Patent Application
20240065489
This disclosure relates to a washable mat material and system that may be used for various applications, including particularly for use in bath mats, but also in kitchen mats, rugs, and other floor coverings.
Bath mats are some of the most commonly used items in households and other places with baths and showers. There are a few characteristics commonly thought of as being desirable for bath mats. For one, it is desirable for bath mats to be absorbent and quick drying as they are typically used in high moisture environments and often have water spill on them. It is also desirable for bath mats to be easy to clean, or even washable in a washing machine. Many bathrooms present a warm and damp environment that tends to facilitate the growth of bacteria, making the washability of bath mats all the more important, as washing helps rid the bath mats of bacterial growth. Another desirable characteristic for bath mats is for them to resist slipping, which is a particular concern in wet environments.
Some bath mats currently available today may exhibit a number of downsides. Some bath mats are not resistant to the growth of bacteria, which can be undesirable because high moisture environments can be conducive to bacterial growth. Material used to make bath mats can be lent a degree of antibacterial properties by infusing them with copper, silver, charcoal, hemp, or similar ingredients.
As already noted, it is desirable for bath mats to be absorbent. Absorbency in a bath mat is helpful insofar as it eliminates or reduces the collection or pooling of water on the surface of the mat. However, some bath mats are water absorbent without being particularly water resistant, such that, for instance, water can soak all the way through the mat and collect on the floor. The collection of water on the floor can damage or reduce the life of the floor surface. It can also reduce the slip resistance of a bath mat, making the bath mat less safe to use.
Typically, slip resistance for a bath mat is achieved by applying a layer of PVC, latex, silicone, or similar material to the bottom surface of the mat. The anti-slip layer may be applied as a coating, e.g., to a floor-facing fabric surface, or it may be manufactured as a discrete layer of material that is then attached to fabric material to make a bath mat. The anti-slip layer may further feature textures, such as dimples, treads, and protrusions, to increase the slip resistance of the bath mat. However, the anti-slip layer of many bath mats tends to deteriorate over time, which causes it to lose some of its effectiveness. The deterioration of the anti-slip material may be accelerated by washing a bath mat in a washing machine, where the mat may endure prolonged exposure to water and heat. Once the anti-slip material has deteriorated to a sufficient degree, the mat would shift and move around on the floor, causing a safety hazard.
Moreover, the anti-slip layer used in some existing bath mats products are relatively thin and lightweight so that the mat would be sufficiently malleable to be folded or rolled up and washed in a washing machine. The downside of this approach is that the anti-slip layer would be quicker to deteriorate compared to a thicker anti-slip layer. However, the use of a thicker anti-slip layer may cause the bath mat to be too stiff to easily wash in a washing machine.
The problems shown in the examples depicted in
Accordingly, there is a need for a bath mat product that provides some of the benefits of existing products while improving on downsides exhibited by some existing products.
Disclosed is a washable mat material and system that may be used for various applications, particularly for use in bath mats, but also in kitchen mats, rugs, and other floor coverings. Some embodiments provide a two-piece system. Other embodiments provide a one-piece system.
This disclosure relates to a washable mat material and system that may be used for various applications, including particularly for use in bath mats, but also in kitchen mats, rugs, and other floor coverings.
The terms listed below each include their plain and ordinary meaning known to a person of skill in the art, which includes at least the provided information.
“Denier” is a unit of measurement of the thickness/weight of yarn. One denier is equal to the mass in grams per 9,000 meters of thread.
“GSM” means grams per square meter (g/m 2).
“Pile” means the raised surface of a fabric, usually including upright loops or strands of yarn.
Two-Piece Bath Mat System
With reference to
Stack Layers of the Top Cover
In an embodiment, the top cover 500 comprising the layers above has a thickness in the range of about 4 mm to about 8 mm, such as about 6 mm, which renders the top cover 500 amenable to various production processes, such as the application of heat and pressure to bond the layers. Available machinery and techniques for applying heat and/or pressure may be limited in the thickness of input materials. The same may be true for available machinery and techniques for applying surface treatment to the top cover 500, such as color application processes.
The layers of the top cover 500 are described in more detail below. It would be appreciated by a skilled artisan from the disclosure herein that embodiments or implementations may arrange the layers in a different order, use a different material for a particular layer, use additional or fewer layers, have liquid resistant layers that reduce rather than eliminate liquid passthrough, or make other changes, all without departing from the spirit or scope of this disclosure.
Layer 1: Tufted Loop Pile Surface
As shown in
The first layer 510 comprises yarns 512 that are tufted through the second layer 520 to create a tufted loop pile face 511. The yarns 512 are preferably selected to provide a satisfying foot feel, exhibit relatively little pilling, and be water absorbent while also being quick to dry. In a preferred embodiment, the weight of the yarns 512 may be in the range of about 4050 denier to about 4950 denier. More preferably, the weight of the yarns 512 may be in the range of about 4275 denier to about 4725 denier, such as about 4500 denier. The yarns 512 may have a density in the range of about 484.5 GSM to about 655.5 GSM. More preferably, the density of the yarns 512 may be in the range of about 513 GSM to about 627 GSM, such as about 570 GSM. The pile height of the tufted loop pile surface 511 may be in the range of about 2 mm to about 8 mm. More preferably, the pile height of the tufted loop pile surface 511 may be in the range of about 3 mm to about 6 mm, such as about 4 mm.
In preferred embodiments, the tufted loop pile face 511 may be made at least in part of polyester or other like material. The yarns may be dyed into a desired color before they are affixed to the second layer 520, such as a white or other light color that is amenable to subsequent treatment using industrial dyeing or other color application processes. The top-facing loop surface of the pile also further optimizes the efficacy of color application because the loops provide more surface area for receiving surface treatment as compared to yarns sticking straight up. Preferably, the tufted loop pile face 511 is engineered to be of relatively uniform pile height to further enhance its ability to receive surface treatments—the uniformity of the pile height helps ensure that any surface application would be taken in a uniform fashion. The ability of the surface layer 510 to accept surface treatments allows for the creation of a limitless range of designs and aesthetics for the bath mat.
Although disclosed with specific reference to materials and manufacturing processes, an artisan will recognize from the disclosure herein different embodiments with different or alternative materials and/or manufacturing processes that accomplish the look and feel of a comfortable top surface that is absorbent yet quick drying. For example, materials such as acrylic, modacrylic, polypropylene, rayon, and nylon may be used instead of or in junction with the above.
Layer 2: Woven Base
As shown in
In an embodiment, the second material layer 520 is woven using polyester yarns having a density in the range of about 157.5 GSM to about 192.5 GSM. More preferably, the density of the yarns may be in the range of about 166.25 GSM to about 183.75 GSM, such as about 175 GSM.
Although disclosed with specific reference to materials and manufacturing processes, an artisan will recognize from the disclosure herein different embodiments with different or alternative materials and/or manufacturing processes that accomplish the aim of a stabilizing base for the yarns of the tufted loop pile face. For example, materials such as acrylic, modacrylic, polypropylene, rayon, and nylon may be used instead of or in junction with the above.
Adhesive
The adhesive 530 comprises an adhesive optimized for bonding synthetic fabric materials. It operates to adhere the second material layer 520 (the woven base) of the top cover 500 to the lower layers, and most directly the third layer 540. The selected adhesive material should be flexible and should retain its adhesive properties to keep the material layers together through rolling and folding and multiple wash and dry cycles. The adhesive 530 may be a 60 GSM polyurethane (PUR) hot melt adhesive comprised of NEL-1016 material. This adhesive has been found to withstand heat exposure during the production process of the top cover 500 as well as through multiple wash and dry cycles.
Although disclosed with specific reference to polyurethane, an artisan will recognize from the disclosure herein different or alternative bonding materials and/or manufacturing processes that adhere the material layers. For example, materials such as thermoplastic polyurethane adhesive may be used instead of or in junction with the above.
Layer 3: Thermoplastic Polyurethane—Liquid Barrier
The third layer 540 shown in
Although disclosed with specific reference to polyurethane, an artisan will recognize from the disclosure herein different or alternative liquid resistant or liquid barrier layers. For example, it is possible to lend a degree of liquid resistance to fabric by the application of spill-resistant coatings, but this may be less preferable as a number of the coatings available on the market contain PFAS chemicals, some of which are deemed to be dangerous and are currently banned or may become banned in some countries and U.S. states.
Adhesive
With continued reference to
Layer 4: Knit Backing—Base
The fourth layer 560 may be the bottom layer of the stack of materials comprising the top cover 500. It may comprise a knit loop material of polyester yarn (e.g., of 50 denier and 120 GSM) such that its bottom surface 561 may removably attach to hook material disposed on the top surface of the bottom mat 600. Alternatively, the fourth layer 560 may comprise hook material while loop material is disposed on the bottom pad 600.
Alternatively, the fourth layer may itself comprise a bottom pad, or one or more additional layers may be placed or adhered below the fourth layer to provide a pad for the top cover 500, allowing it to be used as a bath mat without a separate bottom pad. In still other embodiments, the base layer is configured to contact the floor or ground.
Although disclosed with specific reference to materials and manufacturing processes, an artisan will recognize from the disclosure herein different embodiments with different or alternative materials and/or manufacturing processes for the base layer. For example, materials such as velvet, fleece, felt, and thermoplastic elastomer (TPE) may be used instead of or in junction with the above.
Stack Layers of the Bottom Pad
The layers of the bottom pad 600 are described in more detail below. It would be appreciated by a skilled artisan from the disclosure herein that embodiments or implementations may arrange the layers in a different order, use a different material for a particular layer, use additional or fewer layers, or make other changes, all without departing from the spirit or scope of this disclosure.
Layer 1: Needle-Punched Cling Surface
As shown in
As shown in
Although disclosed with specific reference to materials and manufacturing processes, an artisan will recognize from the disclosure herein different embodiments with different or alternative materials and/or manufacturing processes for the cling surface layer. For example, materials such as thin polyester hooks may be used instead of or in junction with the above.
Layer 2: Cushioning
With continued reference to
The polyester fibers 621 preferably have a thickness in the range of about 7 mm to about 15 mm. More preferably, the polyester fibers 621 have a thickness in the range of about 10 mm to about 12 mm, such as about 11 mm.
Although disclosed with specific reference to materials and manufacturing processes, an artisan will recognize from the disclosure herein different embodiments with different or alternative materials and/or manufacturing processes that accomplish the cushioning for the stack. For example, different cushioning structures, or materials such as 3D spacer fabric, V-Lap, or memory foam may be used instead of or in junction with the above.
Adhesive
The adhesive 630 comprises an adhesive optimized for bonding synthetic fabric materials. It operates to adhere the second material layer 620 (the cushioning layer) of the bottom pad 600 to the lower layers, and most directly the third layer 640.
The adhesive 630 may be the same adhesive used for the top cover. Alternatively, particularly where it is not necessarily needed for the bottom pad 600 to be machine-washable, a different adhesive may be used. For example, the adhesive may be approximately a 50 GSM (give or take 5 GSM) blend of prepolymer of MDI and polyol and diphenylmethane-diisocyanate, which allows the multi-layer bonding to withstand hand washing and air drying.
An artisan will recognize from the disclosure herein different or alternative bonding materials and/or manufacturing processes that adhere the material layers. For example, materials such as thermoplastic polyurethane adhesive may be used instead of or in junction with the above.
Layer 3: Base/Bonding Layer
With continued reference to
Although disclosed with specific reference to materials and manufacturing processes, an artisan will recognize from the disclosure herein different embodiments with different or alternative materials and/or manufacturing processes that accomplish providing a base for bonding non-slip material and other layers. For example, different materials such as knitted or woven fabrics may be used instead of or in junction with the above.
Layer 4: Non-Slip Base
With continued reference to
Although disclosed with specific reference to materials and manufacturing processes, an artisan will recognize from the disclosure herein different embodiments with different or alternative materials and/or manufacturing processes that accomplish a non-slip surface. For example, different materials such as thermoplastic elastomers (TPE), thermoplastic rubber (TPR), modified hot melt polymer, neoprene, styrene-butadiene rubber (SBR), polyvinyl chloride (PVC), or silicone may be used instead of or in junction with the above.
Conditional language used herein, such as, among others, “can,” “could,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without author input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular embodiment. The terms “comprising,” “including, “having,” and the like are synonymous and are used inclusively, in an open-ended fashion, and do not exclude additional elements, features, acts, operations, and so forth. Also, the term “or” is used in its inclusive sense (and not in its exclusive sense) so that when used, for example, to connect a list of elements, the term “or” means one, some, or all of the elements in the list. In addition, the articles “a,” “an,” and “the” as used in this application and the appended claims are to be construed to mean “one or more” or “at least one” unless specified otherwise.
As used herein, a phrase referring to “at least one of” a list of items refers to any combination of those items, including single members. As an example, “at least one of A, B, or C” is intended to cover: A, B, C, A and B, A and C, B and C, and A, B, and C. Conjunctive language such as the phrase “at least one of X, Y and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be at least one of X, Y or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require at least one of X, at least one of Y and at least one of Z to each be present.
Various modifications to the implementations described in this disclosure may be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other implementations without departing from the spirit or scope of this disclosure. Thus, the claims are not intended to be limited to the implementations shown herein, but are to be accorded the widest scope consistent with this disclosure and the principles and the novel features disclosed herein.
