The present invention relates to a mat, and in particular to a heated mat.
Heated mats for heating surfaces are desired.
The present invention, according to one aspect, is directed to a heated mat comprising a bottom protection layer, a middle heated layer, a top layer having a heated surface, and a power cord for supplying power to the middle heated layer. A periphery of the top layer is heated and pressurized against a periphery of the bottom protection layer to sandwich the middle heated layer therebetween in a waterproof manner.
One or more embodiments of the present invention are illustrated by way of example and should not be construed as being limited to the specific embodiments depicted in the accompanying drawings, in which like reference numerals indicate similar elements.
The specific devices and processes illustrated in the attached drawings and described in the following specification are simply exemplary embodiments of the inventive concepts. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting.
For purposes of description herein, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings and described in the following specification are simply exemplary embodiments of the inventive concepts defined herein. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless expressly stated otherwise.
The reference number 10 (
In the illustrated example, the heated mat 10 includes a bottom protection layer 14, a middle heated layer 16 and a top layer 18 having the heated surface 12 thereon. A power cord 20 extends from the heated mat 10 and is configured to supply power to the heated mat 10 to heat the middle heated layer 16, thereby providing heat to the top layer 18 at the heated surface 12. The power cord 20 can be directly plugged into or connected to a power source or could be connected to a multiple mat power source that connects to a plurality of heated mats 10 to heat the plurality of heated mats 10.
The illustrated bottom protection layer 14 of the heated mat 10 is configured to be placed on a support surface (e.g., a floor). The bottom protection layer 14 can be made from any material that provides support and protection for the remaining layers of the heated mat 10. In the illustrated example, the bottom protection layer 14 is formed from 9 mm PP 2000 gsm cellular board. Therefore, in the illustrated example, the bottom protection layer 14 is formed from polypropylene into cells having 2000 grams per square meter and being 9 mm thick. As shown in
In the illustrated example, the middle heated layer 16 is heated to heat the heated mat 10. The middle heated layer 16 comprises a substrate 30 having a heatable material 32 printed thereon. In the illustrated example, the heatable material 32 printed on the substrate 30 is graphene. The graphene of the heatable material 32 is printed across the substrate 30 with a plurality of voids as shown in
The illustrated top layer 18 rests on the bottom protection layer 14 and the middle heated layer 16 and includes the heated surface 12. The top layer 18 can be any layer that transfers heat from the heatable material 32 of the middle heated layer 16 to the heated surface 12. It is contemplated that the top layer 18 can be elastic. In the illustrated example, the top layer 18 can be a TPO (thermoplastic polyolefin) layer having a spun polyester (fleece) backing that is mechanically attached to the TPO layer during an extrusion manufacturing process. The top layer 18 can be referred to as nickel or coin flooring, which means that the top layer 18 can have raised circular projections 40 for extra grip. If the top layer 18 has raised projections 40, the heated surface 12 can be the top of the raised projections 40. The top layer 18 can include a channel 39 in an edge thereof (see
The illustrated heated mat 10 can be formed by connecting the power cord 20 to the metal connectors 34 of the middle heated layer 16 and then sandwiching the middle heated layer 16 between the bottom protection layer 14 and the top layer 18. In the process of making the heated mat, the periphery of the top layer 18 is heated and pressurized to the flat lip 22 of the bottom protection layer 14 to seal the middle heated layer 16 therein. The entrance of the power cord 20 into the rest of the heated mat 10 can also be sealed (e.g., in a waterproof manner) to protect the middle heated layer 16.
In the illustrated example, the power cord 20 can be connected to a source of power as outlined above. For example, an end of the power cord 20 could have a three pronged connection for connecting the power cord 20 to a standard outlet. The power cord 20 can be any cord that supplies sufficient power to the heated mat 10. In the illustrated example, the power cord 20 can be an 18/2 SJO wire 50 having a stainless steel spring cord protector 52 covering at least a portion thereof.
The heated mat 10 can be used in any situation wherein a heated floor is desired. For example, as shown in
The reference number 10a (
The heated mat 10a comprises a laminated structure including a bottom protection layer 14a, an insulation layer 60, a heated layer 16a and a top layer 18a having the heated surface 12a thereon. The bottom protection layer 14a is made of durable material. For example, the bottom protection layer 14a can be formed from thermoplastic polyolefin (TPO) or similar material. The top layer 18a can be any layer that transfers heat from the heatable material 32a of the heated layer 16a to the heated surface 12a. It is contemplated that the top layer 18a can be elastic. In the illustrated example, the top layer 18a can be a TPO (thermoplastic polyolefin) layer having a spun polyester (fleece) backing that is mechanically attached to the TPO layer during an extrusion manufacturing process. The top layer 18a can be referred to as nickel or coin flooring, which means that the top layer 18a can have raised circular projections 40a for extra grip. If the top layer 18a has raised projections 40a, the heated surface 12 can be the top of the raised projections 40a.
In the illustrated example, the insulation layer 60 and the middle heated layer 16 are sandwiched between the top layer 18a and the bottom protection layer 14a. The insulation layer 60 is positioned on the bottom protection layer 14a and provide insulation between the bottom protection layer 14a and the heated layer 16a. The insulation layer 60 can be formed of any insulating material that is safe to use around animals and humans and does not degrade when heat is applied thereto. For example, the insulation layer 60 can be formed of double reflective insulation. The heated layer 16a is configured to heat the heated mat 10a. The heated layer 16a can be formed from any material that can uniformly heat the heated mat 10a. For example, the heated layer 16a can comprise a substrate 30a having a heatable material 32a printed thereon. In the illustrated example, the heatable material 32a printed on the substrate 30a is graphene.
As shown in
A power cord 20a extends from the heated mat 10a and is configured to supply power to the heated mat 10a to heat the heated mat 10a, thereby providing heat to the top layer 18a at the heated surface 12a. The power cord 20a can be directly plugged into or connected to a power source or could be connected to a multiple mat power source that connects to a plurality of heated mats 10a to heat the plurality of heated mats 10a. The power cord 20a can include a tension relief stainless steel spring cord protector 52a covering at least a portion thereof. The intersection and connection of the power cord 20a to the heatable material 32a can include a temperature limiter 62 for limiting the temperature of the heatable material 32a to a certain temperature (e.g., 60° F.). The top layer 18a includes a T-shaped channel 64 configured to seal the intersection of the power cord 20a and the heatable material 32a to protect the intersection from the elements (e.g., rain, etc.) or other items that are undesirable to enter the heated mat 10a (for example, water or animal waste from an animal using the heated mat 10a). A potting and encapsulating compound can cover the intersection and be located within the T-shaped channel 64 and sandwiched between the T-shaped channel 64 and a top surface of the substrate 30a of the heated layer 16a.
The heated mat 10a can be constructed in many different ways to result in the structure as disclosed herein. One non-limiting example of constructing the heated mat 10a includes the following steps (with the order for most steps not being important):
Although particular preferred embodiments of the invention have been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention.
This claims the benefit of U.S. Provisional Application Ser. No. 63/323,740, filed Mar. 25, 2022, the disclosure of which is hereby incorporated by reference in its entirety.
Number | Date | Country | |
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63323740 | Mar 2022 | US |