MAT

Abstract

A mat comprises a first surface and an opposing second surface. The first surface includes a first lugged cleaning area and a second lugged cleaning area in which a plurality of lugs project from the first surface. A drain region is disposed between the first and second lugged cleaning surfaces. The drain region includes at least one drain communicating with the second surface. The mat may optionally further include a removable and replaceable brush disposed in the drain region. The second surface may include a channel formed in the second surface that communicates with the drain.

Description

BACKGROUND OF THE INVENTION

This disclosure relates to mats for cleaning footwear and/or feet.

Door mats or entry mats are commonly placed on the floor before an entryway in both residential and commercial applications in order to permit people to clean their footwear or feet prior to entry. Commonly, entry mats are constructed with a smooth or semi-smooth fibrous, porous, cleaning surface, which allows a standing user to frictionally rub his soles by turns against the cleaning surface in an attempt to remove or reduce the debris on his soles prior to entering.

BRIEF SUMMARY

The present application appreciates that conventional entry mats suffer from a number of deficiencies. For example, the soles of footwear and/or feet are capable of carrying a wide variety of debris that is not easily removed using a common entry mat. In addition, the cleaning surface of a common entry mat is susceptible to contamination, moisture, and debris remaining on the cleaning surface of the mat. As a consequence, the contamination, moisture, and/or debris remaining on the cleaning surface can be unintentionally picked up and carried inside the entry on the soles of subsequent users of the mat. Conventional entry mats formed of coir fiber or the like are also susceptible through repeated use to the breakage and shedding of fibers, which creates additional debris which can be tracked inside the entry way. In light of these and other deficiencies of conventional entry mats, the present application appreciates that a need remains for an entry mat capable of efficiently and completely cleaning debris from the soles of footwear and/or feet.

In at least one embodiment, a mat comprises a first surface and an opposing second surface. The first surface includes a first lugged cleaning area and a second lugged cleaning area in which a plurality of lugs project from the first surface. A drain region is disposed between the first and second lugged cleaning surfaces. The drain region includes at least one drain communicating with the second surface. The mat may optionally further include a removable and replaceable brush disposed in the drain region. The second surface may include a channel formed in the second surface that communicates with the drain.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is an isometric view of an example of a mat in accordance with one embodiment;

FIG. 2 is a top plan view of an example of a mat in accordance with one embodiment;

FIG. 3 is a top plan view of an example of a mat in accordance with one embodiment, which is illustrated as having one or more removable brushes removed;

FIG. 4 is a side elevation view of an example of a mat in accordance with one embodiment;

FIG. 5 is a bottom plan view of an example of a mat in accordance with one embodiment;

FIG. 6 is a section view of an example of a mat along line A-A of FIG. 3 in accordance with one embodiment;

FIGS. 7A-7C depict a brushes that can be utilized with a mat in accordance with one embodiment; and

FIG. 8 is an isometric view of an example of a mat in accordance with another embodiment.

DETAILED DESCRIPTION

With reference now to FIGS. 1-6, there is depicted an example of a mat in accordance with one embodiment. In particular, FIG. 1 is an isometric view, FIGS. 2-3 are top plan views, and FIG. 4 is a side elevation view, FIG. 5 is a bottom plan view, and FIG. 6 is a section view of an example of a mat 100 taken along line A-A of FIG. 3.

In the depicted example, mat 100 has an overall rectangular shape having two pair of parallel edges 102a-102b and 102c-102d. In other embodiments, a mat in accordance with the present invention may have, for example, a circular or semi-circular shape, an ovoid shape, an elliptical shape, a triangular shape, a trapezoidal shape, a heart shape, a rhomboid shape, or an irregular shape. Mat 100 can be sized in area as desired for any given application. In at least some embodiments, mat 100 can be made of an elastomeric resilient material, such as rubber or Thermoplastic Polyurethane Elastomer (TPE). Mat 100 can be formed, for example, by injection molding. Forming mat 100 from a resilient elastomeric material provides enhanced ease of cleaning and more rapid drying than conventional fabric mats. The hardness of the elastomeric material can vary depending on the desired use. For example, for an exterior mat, a Shore A 60 durometer rubber can be used, while for interior use (e.g., as an anti-fatigue mat) a softer material, such as a Shore A 30 durometer elastomer, can be utilized.

As shown, mat 100 has a first surface 104a (see, FIGS. 1-4 and 6) and an opposed second surface 104b (see, FIG. 5). First surface 104a, which can be employed in use of mat 100 as the upper surface, has a smooth inwardly sloping border region 106 along one or more of edges 102. First surface 104a has projecting therefrom a plurality of lugs 108 to assist in cleaning snow, sand, moisture, contaminants, and/or debris from the soles of footwear and/or feet. Lugs 108 are preferably configured and spaced apart to support the soles of a user above the underlying first surface 104a while allowing sufficient interstitial space for dirt, snow, sand, moisture and/or other debris to settle and keep the cleaning surfaces of lugs 108 relatively free of debris and moisture. A user can remove debris and contaminants from his soles by wiping the soles over the top and/or sides of lugs 108. The configuration and spacing of lugs 108 promotes the movement of debris from the upper contact surfaces of lugs 108 to first surface 104a, leaving the upper contact surfaces of lugs 108 relatively clean.

In the illustrated embodiment, lugs 108 may include lugs 108a, 108b of different shapes. In this example, lugs 108a are dome-shaped lugs, which may, for example, have a major dimension in plan of ½″ and a height of ¼″ above first surface 104a. Lugs 108b are narrower than 108a and may, for example, have a generally tooth shape or frusto-conical shape. In one example, lugs 108b may be ¼″ tall and have a ¼″ major dimension in plan. Of course, in other examples, lugs 108 may include only one size and shape of lug or more than two sizes and/or shapes of lugs.

In the illustrated embodiment, lugs 108 are arranged in a regular pattern. In particular, mat 100 includes at least two (and in this case, four) lugged cleaning regions 110. In this example, the lug pattern in each lugged cleaning region 110 includes a field of lugs 108a surrounded by a border of lugs 108b. Of course, in other embodiments, alternative lug patterns may be employed.

Each pair of adjacent lugged cleaning regions 110 is separated by a drain region 112 including one or more (and preferably a plurality of) drains 114 to allow snow, sand, moisture, debris, and/or contaminants gathered on first surface 104a to pass through first surface 104a and into one or more passages 116 formed into the second surface 104b of mat 100. Although not required, it is preferred in at least some embodiments for drain regions 112 and passages 116 to be orthogonal. To promote the passage of snow, sand, moisture, debris, and/or contaminants through drains 114, each drain region 112 can comprise a hollow, indentation, or relief formed into first surface 104a.

Drain regions 112 can optionally further include a channel 120 (best seen in FIGS. 3, 4 and 6), which as shown in FIG. 3 can be formed in one or more lands 130 between drains 114. In at least some embodiments, one or more channels 120 can be configured to receive and retain therein a removable and replaceable brush 122, illustrated in isometric, front elevation, and side elevation views in FIGS. 7A-7C, respectively.

In the embodiment depicted in FIGS. 7A-7C, each brush 122 includes a carrier 124, which is preferably formed of aluminum, stainless steel, rubber, plastic, or other rigid or semi-rigid material, and bristles 126 retained within carrier 124. In the illustrated embodiment, bristles 126 are implemented as a plurality of tufts of (e.g., nylon) fiber. In at least one embodiment, the tufts of bristles 126 are spaced so that debris removed from the user's soles does not clog the bristles 126 and will pass into drain regions 112. Individual bristles 126 are preferably in the range of 0.1 to 0.2 mm in diameter so that bristles are sufficiently rigid to remain upright in use. Brush 122 is characterized by an overall height H, a width W along its lesser dimension, and a length L along its greater dimension.

Carrier 124 is preferably configured to be received and retained within a corresponding channel 120. For example, in one preferred embodiment, channel 120 has inwardly sloping opposing sidewalls that are more closely spaced at the top than the bottom of channel 120. The inward slope of the sidewalls may be, for example, between 10 and 35 degrees, are more particularly, between 10 and 20 degrees, and still more particularly, about 15 degrees. This inward slope can be selected to equal or closely correspond to the angle Φ describing the inward slope of the long sides of carrier 124, as best seen in FIG. 7B. Further, the width of the channel 120 can be selected to equal or closely correspond to the width W of carrier 124. As will be appreciated, there need not be any correspondence or direct relationship between the length of a channel 120 and the length of carrier 124, as a channel 120 can be longer or shorter than the carrier 124 of a brush 122 installed in the channel 120.

As a result of the correspondence between the configuration of a brush 122 and channel 120, a brush 122 can be inserted and removed manually from a channel 120 by sliding the brush 122 in from either end of channel 120. In at least some embodiments, the width W and angle Φ of a brush 122 are selected to closely correspond to (and in some embodiments are equal to or even greater than) the corresponding dimensions of an associated channel 120 so that the brush 122 will be snugly retained within the associated channel 120 by interference fit and/or slight compliant deformation of the sidewalls of channel 120. For example, if a Shore A 60 durometer rubber or material of similar hardness is utilized to form mat 100, the stiffness of the mat material as well as the user's downward force applied to upper surface 104a cooperate to ensure that, once installed, brushes 122 remain in channels 120 until replacement is desired.

When brush 122 is installed a corresponding channel 120, bristles 126 preferably extend beyond lugs 108 to enable the user to sweep the soles of his footwear and/or feet across bristles 126 without contacting lugs 108 or by contacting both bristles 126 and lugs 108. For example, in some embodiments, bristles 126 extend between 0.15 and 0.25 inches above a top surface of lugs 108 to enable deep sole contact, sweeping, and cleaning. Bristles 126 can thus be used to perform more detailed cleaning of the soles and/or sides of the user's footwear and/or feet. Although FIG. 2 illustrates an embodiment in which brushes 122 do not span drains 114, in other embodiments such as that illustrated in FIG. 4, a brush 122 can span one or more drains 114 and can, in some cases, span substantially all of the width of mat 100.

As further illustrated in FIG. 8, in some embodiments, one or more brushes 122 may alternatively or additionally be implemented in one or more of lugged cleaning regions 110 of a mat 100′. In such embodiments, the brushes 122 disposed within lugged cleaning regions 110 may be configured to be non-replaceable and permanently attached to mat 100′, for example, utilizing epoxy, adhesive, and/or overmolding.

Referring now specifically to FIG. 5, in at least one embodiment, second surface 104b may have a texture molded into its surface finish or applied thereto to increase its coefficient of friction and to resist sliding on slick underlying surfaces. In the illustrated embodiment, second surface 104b can include one or more inset passages 116 formed therein in which the second surface 104b is spaced above the underlying surface. In some embodiments, each channel 116 communicates with at least one drain 114, such that the channel 116 serves as a conduit for snow, sand, moisture, contaminants, and/or debris passing through the drain 114 from the other side of mat 100 to an edge 102 of mat 100. For example, in the embodiment of FIG. 5, each of multiple passages 116 communicates between each of multiple drains 114 within a “column” of drains 114 and edges 102c, 102d. Although the number and arrangement of passages 116 formed in second surface 104b may vary, it is preferred that the width, depth, and spacing of passages 116 and material from which mat 100 is formed are selected such that weight of a user (e.g., up to 300 lbs.) does not collapse one or more of passages 116 onto the surface underlying mat 100 in use.

As further illustrated in FIGS. 5-6, in order to reduce weight and material cost, in some embodiments, a plurality of recesses 140 may be formed in second surface 104b, including within passages 116. The number, size, and position of recesses 140 may, but need not, correspond in any way to lugs 108a, 108b extending from first surface 104a.

As has been described, in at least one embodiment, a mat comprises a first surface and an opposing second surface. The first surface includes a first lugged cleaning area and a second lugged cleaning area in which a plurality of lugs project from the first surface. A drain region is disposed between the first and second lugged cleaning surfaces. The drain region includes at least one drain communicating with the second surface. The mat may optionally further include a removable and replaceable brush disposed in the drain region. The second surface may include a channel formed in the second surface that communicates with the drain.

A mat 100 or 100′ as described herein can be made as a unitary piece, for example, by injection molding. Brushes 122 can similarly be formed by injection molding or compression molding, as is known in the art. The brushes 122 can then be assembled to the mat 100 or 100′, for example, by sliding brushes into corresponding channels 120. Brushes 122 that become worn through use can thereafter be individually replaced as needed.

In one implementation, specific dimension that may be employed for a rectangular mat are as follows:

• • Overall mat dimensions:
    • Width (along greatest dimension): Between 24 in and 48 in, and more particularly, between 24 in and 40 in, and even more particularly, about 34 in
    • Length (orthogonal to width): Between 18 in and 36 in, and more particularly, between 20 in and 30 in, and still more particularly, 22.0 in
    • Height: Between 0.5 and 1.0 in, and more particularly, between 0.5 in and 0.75 in, and still more particularly, 0.6850 in
  • Channel dimensions:
    • Height: Between 0.10 in and 0.25 in, and more particularly, between 0.10 in and 0.2 in, and still more particularly, about 0.125 in height
    • Width: Between 1.0 in and 3.0 in, and more particularly between 1.5 in and 2.5 in, and still more particularly about 2.0 in
  • Lugged cleaning region dimension: Between 3.0 in and 6.0 in along the length of the mat, and more particularly, between 3.5 and 5.0 in, and still more particularly, about 4.5 in
  • Border dimensions: Between 0.50 and 1.0 in, and more particularly, about 0.75 in width, with a slope of 20-30° and, more particularly, about 26°
  • Drain region dimension:
    • Narrow dimension: 0.5 and 2.0 in, and more particularly, about 1.0 in
    • Depth: 0.10 and 0.30 in and, more particularly, about 0.1875 in
    • Sidewall slope of between 5° and 10° and, more particularly, about 7°
  • Drain dimensions:
    • Width (greater dimension): between 1.25 in and 4.0 in, and more particularly, about 3.0 in
    • Length (orthogonal to width): Between 0.75 and 2.0 in, and more particularly, about 1.0 in
  • Lands: Between 2.0 and 5.0 in wide and, more particularly, about 3.0 inches wide

While the present invention has been particularly shown as described with reference to one or more preferred embodiments, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. For example, in some embodiments, mat 100 may additionally be provided with illumination, such as light-emitting diode (LED) lighting, which can be incorporated, for example, in border region 106. Additionally, in some embodiments, mat 100 can include integral heating, such as resistive heating elements encapsulated within the body of mat 100. Power for lighting and/or heat can be provided, for example, through an electrical cord connected to a standard 110 V outlet or a battery pack. If desired, the rigidity of mat 100 can also be increased by overmolding a plastic or metal (e.g., aluminum) core, which can also advantageously be utilized to form channels 120. In some embodiments, mat 100 can be formed of a relatively low durometer material (e.g., 30±10 on the Shore A scale) and can double for use as an anti-fatigue mat on which a user can stand. In these embodiments, lugged cleaning regions 110 can be sized to accommodate the user's feet. Mat 100, including brushes 122, can also be impregnated with or coated with antimicrobial and/or antiviral surface treatment to neutralize, counteract, or otherwise ameliorate potential contaminants. Mat 100 can also be impregnated with additives to promote UV resistance and/or to provide desired colors/pigmentation and can additionally have a surface decoration or stamp applied to achieve a desired decorative appearance.

The singular as utilized herein includes the use of the plural unless explicitly or implicitly indicated by context. Further, the terms “about” and “corresponding” are used herein with reference to dimensions to mean a dimension, size, or amount within 5% of the stated dimension, size, or amount.

The figures described above and the written description of specific structures and functions below are not presented to limit the scope of what Applicants have invented or the scope of the appended claims. Rather, the figures and written description are provided to teach any person skilled in the art to make and use the inventions for which patent protection is sought. Those skilled in the art will appreciate that not all features of a commercial embodiment of the inventions are described or shown for the sake of clarity and understanding. Persons of skill in this art will also appreciate that the development of an actual commercial embodiment incorporating aspects of the present inventions will require numerous implementation-specific decisions to achieve the ultimate goal for the commercial embodiment. Such implementation-specific decisions may include, and likely are not limited to, compliance with system-related, business-related, government-related and other constraints, which may vary by specific implementation, location and from time to time. While a developer's efforts might be complex and time-consuming in an absolute sense, such efforts would be, nevertheless, a routine undertaking for those of skill in this art having benefit of this disclosure. It must be understood that the inventions disclosed and taught herein are susceptible to numerous and various modifications and alternative forms. Lastly, the use of a singular term, such as, but not limited to, “a” is not intended as limiting of the number of items.

Claims

1. A mat comprising: a first surface and an opposing second surface, wherein the first surface includes a first lugged cleaning area and a second lugged cleaning area in which a plurality of lugs project from the first surface; anda drain region between the first and second lugged cleaning surfaces, wherein the drain region includes at least one drain communicating with the second surface.

2. The mat of claim 1, and further comprising a brush disposed in the drain region.

3. The mat of claim 2, wherein: the drain region includes a channel formed therein; andthe channel is configured to removably retain the brush.

4. The mat of claim 3, wherein the channel has inwardly sloping opposing sidewalls.

5. The mat of claim 2, wherein the brush spans the at least one drain.

6. The mat of claim 2, wherein: the brush includes bristles; andthe bristles extend from the first surface more than the plurality of lugs.

7. The mat of claim 1, wherein the mat is formed of a resilient material.

8. The mat of claim 1, wherein: the mat has an edge; andthe second surface has at least one passage formed therein communicating between the at least one drain and the edge.

9. The mat of claim 1, wherein the plurality of lugs includes lugs of differing shapes and sizes.

10. The mat of claim 1, wherein the plurality of lugs includes dome-shaped lugs.

11. A mat comprising: a first surface and an opposing second surface, wherein the first surface includes a first lugged cleaning area and a second lugged cleaning area in which a plurality of lugs project from the first surface;a drain region between the first and second lugged cleaning surfaces, wherein the drain region includes at least one drain communicating with the second surface; anda brush disposed in the drain region.

12. The mat of claim 11, wherein: the drain region includes a channel formed therein; andthe channel has inwardly sloping opposing sidewalls configured to removably retain the brush.

13. The mat of claim 11, wherein: the brush includes bristles; andthe bristles extend from the first surface more than the plurality of lugs.

14. The mat of claim 11, wherein: the mat has an edge; andthe second surface has at least one passage formed therein communicating between the at least one drain and the edge.

15. The mat of claim 11, wherein the mat is formed of a unitary piece of resilient material.

16. A mat comprising: a first surface, an opposing second surface, and a peripheral edge, wherein the first surface includes a first lugged cleaning area and a second lugged cleaning area in which a plurality of lugs project from the first surface;a drain region between the first and second lugged cleaning surfaces, wherein the drain region includes at least one drain communicating with the second surface;a brush disposed in the drain region; andat least one passage formed in the second surface that communicates between the at least one drain and the peripheral edge.

17. The mat of claim 16, wherein: the drain region includes a channel formed therein; andthe channel has inwardly sloping opposing sidewalls configured to removably retain the brush.

18. The mat of claim 16, wherein: the brush includes bristles; andthe bristles extend from the first surface more than the plurality of lugs.

19. The mat of claim 16, wherein the mat is formed of a unitary piece of resilient material.