elongate member shown in Figure 4; Figure 6 is a side view of an elongate member according to a second embodiment of the present invention;

Figure 7 is a perspective view of the elongate member shown in Figure 6;

Figure 8 is a side view of an elongate member according to a third embodiment of the present invention;

Figure 9 is a perspective view of the elongate member shown in Figure 8; Figure 10 is a side view of an elongate member according to a fourth embodiment of the present invention;

Figure 11 is a perspective view of the elongate member shown in Figure 10; Figure 12 is a side view of an elongate member according to a fifth embodiment of the present invention;

Figure 13 is a perspective view of the elongate member shown in Figure 12;

Figure 14 represents a lower surface of a mat according to a sixth embodiment of the present invention; and

Figure 15 represents a side view of part of a mat according to a seventh embodiment of the present invention.

DETAILED DESCRIPTION

Figures 1, 2 and 3 represent an entrance mat, generally designated 10. The mat 10 comprises three elongate members 12 and two elongate members 14. The elongate members 12,14 extend from one side of the mat 10 to the other. As shown in Figures 1 and 3, the elongate members 14 are a half-section of elongate members 12.

The mat 10 comprises a main body section 16 with an upper surface 18 and a lower surface 20. Between the elongate members 12,14 there are defined a series of slots 22. As shown in Figure 3, carpet strips 23 are inserted into the slots 22 and are retained snugly therein. Figure 3 also shows that the pile 25 of the carpet strips 23 extends slightly above an upper surface of the elongate members 12,14; thereby enabling the carpet strips 23 to help remove loose dirt, dust or snow from people walking over the mat 10. Figures 4 and 5 are expanded views of elongate members 12. As shown in Figures 4 and 5, the elongate members 12 comprise a substantially horizontal upper portion 24, a substantially vertical portion 28 and a substantially horizontal lower portion 30. The substantially horizontal upper portion 24 is wider than the substantially horizontal lower portion 30. The elongate member 12 is substantially 'T' -shaped in cross- section. On the top surface of the substantially horizontal upper portion 24 there are horizontal grooves 26 which function as drainage channels and may help to remove loose dirt, dust or snow from people walking over the mat 10. The elongate member 12 is formed from aluminium.

Figures 6 and 7 are expanded views of elongate member 14 which may be formed by cutting the elongate member 12 in half. The elongate member 14 comprises a substantially horizontal upper portion 32, a substantially vertical portion 36 and a substantially horizontal lower portion 38. The substantially horizontal upper portion 32 is wider than the substantially horizontal lower portion 38. The elongate member 14 is substantially 'U'-shaped in cross-section. A top surface of the substantially horizontal upper portion 32 comprises a series of horizontal grooves 34. The horizontal grooves 34 act as drainage channels and may remove loose dirt, dust or snow from people walking over the mat 10.

The mat 10 is formed as follows. First of all, the part of the elongate members 12,14 intended to be in contact with the main body 16 of the mat 10 is coated with a chemical. The chemical bonds the elongate members 12,14 to the main body 16 of the mat 10. The chemical is brushed or sprayed on to the elongate members 12,14. The elongate members 12,14 are then positioned and clamped in place in a mould (not shown) . The mould forms the shape of the mat 10. A settable material is poured into the mould until the required level of the settable material is reached. The lower portions 30,38 are completely submerged and about half of the vertical portions 28,36 are submerged in the settable material. As shown in Figure 1, the elongate members 12,14 are partly embedded in the main body 16 of the mat 10. Polyurethane is used in a cold pour/ process by simply pouring the polyurethane at room temperature into the mould. The polyurethane sets in about ten minutes and on setting securely engages and secures the elongate members 12,14 in the main body 16 of the mat 10.

In use, the mat 10 will be placed in a shallow tray at the entrance to, for example, a public building, a shop, a shopping complex, a cinema, a car park, a school, an office block, a sports arena, a church or cathedral, housing, a hotel, a bus depot, a train depot, a ferry terminal or an airport. The tray is provided with drainage holes which allows collected water to drain away. The mat 10 is cut to fit neatly within the tray and the carpet strips 23 oriented to be substantially perpendicular to the direction of traffic. As people walk over the mat 10, loose dirt, dust or snow will be dislodged by the carpet strips 23 and the elongate members 12,14.

Once the carpet strips 23 become dirty, the mat 10 may be removed from the tray and the carpet strips 23 removed. The carpet strips 23 may then be either cleaned or replaced.

To further enhance the attachment of the elongate members 12,14 in the main body 16 of the mat, the elongate members 12,14 may be provided with a variety of configurations of apertures i.e. keying holes.

Figure 8 represents an elongate member 112 comprising a substantially horizontal upper portion 124, a substantially vertical portion 128 and a substantially horizontal lower portion 130. On the upper portion 124 there is a plurality of horizontal grooves 126. As shown in Figure 8, the substantially vertical portion 128 comprises a series of apertures 140 capable of functioning as keying holes . During the pouring of a settable material into a mould, the settable material will flow and pass through the apertures 140. The level of the settable material is above the highest point of the apertures 140. On the setting of the settable material, the settable material will therefore securely engage the elongate member 112 by extending through the apertures 140.

Figure 9 represents a further elongate member 212 containing a substantially horizontal upper portion 224, a substantially vertical portion 228 and a substantially horizontal lower portion 230. On the upper portion 224 there is a plurality of horizontal grooves 226. The substantially horizontal lower portion 238 comprises a series of apertures 242 allowing the settable material to extend therethrough and thereafter harden. Although not shown in Figure 9, there are further apertures 242 located behind the substantially vertical portion 228.

Figure 10 shows a yet further elongate member 312 containing a substantially horizontal upper portion 324, a substantially vertical portion 328 and a substantially horizontal portion 330. On the upper portion there is a plurality of horizontal grooves 326. As shown in Figure 10, both the substantially vertical portion 328 and the substantially horizontally lower portion 330 contain apertures 340,342 capable of functioning as keying holes. By providing apertures 340,342 in both the substantially vertical portion 328 and the substantially horizontal lower portion 330, provides additional support for retaining the elongate member 312 in position in the mat 10.

Figure 11 represents an elongate member 414 which is similar to that of elongate member 14. The elongate member 14 comprises a substantially horizontal upper portion 432, a substantially vertical portion 436 and a substantially horizontal lower portion 438. On the upper portion 432 there is a plurality of horizontal grooves 434. The substantially vertical portion 436 comprises a series of apertures 444.

Figure 12 represents a further elongate member 514 comprising a substantially horizontal upper portion 532, a substantially vertical portion 536 and a substantially horizontal portion 538. On the upper portion 532, there

^■ is a plurality of horizontal grooves 634. The substantially horizontal lower portion 538 comprises a series of apertures 546.

Figure 13 shows a yet further elongate member 614. Elongate member 614 comprises a substantially horizontal upper portion 632, a substantially vertical portion 636 and a substantially horizontal lower portion 638. On the upper portion 636 there is a plurality of horizontal grooves 634. Both of the substantially vertical portion 636 and the substantially horizontal lower portion 638 comprise apertures 644,646. Elongate members 212,312,312 are intended to be provided away from the sides of a mat whereas elongate members 414,514,614 are intended to be provided along the sides of a mat.

Therefore, by providing the elongate members with apertures forming keying holes, the settable material may extend through the holes and provide further mechanical means for retaining the elongate members in place.

To provide further additional means for retaining the elongate members 112,212,312,414,514,614 in place, the elongate members 112,212,312,414,514,614 are coated with a chemical which chemically bonds on to the main body 16 of the mat 10. The chemical material is brushed or sprayed on to the elongate members 112,212,312,414,514,614. Figure 14 represents a lower surface 720 of a mat 700. The lower surface 720 of the mat 700 comprises protruding members 750 which are intended to engage with a floor. The protruding members 750 allow the amount of settable material forming a main body of the mat 700 to be minimised and also provides additional cushioning and comfort to a user walking over the mat 700.

Figure 15 represents an elongate member 812 according to the present invention which may be snap- fitted into an elongate channel 813 in a mat. The elongate member 812 comprises two elongate protruding sections 812a, 812b which distend slightly outwardly with respect to each other. The outwardly extending members 812a, 812b may be snap-fitted into the elongate channel 813 using, for example, a small hammer. The carpet may then be fitted by simply sliding in from the side.

It will be clear to those of skill in the art that various modifications and improvements may be made to the invention without departing from the scope of the invention. For example, the elongate members may be attached within the main body of the mat using any suitable mechanical or chemical means, or combination thereof. Furthermore, any suitable form of plastics or rubber-like material may be used to form the main body of the mat. The elongate members may also be of any suitable shape so long as they are capable of being engaged within the main body of the mat and defining slots to receive and engage carpet strips. Additionally, any number of different mat sections may be attached to one another using any suitable type of interconnecting mechanism.

Claims

1. A mat comprising: a main body; and at least one elongate member partly embedded and/or inserted in the main body.

2. A mat according to claim 1, wherein the at least one elongate member defines a series of slots adapted to receive and engage carpet strips.

3. A mat according to any of claims 1 or 2, wherein the at least one elongate member is formed from a single or multiple-component member.

4. A mat according to any preceding claim, wherein the at least one elongate member is upstanding and extends from an upper surface of the main body.

5. A mat according to any preceding claim, wherein the at least one elongate member is substantially 'I '-shaped or "T'-shaped.

6. A mat according to any preceding claim, wherein the at least one elongate member comprises a lower portion which is embedded and/or inserted in the main body of the mat .

7. A mat according to¹ any preceding claim, wherein the at least one elongate member is partly embedded and/or inserted into a channel in the main body of the mat by- using a snap-fit mechanism.

8. A mat according to any preceding claim, wherein a top surface of the at least one elongate member is profiled or textured.

9. A mat according to any preceding claim, wherein the at least one elongate member is manufactured from a metal, plastics, composite or alloy.

10. A mat according to any preceding claim, wherein the at least one elongate member comprises at least one aperture through which settable material may set in the forming of the main body of the mat.

11. A mat according to any preceding claim, wherein the at least one elongate member comprises protruding members or depressions including that of grooves, bars, flanges which help in securing and engaging the least one elongate member in the main body of the mat.

12. A mat according to any preceding claim, wherein the at least one elongate member is bonded to the main body of the mat using chemical bonding.

13. A mat according to any preceding claim, wherein the at least one elongate member is bonded to the mat using both mechanical and chemical means.

14. A mat according to any preceding claim, wherein the main body of the mat is of a unitary structure and is formed from a plastics or rubber-like material.

15. A mat according to any preceding claim, wherein a bottom surface of the mat comprises a patterned or profiled surface which prevents the mat from slipping and also allows the mat to dry freely.

16. A mat according to any preceding claim, wherein carpet strips are insertable into slots formed between two elongate members .

17. A mat according to any preceding claim, wherein carpet strips inserted into the mat, may be removed and either cleaned or replaced.

18. An elongate member intended to form part of a mat, said elongate member comprising: an upper portion and a lower portion; said lower portion capable of being embedded and/or inserted in a main body of a mat.

19. A method of forming a mat comprising: providing at least one elongate member, said elongate member comprising an upper and lower portion; providing a settable material around at least the lower portion of the at least one elongate member; said settable material setting to form a main body of the mat; and wherein on the setting of the settable material, the at least one elongate member is fixed to the main body of the mat .