The present invention relates generally to a floor-covering material and, more particularly, to a floor-covering material that is particularly suited for moisture-prone applications and that provides superior traction and comfort.
The flooring surfaces of marine vessels, which are generally made of fiberglass, aluminum, or wood, are typically provided with gelcoat or a coat of marine-grade paint and either left uncovered or are covered with a marine-grade floor covering, e.g., a carpet material. When left uncovered, the flooring surface can be slippery, often gets hot due to direct exposure to the sun, and is, generally, not very comfortable to bare feet. Unfortunately, presently-known floor coverings suffer from many shortcomings as well. For example, carpet material, which, due to its presence on a boat deck, is exposed to the elements, e.g., intense sunlight/heat, rain, humidity, etc. This exposure causes rapid deterioration of the material and replacement is frequently necessary. The deterioration is accelerated by the carpet material's retention of moisture, which results in the development of mold and mildew. Furthermore, flooring made from carpet materials tend to be difficult to hold in place without adhesive, which can be difficult to deal with when the carpet has to be removed and replaced.
One alternative material that does not absorb moisture is matting material distributed under the name 3M™ Nomad™ Vinyl Scraper Matting. This material has a top surface made of a coiled web of continuous filaments and is provided either with a solid backing material or without any backing material at all. Notably, the Nomad™ matting has a coiled web of continuous filaments that are stiff and are intended to serve as a resistive material that scrapes debris from shoe soles. This stiff coiled web of filaments is, therefore, not suitable for applications in which bare feet or bare skin contact the filaments for any length of time. Moreover, neither the matting having the solid backing material nor the unbacked matting is suitable for placement on the deck of a marine vessel. Particularly, the unbacked matting is not suitable for appropriately gripping the deck of the marine vessel and the backed material results moisture being retained between the deck of the marine vessel and the backing, which can result in the growth of mold and mildew between the surfaces.
Other options for covering the deck of a marine vessel are hardened vinyl and perforated rubber, which are not aesthetically pleasing or comfortable on bare feet.
Therefore, a need exists to overcome the problems with the prior art as discussed above.
The invention provides a porous anti-slip floor covering that overcomes the hereinabove-mentioned disadvantages of the heretofore-known devices and methods of this general type and that provides floor covering that can be implemented in an efficient manner, is aesthetically pleasing, and provides comfort to the bare feet of a user.
With the foregoing and other objects in view, there is provided, in accordance with the invention, a flooring assembly that includes an underlayment with an upper surface, an opposing lower surface, and defining a plurality of voids extending from the upper surface to the lower surface. A working layer is disposed on top of the underlayment, the working layer including a plurality of flexible curled strands, each curled strand having a first end and a second end opposite the first end, the first end of each curled strand being directly physically coupled to a first end of at least one other of the curled strands in the plurality of curled strands and, together, defining a lower surface and the second end of each curled strand being physically independent from each second end of each of the curled strands in the plurality of curled strands, wherein each second end of each curled strand is able to move independent of the second end of each other curled strand and the coupled first ends of the plurality of curled strands define a plurality of openings thereat.
In accordance with a further feature of the present invention, the curled strands are formed from PVC material.
In accordance with another feature of the present invention, the working layer and the underlayment are waterproof.
In accordance with one more feature of the present invention, the working layer is between about 8 mm to about 18 mm in height.
In accordance with an additional feature of the present invention, the curled strands are coated in a PLASTISOL material.
In accordance with a further feature of the present invention, the underlayment is of a non-marking material.
In accordance with still another feature of the present invention, the underlayment has a first frictional coefficient and the working layer has a second frictional coefficient, the first frictional coefficient being larger than the second frictional coefficient.
In accordance with yet one more feature of the present invention, the lower surface of the underlayment has a shape that defines a plurality of water channels between the lower surface of the underlayment and a surface upon which the lower surface of the underlayment is placed.
In accordance with an additional feature of the present invention, the lower surface of the underlayment is provided with legs that define a plurality of water channels between the lower surface of the underlayment and a surface upon which the lower surface of the underlayment is placed.
In accordance with the present invention, a method of manufacturing a flooring assembly includes forming a working surface by depositing a plurality of heated flexible strands of material onto a surface and cooling the plurality of heated flexible strands so that a first end of each strand is directly physically coupled to a first end of at least one other strand in the plurality of strands so that the coupled first ends of the plurality of strands define a plurality of openings and a second end, opposite the first end, of each strand is physically independent from each second end of each of the strands in the plurality of strands so that each second end of each strand is able to move independent of the second end of each other strand. The method further includes providing a mesh underlayment having an upper surface, an opposing lower surface, and defining a plurality of openings spanning from the upper surface to the lower surface and permanently adhering the coupled first ends of the plurality of strands to the upper surface of the underlayment.
In accordance with a feature of the present invention, a method of manufacturing a flooring assembly further includes applying a coating of PLASTISOL to the working layer and applying a coating of PLASTISOL to the underlayment.
In accordance with a feature of the present invention, a method of manufacturing a flooring assembly also includes applying heat to the working surface and the mesh underlayment so that the PLASTISOL reaches a melting point.
Although the invention is illustrated and described herein as embodied in a porous anti-slip floor covering, it is, nevertheless, not intended to be limited to the details shown because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims. Additionally, well-known elements of exemplary embodiments of the invention will not be described in detail or will be omitted so as not to obscure the relevant details of the invention.
Other features that are considered as characteristic for the invention are set forth in the appended claims. As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one of ordinary skill in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the invention. While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward. The figures of the drawings are not drawn to scale.
Before the present invention is disclosed and described, it is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. The terms “a” or “an,” as used herein, are defined as one or more than one. The term “plurality,” as used herein, is defined as two or more than two. The term “another,” as used herein, is defined as at least a second or more. The terms “including” and/or “having,” as used herein, are defined as comprising (i.e., open language). The term “coupled,” as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically.
As used herein, the terms “about” or “approximately” apply to all numeric values, whether or not explicitly indicated. These terms generally refer to a range of numbers that one of skill in the art would consider equivalent to the recited values (i.e., having the same function or result). In many instances these terms may include numbers that are rounded to the nearest significant figure.
The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and explain various principles and advantages all in accordance with the present invention.
While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward. It is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms.
The present invention provides a novel anti-slip, anti-stain, anti-fade, and anti-mold water-shedding floor covering that does not store moisture. Embodiments of the invention provide an upper layer of resilient flexible coiled waterproof fibers disposed in a loosely-organized fashion on a solid layer of porous anti-slip material. In addition, embodiments of the invention provide a stain-free, fade-free, slip-free, mold-free decorative flooring for boats, pool areas, porches, patios, or anywhere else.
Referring now to
Although other materials may be utilized, in accordance with one embodiment of the present invention, the curled strands 104 are formed of extruded polyvinyl chloride (PVC) material. The PVC can be either new or recycled from other applications of PVC. A curled strand formation process is illustrated in the elevational side view of
Upon being deposited on the intermediate surface 202, cooling occurs relatively rapidly. As the cooling occurs, the shape of the upper portion of the strands of material 104 locks into random spaghetti shapes that resemble that shown in
PVC material has many advantages over prior-art flooring material. For example, PVC material does not absorb water like carpets and other materials that are commonly used as outdoor flooring, e.g., boat flooring. PVC material is extremely durable and is not likely to show wear over time, as would typical flooring materials. Furthermore, PVC material 104 extruded in small strands, such as that making up the working layer 102 of the floor covering assembly 100, expresses great flexibility and resilience to return to its original shape. This provides a comfortable surface against the user's feet as they walk on the working layer 102. In addition to comfort, the easily temporarily deformed strands of PVC material 104 create depressed areas in the shape of the users foot, which results in secure, slip-free footing for the user. Advantageously, the PVC material 104, in accordance with an embodiment of the present invention, can be further softened by adding fillers of, for instance, petroleum and limestone, which results in increased flexibility of each of the strands of PVC material 104 and provides even further comfort and secure footing on the floor covering assembly at the working surface 102.
Embodiments of the present invention provide the PVC material 104 with ultraviolet (UV) stabilizers, which allow the working layer 102 of the floor covering assembly 100 to withstand extensive exposure to sunlight. UV stabilizers are well known in the art. In addition, pigments can be easily added to the PVC material 104 to produce a virtually unlimited number of colors, shapes, and patterns that can be provided in the working layer 102.
Returning to
In accordance with one embodiment of the present invention, the underlayment 106 is a mesh substrate 300, as shown in the elevational edge view of
In accordance with embodiments of the present invention, both the working layer 102 and the underlayment 106 are waterproof Waterproof, as used herein, is intended to indicate a material that is relatively unaffected by water and resists the penetration or permeation of water and water vapors.
The mesh substrate 300 is preferably provided with an overall thickness T of between about 8 mm to about 18 mm, with 8 mm being the preferred thickness. The mesh substrate 300 has a upper surface 304, which is the surface that makes contact with and is coupled to the lower working surface 110 of the working layer 102 of the flooring assembly 100 (see
As shown in the downward-looking plan view of
The repeating curved shape of the application surface 306 (see
For permanent attachment of the working layer 102 to the underlayment 106, applicant discovered that extrusion strands 104 directly onto the mesh substrate 300 resulted in the strands 104 sealing the voids 310a-n in the mesh substrate 300, which in turn would prevent liquid from passing through the voids 310a-n. After extensive testing, it was discovered that producing the inventive flooring assembly in the manner partially illustrated in
Looking now to
In step 508, the lower working surface 110 of the working layer 102 is placed directly on the upper surface 304 of the underlayment 106. The two layers 102, 106 are then subjected, in step 510, to a temperature sufficient to cause the PLASTISOL to melt and adhere the working layer 102 to the underlayment 106 (mesh substrate 300). In step 512, the flooring assembly 100 is removed from the heat and, in step 514, the process ends. The result is a novel anti-slip floor covering that allows water or other liquids to immediately pass therethrough. In alternative steps that precede step 504, anti-stain and/or anti-fade and/or anti-mold additives can be added to the material, e.g., PVC, prior to the extrusion process. In other embodiments, anti-stain and/or anti-fade and/or anti-mold additives are applied to the working layer after the extrusion process. Anti-fade, as used herein, is intended to indicate a material that will endure approximately 1500 hours of exposure to sunlight without evidencing a noticeable change in color properties. To achieve anti-mold properties, anti-microbial composites are added to the materials. Anti-stain, as used herein, is intended to indicate a material that will not readily absorb pigment.
In
Referring now to
The underlayment 606 further includes one or more couplers 706, which can be used to couple an adjacent floor covering assembly 600 for the purpose of providing a configurable and expandable flooring surface.
Referring back to
The mesh substrate 612 disposed between the working layer 602 and the underlayment 606 provides several advantages. First, the mesh substrate 612, which has pores or voids that are much smaller than the voids 704a-n of the underlayment 606, supports the lower working surface 610 of the working layer 602 and prevents it from falling within and conforming to the voids 704a-n of the underlayment 606. Second, the inventive flooring assembly 600 is intended be utilized in outdoor conditions that can experience drastic variations in temperatures. These temperature gradients have been found to result in an expansion and contraction of the underlayment 606 that is not equal to a corresponding expansion and contraction of the working layer 602. Advantageously, the mesh substrate 612 serves as a buffer to the two layers. Additionally, the mesh substrate 612 provides an improved bonding surface for both layers to adhere to one another.
For each of the embodiments shown and described herein, patterns and logos can be cut out of the working surface material and fit into a second working surface with contrasting colors and having a corresponding same shape cutout. In addition to flooring, the presently-inventive flooring products have been found useful in other applications. For example, at least the working surface has been found to be very well suited as a saddle pad, where it provides insulation between the horse and saddle. In addition, the flooring assembly can be used as a bed liner of a truck, as a pet mat, in the door area of ski resorts, under water fountains, under ice machines, as flooring behind bars or food-preparation lines, on any other floor area, and many more.
A floor mat assembly has been disclosed that can be utilized in many applications and that readily passes liquid and other particulates therethrough, while maintaining an attractive appearance, similar to that of high-grade carpet materials. The inventive product is durable in shape, resists fading, resists mold, is not water soluble, and provides superior traction.
This application is a continuation application of U.S. patent application Ser. No. 13/228,525, filed on Sep. 9, 2011, which claims the benefit of U.S. Provisional Application No. 61/393,012, filed on Oct. 14, 2010, and U.S. Provisional Application No. 61/393,503, filed on Oct. 15, 2010, the prior applications are herewith incorporated by reference in their entirety.
Number | Date | Country | |
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61393012 | Oct 2010 | US | |
61393503 | Oct 2010 | US |
Number | Date | Country | |
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Parent | 13228525 | Sep 2011 | US |
Child | 13887601 | US |