Slip resistant mat and method and system for making same

Abstract

A system and method for making a slip resistant mat can include assembling parts with predetermined geometries to form a mold that can be used for making slip resistant mats that have channels to account for moisture between the mat and the floor. The unique geometries of the parts which form the mold can be manufactured efficiently and with reduced costs. The mold of this invention can be used to make slip resistant mats with channels that can both dissipate water and offer a high degree of mat to floor surface contact.

Description

[0001]This claims priority to U.S. Provisional Patent Application Ser. No. 61 / 781,148, filed Mar. 14, 2013 and is a continuation of PCT Application Serial No. PCT / US13 / 54488, filed Aug. 12, 2013, each of which is hereby incorporated by reference in its entirety.BACKGROUND OF THE INVENTION[0002]This invention relates generally to slip resistant, anti-skid or anti-creep mats. Specifically, this invention relates to such mats and a method and system for making slip resistant mats.[0003]In the past, floor mats, consisting of rubber backed carpet tuft, were made with either a smooth back, primarily for solid or non carpeted floors, or with a variety of “grippers” or “cleats” arranged to reduce the movement of the mat on carpeted floors. However, both of these approaches resulted in floor mats that were not skid resistant on smooth floors, especially those floors with residual moisture under the mat, perhaps from the moping of the floor and then the mat being replaced, or the mat being sl...

AI Technical Summary

Benefits of technology

This invention describes a mat design that resists slipping better than existing mats, even in the presence of moisture. It also provides additional cushioning for pedestrian and vehicular traffic. The mat does not require any permanent fastening means and is easy to move to different locations. The channels in the mat provide anti-fatigue effects and reduce wear and tear. The invention can be used on a wide variety of surfaces. The system and method used to make the mat involves assembling parts with predetermined geometries to form a mold screen, which can be manufactured efficiently and with reduced cost. The raw material used to form the mat may include rubber, which can have a predefined geometry including channels that match the ones in the platen. A casting system using a model platen and a negative of the channels is also described.

Problems solved by technology

However, both of these approaches resulted in floor mats that were not skid resistant on smooth floors, especially those floors with residual moisture under the mat, perhaps from the moping of the floor and then the mat being replaced, or the mat being slightly damp when delivered and rolled out.

In such cases, the water on the back of the mat becomes a slip hazard.

For the smooth back mats, movement of the mat results from similar forces and the lack of any device or feature intended to secure the mat in place.

While this approach is well-developed, it results in floor mats that are difficult or impossible to move from place to place and the structures required to attach the mat add cost to the mat and difficulty to the installation.

If the frame is fastened or embedded, the other problems mentioned above still remain.

While this approach provides acceptable slip-resistance for light shower and bath mat applications, traditional suctions cups are not sufficient to provide sufficient anti-skidding forces to prevent slipping and movement in high traffic and high load areas.

Traditional suction cups also result in a wavy mat surface which is more difficult for individuals and loads to traverse.

As mentioned, existing approaches to reducing movement of mats include significant limitations.

Further, the known approaches require additional space, components, installation effort and expense.

In addition to the problem of slip resistant mats moving when traversed by heavy loads or wheeled carts, another drawback of known slip resistant mats relates to the manufacturing process of these mats.

When the grippers are wet, the potential for mat slippage and possible resulting injuries increase.

The more metal that is removed with punching, the less resilient it is to being deformed and once bent, it is of no use in the manufacturing process.

This has limited the open area of the screens and meant that there is a physical limit on the pattern on the back of the mat.

Conventional manufacturing techniques have not addressed these problems often associated with conventional slip resistant mats and the associated systems and methods for mat production.

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