Foldable water-absorbent and anti-slip floor mat based on foamed recycled sponge

Abstract

A foldable water-absorbent anti-slip floor mat based on foamed recycled sponge includes a bottom layer, a foamed sponge middle layer, and a surface layer. The bottom layer, the foamed sponge middle layer, and the surface layer are laminated together. The surface layer includes a water-absorbent polyester fabric formed by knitting and weaving. The middle layer includes an elastomer made of foamed recycled sponge. The bottom layer includes an anti-slip layer, and ridge-shaped folding marks are formed on the surface of the bottom layer. The foldable configuration of the anti-slip floor mat enables the mat to be compactly folded for storage and display.

Description

REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to Chinese Patent Application No. 2024119195151, filed Dec. 25, 2024.FIELD

[0002] The present disclosure relates to a floor mat, in particular, to a foldable water-absorbent anti-slip floor mat based on foamed recycled sponge.BACKGROUND

[0003] Conventional anti-slip floor mats, particularly water-absorbent anti-slip floor mats intended for bathroom use, are often manufactured in relatively large sizes. As the size of such floor mats increases, the weight of the mats generally increases, which can lead to higher material consumption and manufacturing costs. In addition, large-sized floor mats typically require increased storage and display space during transportation and retail presentation, which may reduce the efficiency of space utilization for sellers.SUMMARY

[0004] The present disclosure provides a foldable water-absorbent anti-slip floor mat based on foamed recycled sponge. The foldable configuration of the anti-slip floor mat enables the mat to be compactly folded for storage and display.

[0005] The present disclosure provides a foldable water-absorbent anti-slip floor mat based on foamed recycled sponge, including a bottom layer, a foamed sponge middle layer, and a surface layer. The bottom layer, the foamed sponge middle layer, and the surface layer are laminated together. The surface layer includes a water-absorbent polyester fabric formed by knitting and weaving. The middle layer includes an elastomer made of foamed recycled sponge. The bottom layer includes an anti-slip layer, and ridge-shaped folding marks are formed on the surface of the bottom layer.

[0006] In some embodiments, peaks of the ridge-shaped folding marks are flush with the surface of the bottom layer, and a height difference from valleys to peaks is from one-third to two-thirds of a total thickness of the anti-slip floor mat.

[0007] In some embodiments, the foamed sponge middle layer is made of recycled sponge and recycled sponge with a hard skin.

[0008] In some embodiments, in the foamed sponge middle layer, a ratio of the recycled sponge to the recycled sponge with a hard skin is 10:3.

[0009] In some embodiments, the bottom layer includes one selected from the group consisting of a rubber foam layer, a PVC foam layer, a fabric anti-slip layer coated with a hot melt adhesive, and an SBR foam layer.

[0010] The present disclosure further provides a method for preparing the anti-slip floor mat described above, including:

[0011] 1) providing upper and lower molds configured to open and close on a hydraulic press, and a central portion of the upper mold is ridge-shaped;

[0012] 2) laying the surface layer in the lower mold and spraying polyurethane adhesive to form an adhesive film;

[0013] 3) mixing a material of the middle layer with polyurethane adhesive and a foaming agent, stirring the mixture uniformly, and evenly laying the mixture on the surface layer;

[0014] 4) coating an inner side of the anti-slip layer with polyurethane adhesive, drying the polyurethane adhesive to form an adhesive film, and covering the middle layer with the anti-slip layer; and

[0015] 5) closing the molds, heating and pressing the molds for a predetermined period of time, and demolding to obtain the anti-slip floor mat.

[0016] In some embodiments, a ratio of the material of the middle layer, the polyurethane adhesive, and the foaming agent is 10:(1-3):2.

[0017] In some embodiments, in step 5), after the molds are closed, a pressure of 1.2-1.5 atmospheres is applied to the molds, the molds are heated to a temperature of 60-180° C., and the pressure and temperature are maintained for 2-8 minutes.

[0018] The floor mat of the present disclosure utilizes recycled rubber to form a foamed middle layer. Ridge-shaped folding marks are formed on the anti-slip bottom surface, such that a large-area floor mat can be folded along the folding marks. This configuration allows the floor mat to be compactly folded during transportation and display, thereby facilitating storage, handling, and retail presentation.BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The present disclosure is further described below in conjunction with the accompanying drawings:

[0020] FIG. 1 is a schematic diagram of a foldable water-absorbent anti-slip floor mat based on a foamed recycled sponge of the present disclosure.DETAILED DESCRIPTION

[0021] As shown in FIG. 1, a foldable water-absorbent anti-slip floor mat based on foamed recycled sponge includes a bottom layer 1, a foamed sponge middle layer 2 and a surface layer 3. The bottom layer, the foamed sponge middle layer, and the surface layer are laminated together. The surface layer includes a water-absorbent polyester fabric formed by knitting and weaving. The middle layer includes an elastomer made of foamed recycled sponge. The bottom layer includes an anti-slip layer, and ridge-shaped folding marks 4 are formed on the surface of the bottom layer.

[0022] Peaks of the ridge-shaped folding marks are flush with the surface of the bottom layer, and a height difference from valleys to peaks is from one-third to two-thirds of a total thickness of the anti-slip floor mat.

[0023] The foamed sponge middle layer is made of recycled sponge and recycled sponge with a hard skin.

[0024] In the foamed sponge middle layer, a ratio of the recycled sponge to the recycled sponge with a hard skin is 10:3.

[0025] The bottom layer includes one selected from the group consisting of a rubber foam layer, a PVC foam layer, a fabric anti-slip layer coated with a hot melt adhesive, and an SBR foam layer.

[0026] The present disclosure further provides a method for preparing the anti-slip floor mat described above, including:

[0027] 1) providing upper and lower molds configured to open and close on a hydraulic press, and a central portion of the upper mold is ridge-shaped;

[0028] 2) laying the surface layer in the lower mold and spraying polyurethane adhesive to form an adhesive film;

[0029] 3) mixing a material of the middle layer with polyurethane adhesive and a foaming agent, stirring the mixture uniformly, and evenly laying the mixture on the surface layer;

[0030] 4) coating an inner side of the anti-slip layer with polyurethane adhesive, drying the polyurethane adhesive to form an adhesive film, and covering the middle layer with the anti-slip layer; and

[0031] 5) closing the molds, heating and pressing the molds for a predetermined period of time, and demolding to obtain the anti-slip floor mat.

[0032] A ratio of the material of the middle layer, the polyurethane adhesive, and the foaming agent is 10:(1-3):2.

[0033] In step 5), after the molds are closed, a pressure of 1.2-1.5 atmospheres is applied to the molds, the molds are heated to a temperature of 60-180° C., and the pressure and temperature are maintained for 2-8 minutes.

[0034] During transportation and retail display, the floor mat may be folded in half along a central folding mark. When the floor mat has a relatively large width, additional folding marks may be provided at one-third and two-thirds positions along the width direction, such that opposite side portions of the floor mat can be folded inward along the folding marks. After folding, the floor mat may be covered with a packaging sleeve. In this manner, the folded configuration reduces the occupied space during transportation and storage.

Examples

Embodiment Construction

[0021]As shown in FIG. 1, a foldable water-absorbent anti-slip floor mat based on foamed recycled sponge includes a bottom layer 1, a foamed sponge middle layer 2 and a surface layer 3. The bottom layer, the foamed sponge middle layer, and the surface layer are laminated together. The surface layer includes a water-absorbent polyester fabric formed by knitting and weaving. The middle layer includes an elastomer made of foamed recycled sponge. The bottom layer includes an anti-slip layer, and ridge-shaped folding marks 4 are formed on the surface of the bottom layer.

[0022]Peaks of the ridge-shaped folding marks are flush with the surface of the bottom layer, and a height difference from valleys to peaks is from one-third to two-thirds of a total thickness of the anti-slip floor mat.

[0023]The foamed sponge middle layer is made of recycled sponge and recycled sponge with a hard skin.

[0024]In the foamed sponge middle layer, a ratio of the recycled sponge to the recycled sponge with a ha...

REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to Chinese Patent Application No. 2024119195151, filed Dec. 25, 2024.FIELD

[0002] The present disclosure relates to a floor mat, in particular, to a foldable water-absorbent anti-slip floor mat based on foamed recycled sponge.BACKGROUND

[0003] Conventional anti-slip floor mats, particularly water-absorbent anti-slip floor mats intended for bathroom use, are often manufactured in relatively large sizes. As the size of such floor mats increases, the weight of the mats generally increases, which can lead to higher material consumption and manufacturing costs. In addition, large-sized floor mats typically require increased storage and display space during transportation and retail presentation, which may reduce the efficiency of space utilization for sellers.SUMMARY

[0004] The present disclosure provides a foldable water-absorbent anti-slip floor mat based on foamed recycled sponge. The foldable configuration of the anti-slip floor mat enables the mat to be compactly folded for storage and display.

[0005] The present disclosure provides a foldable water-absorbent anti-slip floor mat based on foamed recycled sponge, including a bottom layer, a foamed sponge middle layer, and a surface layer. The bottom layer, the foamed sponge middle layer, and the surface layer are laminated together. The surface layer includes a water-absorbent polyester fabric formed by knitting and weaving. The middle layer includes an elastomer made of foamed recycled sponge. The bottom layer includes an anti-slip layer, and ridge-shaped folding marks are formed on the surface of the bottom layer.

[0006] In some embodiments, peaks of the ridge-shaped folding marks are flush with the surface of the bottom layer, and a height difference from valleys to peaks is from one-third to two-thirds of a total thickness of the anti-slip floor mat.

[0007] In some embodiments, the foamed sponge middle layer is made of recycled sponge and recycled sponge with a hard skin.

[0008] In some embodiments, in the foamed sponge middle layer, a ratio of the recycled sponge to the recycled sponge with a hard skin is 10:3.

[0009] In some embodiments, the bottom layer includes one selected from the group consisting of a rubber foam layer, a PVC foam layer, a fabric anti-slip layer coated with a hot melt adhesive, and an SBR foam layer.

[0010] The present disclosure further provides a method for preparing the anti-slip floor mat described above, including:

[0011] 1) providing upper and lower molds configured to open and close on a hydraulic press, and a central portion of the upper mold is ridge-shaped;

[0012] 2) laying the surface layer in the lower mold and spraying polyurethane adhesive to form an adhesive film;

[0013] 3) mixing a material of the middle layer with polyurethane adhesive and a foaming agent, stirring the mixture uniformly, and evenly laying the mixture on the surface layer;

[0014] 4) coating an inner side of the anti-slip layer with polyurethane adhesive, drying the polyurethane adhesive to form an adhesive film, and covering the middle layer with the anti-slip layer; and

[0015] 5) closing the molds, heating and pressing the molds for a predetermined period of time, and demolding to obtain the anti-slip floor mat.

[0016] In some embodiments, a ratio of the material of the middle layer, the polyurethane adhesive, and the foaming agent is 10:(1-3):2.

[0017] In some embodiments, in step 5), after the molds are closed, a pressure of 1.2-1.5 atmospheres is applied to the molds, the molds are heated to a temperature of 60-180° C., and the pressure and temperature are maintained for 2-8 minutes.

[0018] The floor mat of the present disclosure utilizes recycled rubber to form a foamed middle layer. Ridge-shaped folding marks are formed on the anti-slip bottom surface, such that a large-area floor mat can be folded along the folding marks. This configuration allows the floor mat to be compactly folded during transportation and display, thereby facilitating storage, handling, and retail presentation.BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The present disclosure is further described below in conjunction with the accompanying drawings:

[0020] FIG. 1 is a schematic diagram of a foldable water-absorbent anti-slip floor mat based on a foamed recycled sponge of the present disclosure.DETAILED DESCRIPTION

[0021] As shown in FIG. 1, a foldable water-absorbent anti-slip floor mat based on foamed recycled sponge includes a bottom layer 1, a foamed sponge middle layer 2 and a surface layer 3. The bottom layer, the foamed sponge middle layer, and the surface layer are laminated together. The surface layer includes a water-absorbent polyester fabric formed by knitting and weaving. The middle layer includes an elastomer made of foamed recycled sponge. The bottom layer includes an anti-slip layer, and ridge-shaped folding marks 4 are formed on the surface of the bottom layer.

[0022] Peaks of the ridge-shaped folding marks are flush with the surface of the bottom layer, and a height difference from valleys to peaks is from one-third to two-thirds of a total thickness of the anti-slip floor mat.

[0023] The foamed sponge middle layer is made of recycled sponge and recycled sponge with a hard skin.

[0024] In the foamed sponge middle layer, a ratio of the recycled sponge to the recycled sponge with a hard skin is 10:3.

[0025] The bottom layer includes one selected from the group consisting of a rubber foam layer, a PVC foam layer, a fabric anti-slip layer coated with a hot melt adhesive, and an SBR foam layer.

[0026] The present disclosure further provides a method for preparing the anti-slip floor mat described above, including:

[0027] 1) providing upper and lower molds configured to open and close on a hydraulic press, and a central portion of the upper mold is ridge-shaped;

[0028] 2) laying the surface layer in the lower mold and spraying polyurethane adhesive to form an adhesive film;

[0029] 3) mixing a material of the middle layer with polyurethane adhesive and a foaming agent, stirring the mixture uniformly, and evenly laying the mixture on the surface layer;

[0030] 4) coating an inner side of the anti-slip layer with polyurethane adhesive, drying the polyurethane adhesive to form an adhesive film, and covering the middle layer with the anti-slip layer; and

[0031] 5) closing the molds, heating and pressing the molds for a predetermined period of time, and demolding to obtain the anti-slip floor mat.

[0032] A ratio of the material of the middle layer, the polyurethane adhesive, and the foaming agent is 10:(1-3):2.

[0033] In step 5), after the molds are closed, a pressure of 1.2-1.5 atmospheres is applied to the molds, the molds are heated to a temperature of 60-180° C., and the pressure and temperature are maintained for 2-8 minutes.

[0034] During transportation and retail display, the floor mat may be folded in half along a central folding mark. When the floor mat has a relatively large width, additional folding marks may be provided at one-third and two-thirds positions along the width direction, such that opposite side portions of the floor mat can be folded inward along the folding marks. After folding, the floor mat may be covered with a packaging sleeve. In this manner, the folded configuration reduces the occupied space during transportation and storage.

Examples

Embodiment Construction

[0021]As shown in FIG. 1, a foldable water-absorbent anti-slip floor mat based on foamed recycled sponge includes a bottom layer 1, a foamed sponge middle layer 2 and a surface layer 3. The bottom layer, the foamed sponge middle layer, and the surface layer are laminated together. The surface layer includes a water-absorbent polyester fabric formed by knitting and weaving. The middle layer includes an elastomer made of foamed recycled sponge. The bottom layer includes an anti-slip layer, and ridge-shaped folding marks 4 are formed on the surface of the bottom layer.

[0022]Peaks of the ridge-shaped folding marks are flush with the surface of the bottom layer, and a height difference from valleys to peaks is from one-third to two-thirds of a total thickness of the anti-slip floor mat.

[0023]The foamed sponge middle layer is made of recycled sponge and recycled sponge with a hard skin.

[0024]In the foamed sponge middle layer, a ratio of the recycled sponge to the recycled sponge with a ha...

Claims

1. A foldable water-absorbent anti-slip floor mat based on foamed recycled sponge, comprising a bottom layer, a foamed sponge middle layer, and a surface layer, whereinthe bottom layer, the foamed sponge middle layer, and the surface layer are laminated together;the surface layer comprises a water-absorbent polyester fabric formed by knitting and weaving;the middle layer comprises an elastomer made of foamed recycled sponge; andthe bottom layer comprises an anti-slip layer, and ridge-shaped folding marks are formed on a surface of the bottom layer.

2. The anti-slip floor mat of claim 1, wherein peaks of the ridge-shaped folding marks are flush with the surface of the bottom layer, and a height difference from valleys to peaks is from one-third to two-thirds of a total thickness of the anti-slip floor mat.

3. The anti-slip floor mat of claim 1, wherein the foamed sponge middle layer is made of recycled sponge and recycled sponge with a hard skin.

4. The anti-slip floor mat of claim 3, wherein in the foamed sponge middle layer, a ratio of the recycled sponge to the recycled sponge with a hard skin is 10:3.

5. The anti-slip floor mat of claim 1, wherein the bottom layer comprises one selected from the group consisting of a rubber foam layer, a PVC foam layer, a fabric anti-slip layer coated with a hot melt adhesive, and an SBR foam layer.

6. A method for preparing the anti-slip floor mat of claim 1, comprising:1) providing upper and lower molds configured to open and close on a hydraulic press, wherein a central portion of the upper mold is ridge-shaped;2) laying the surface layer in the lower mold and spraying polyurethane adhesive to form an adhesive film;3) mixing a material of the middle layer with polyurethane adhesive and a foaming agent, stirring the mixture uniformly, and evenly laying the mixture on the surface layer;4) coating an inner side of the anti-slip layer with polyurethane adhesive, drying the polyurethane adhesive to form an adhesive film, and covering the middle layer with the anti-slip layer; and5) closing the molds, heating and pressing the molds for a predetermined period of time, and demolding to obtain the anti-slip floor mat.

7. The method of claim 6, wherein a ratio of the material of the middle layer, the polyurethane adhesive, and the foaming agent is 10:(1-3):2.

8. The method of claim 6, wherein in step 5), after the molds are closed, a pressure of 1.2-1.5 atmospheres is applied to the molds, the molds are heated to a temperature of 60-180° C., and the pressure and temperature are maintained for 2-8 minutes.

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