Temporary floor protection fabric

Abstract

A high-strength temporary floor protection fabric (10, 30, 40) has a water-absorbent top layer (12) comprising a non-woven polymeric material comprising polypropylene, having a plurality of channels (20) in its top surface (24), an intermediate cushioning layer (16) of spun bonded non-woven polypropylene, an adhesive layer (14) of polypropylene bonding the top layer to the intermediate layer, and a waterproof bottom layer (18, 32) bonded to the intermediate cushioning layer. The bottom layer comprises polypropylene and polyethylene, and has an anti-slip texture on its bottom surface. The channels (20) in the top surface of the fabric trap dirt and liquid, and provide an anti-slip surface.

Description

[0001] TEMPORARY FLOOR PROTECTION FABRIC

[0002] Field of the Invention

[0003] The invention pertains to temporary floor protection products for protecting floors during construction, renovation, painting, moving and similar activities.

[0004] Background of the Invention

[0005] Floors can be damaged during projects such as construction, renovation, restoration, abatement, painting and moving. Such damage can be caused by tools, foot traffic, dollies, wheelbarrows, ladders, machinery, and by spills and impacts. The standard floor protectors that are used are cardboard temporary floor protectors. Such products have several disadvantages. They are not strong and have a low tear strength, with the result that they are not re-used. They have limited resistance to impacts. Their top surface is flat, so dirt remains on the surface. They are not waterproof, so spills soak through them onto the flooring. There is a need for effective products for temporarily protecting floors which ameliorate the disadvantages of such existing products.

[0006] Summary of the Invention

[0007] The invention provides a temporary floor protection fabric that is high-strength, able to absorb spills, and gives waterproof protection to the floor. It has an anti-slip surface to prevent slipping, making a safer working environment. Channels in the top surface trap dirt and liquid, keeping the surface clean. The fabric can withstand multiple uses.

[0008] The fabric may be furnished on a roll, for example a roll having about half the weight of a cardboard roll of the same size. It is therefore much easier for users to carry it due to its relatively light weight. The fabric does not curl back during installation, which substantially reduces the installation time. One aspect of the invention provides a temporary floor protection fabric comprising: (a) a top layer comprising a non-woven polymeric material comprising polypropylene, the top layer having a plurality of channels in its top surface, the top surface being hydrophilic and capable of absorbing water; (b) an intermediate cushioning layer of spun bonded non-woven material comprising polypropylene; (c) an adhesive layer bonding the top layer to the intermediate layer, the adhesive layer comprising polypropylene; and (d) a waterproof bottom layer bonded to the intermediate cushioning layer, the bottom layer comprising polypropylene and polyethylene, the bottom layer having an anti-slip texture on its bottom surface.

[0009] Another aspect of the invention provides temporary floor protection fabric comprising: (a) a top layer comprising a non-woven polymeric material comprising polypropylene, the top layer having a plurality of channels in its top surface, the top surface being hydrophilic and capable of absorbing water; (b) an intermediate cushioning layer of needle-punched fabric comprising polyester; (c) an adhesive layer bonding the top layer to the intermediate layer, the adhesive layer comprising polypropylene; and (d) a waterproof bottom layer bonded to the intermediate cushioning layer, the bottom layer comprising polyester with water-based glue applied to the bottom surface of the intermediate cushioning layer.

[0010] Further aspects of the invention and features of specific embodiments of the invention are described below.

[0011] Brief Description of the Drawings

[0012] Figure 1 is a cross-sectional view of the temporary floor protection fabric according to one embodiment of the invention.

[0013] Figure 2 is a top plan view of the top surface of the fabric of Figure 1 , showing the pattern of channels in the surface.

[0014] Figure 3 is a cross-sectional view of the temporary floor protection fabric according to a second embodiment of the invention. Figure 4 is a cross-sectional view of the temporary floor protection fabric according to a third embodiment of the invention.

[0015] Figure 5 is a cross-sectional view of the temporary floor protection fabric according to a fourth embodiment of the invention.

[0016] Detailed Description

[0017] Referring first to Figures 1 and 2, one embodiment of the temporary floor protection fabric 10 comprises a top layer 12, an adhesive bonding layer 14, an intermediate cushioning layer 16 and a bottom layer 18.

[0018] Figure 2 depicts the pattern of channels 20 separated by ridges 22 in the top surface 24 of the top layer 12. The ridges are raised fiber areas between the channels. The channels 20 may extend in one direction or in multiple directions, for example in one to five directions. In the embodiment shown in Figures 2, the channels 20 extend in three directions. There is a plurality of groups 26 of channels, each group 26 comprising three sets 28A, 28B and 28C of parallel channels 20. The channels of each of the three sets extend in different directions, at an angle to each other, for example at an angle of about 120°. In some embodiments, the angle may be between 10° and 180°.

[0019] In one embodiment, the channels 20 may be for example about 2 mm wide and 3.5 to 6.2 mm long. The ridges 22 may be about 6 mm wide. The width of a group 26 of channels may be about 145 mm.

[0020] The multi-directional channels 20 and ridges 22 provide an anti-slip surface to prevent slipping, thus enhancing user safety by providing traction in multiple directions. The channels 20 also trap dirt and liquid, while maintaining the anti-slip surface.

[0021] The top layer 12 may comprise mostly polypropylene, for example 85 to 95 wt.%. It may also contain a small proportion of calcium carbonate, for example 2 to 10 wt.%. Calcium carbonate acts as a modifier to the polypropylene, and enhances adhesion, chemical resistance, thermal stability and impact strength, and it helps minimize shrinkage and warping. The calcium carbonate may be recycled or waste calcium carbonate, whose use thereby reduces the environmental footprint of the fabric, promoting sustainability.

[0022] The top layer 12 may also contain a small proportion of polymer additives, for example 2 to 6 wt.%, or 2 to 4 wt.%. These additives may include antioxidants, antimicrobial agents, processing aids, UV stabilizers and antistatic agents.

[0023] A hydrophilic spray is applied to the top surface 24 of the top layer 12. The hydrophilic solution is sprayed onto the surface of the non-woven fabric using a spray system. The spray may contain hydrophilic polymers such as polyethylene glycol (PEG), polyvinyl alcohol (PVA), or surfactants like alkyl ethoxylates. After the spray application, the treated non-woven fabric is hot air dried. The hydrophilic spray application allows the fabric 10 to absorb water from its top surface.

[0024] The weight (mass per unit area) of the top layer 12 may be in the range of 70 to 160 grams per square meter (gsm), alternatively in the range of 30 to 300 gsm.

[0025] The intermediate cushioning layer 16 is bonded to the top layer 12 by an adhesive bonding layer 14. The bonding layer 14 may comprise primarily polypropylene, for example, about 95 wt.% polypropylene, and about 5 wt.% polymer additives. Examples of useful additives include ethylene-vinyl acetate (EVA), thermoplastic elastomers (TPE), polyethylene (PE) and styrene-butadiene rubber (SBR).

[0026] Examples of the proportions of polymer additives are 2 wt.% EVA, 2 wt.% TPE, and 1 wt.% PE. In some embodiments, the bonding layer 14 comprises 0.1 to 50 wt.% polypropylene and 0.1 to 50 wt.% polymer additives.

[0027] The adhesive bonding layer 14 enhances the structural integrity and stability of the multi-layered fabric 10. By providing secure adhesion between layers, it ensures the durability and longevity of the fabric 10. The weight of the adhesive bonding layer 14 may be in the range of 20 to 300 gsm, alternatively 20 to 60 gsm.

[0028] The intermediate cushioning layer 16 is a spun bonded non-woven fabric. It comprises primarily polypropylene, for example about 98 wt.%, and may include a small proportion of calcium carbonate, for example about 2 wt.%. In some embodiments the proportion of calcium carbonate is in the range of 0.1 to 30 wt.%, alternatively 0.1 to 15 wt.%. The weight of the intermediate cushioning layer 16 may be in the range of 10 to 300 gsm, alternatively in the range of 70 to 160 gsm.

[0029] The intermediate cushioning layer 16 provides additional structural support for the fabric 10 and enhances its dimensional stability. It helps to absorb shocks from dropped objects. It has a soft texture that provides a soft and comfortable feel underfoot for users. It is resilient, retaining its shape and its cushioning properties even after prolonged use.

[0030] The bottom layer 18 is bonded to the bottom surface of the intermediate cushioning layer 16. It is a waterproof, non-marking, coating layer with anti-slip properties. The material of the bottom layer 18 may comprise polypropylene and polyethylene, for example 75 to 85 wt.% polypropylene and 15 to 25 wt.% polyethylene. In some embodiments, the amount of polyethylene is in the range of 1 to 50 wt.%. The bottom layer 18 has an anti-slip texture on its bottom surface 29, which contacts the flooring, providing traction to prevent slipping of the fabric 10, particularly on smooth or slippery flooring surfaces. The weight of the bottom layer 18 may be in the range of 20 to 80 gsm, alternatively in the range of 20 to 300 gsm.

[0031] The waterproof barrier provided by the bottom layer 18 prevents liquids from seeping through the fabric 10 and damaging the floor, for example liquids spilled on the fabric.

[0032] Referring next to Figure 3, which shows a second embodiment 30 of the temporary floor protection fabric, the fabric 30 comprises a top layer 12, an adhesive bonding layer 14, an intermediate cushioning layer 16 and a bottom layer 32. The layers 12, 14 and 16 of the fabric 30 are identical to the correspondingly-numbered layers of the fabric 10 as described above. The difference is in the bottom layer 32.

[0033] The bottom layer 32 is bonded to the bottom surface of the intermediate cushioning layer 16. It is a waterproof, non-marking, coating layer with anti-slip properties. The material of the bottom layer 32 may comprise polypropylene and polyethylene, for example 70 to 80 wt.% polypropylene and 15 to 20 wt.% polyethylene. In some embodiments, the amount of polyethylene is in the range of 1 to 50 wt.%. The bottom layer 32 also comprises PVC, for example 4 to 10 wt.% PVC, to add texture and improve traction, reducing the risk of slips and falls.

[0034] The bottom layer 32 has an anti-slip texture on its bottom surface 34, which contacts the flooring, providing traction to prevent slipping of the fabric 30, particularly on smooth or slippery flooring surfaces. The weight of the bottom layer 32 may be in the range of 20 to 300 gsm, alternatively in the range of 20 to 100 gsm.

[0035] The waterproof barrier provided by the bottom layer 32 prevents liquids from seeping through the fabric 30 and damaging the floor, for example liquids spilled on the fabric.

[0036] Referring next to Figure 4, which shows a third embodiment 40 of the temporary floor protection fabric, the fabric 40 comprises a top layer 12, an adhesive bonding layer 14, an intermediate cushioning layer 16 and a bottom layer 42. The layers 12, 14 and 16 of the fabric 40 are identical to the correspondingly-numbered layers of the fabric 10 as described above. The difference is in the bottom layer 42.

[0037] The bottom layer 42 is bonded to the bottom surface of the intermediate cushioning layer 16. It is a waterproof, non-marking, coating layer with anti-slip properties. The material of the bottom layer 42 may comprise polypropylene and polyethylene, for example 70 to 80 wt.% polypropylene and 15 to 20 wt.% polyethylene. It also comprises silicon, for example 4 to 10 wt.% silicon, to add texture and improve traction, reducing the risk of slips and falls.

[0038] The bottom layer 42 has an anti-slip texture on its bottom surface 44, which contacts the flooring, providing traction to prevent slipping of the fabric 40, particularly on smooth or slippery flooring surfaces. The weight of the bottom layer 42 may be in the range of 20 to 100 gsm, alternatively in the range of 20 to 300 gsm.

[0039] The waterproof barrier provided by the bottom layer 42 prevents liquids from seeping through the fabric 40 and damaging the floor, for example liquids spilled on the fabric. Referring next to Figure 5, which shows a fourth embodiment 50 of the temporary floor protection fabric, the fabric 50 comprises a top layer 12, an adhesive bonding layer 14, an intermediate cushioning layer 52 and a bottom layer 54. The layers 12 and 14 of the fabric 50 are identical to the correspondingly-numbered layers of the fabric 10 as described above. The difference is in the intermediate cushioning layer 52 and the bottom layer 54.

[0040] The intermediate cushioning layer 52 of the fabric 50 is a needle-punched fabric comprising polyester, for example 100 wt.% polyester resin. The weight of the intermediate cushioning layer 52 may be in the range of 50 to 200 gsm, alternatively 100 to 200 gsm. This layer provides enhanced thickness and comfort, serving as a supportive padding for the fabric 50. As in the previous embodiments, the intermediate cushioning layer 52 provides additional structural support for the fabric 50 and enhances its dimensional stability. It helps to absorb shocks from dropped objects. It has a soft texture that provides a soft and comfortable feel underfoot for users. It is resilient, retaining its shape and its cushioning properties even after prolonged use.

[0041] The bottom layer 54 is a waterproof bottom layer bonded to the intermediate cushioning layer 52. It comprises polyester with water-based glue that is applied by spray to its bottom surface. The sprayed glue is not visible but can be felt by touch. Examples of suitable water-based glues include formulations similar to those used in painters tape, gaffer tape, masking tape, and tack, but modified for spray application. These adhesives can be diluted or adjusted to achieve the appropriate viscosity for spraying, ensuring a uniform application and strong bond upon drying.

[0042] The water-based glue of the bottom layer 54 may be mixed with one or more of ethylene-vinyl acetate (EVA), thermoplastic elastomers (TPE), styrene-butadiene rubber (SBR and polyethylene (PE).

[0043] The bottom layer 54 acts as an anti-slip bottom layer by removably adhering the fabric 50 to the floor upon installation. It thus prevents slipping and movement of the fabric, enhancing safety and stability. It adheres well to, and is suitable for use on, various floor surfaces, including tiles, concrete, laminate and hardwood floors without causing damage. It leaves no residue upon removal of the fabric. Temporary floor protection fabrics 10, 30, 40 and 50 structured as explained above have a tear strength in the range of 5 to 40 lbs, preferably at least 30 lbs, measured in accordance with ASTM test method No. D5034. They have an elongation of up to 40%, measured in accordance with ASTM test method No. D4533.

[0044] The embossed top layer 12 of the fabrics of the invention may be made by methods known in the art, using an embossing roller to press a sheet to create elevated portions and depressed portions on the sheet. Dimensions may vary depending on the embossing roller, the thickness of the starting sheet, and the amount of pressure asserted by the roller against the sheet. During embossing, the roller compresses fibers on the sheet. The compressed fibers are not melted or fused together if a non-heated roller is used, or if a heated roller is used but with the heat sufficiently low that melting of fibers will not occur. Both the bottom of the roller cavity and the raised channel lines on the roller compress the sheet, but to differing degrees. The resulting pressed sheet has depressed portions and elevated portions.

[0045] Throughout the foregoing description and the drawings, in which corresponding and like parts are identified by the same reference characters, specific details have been set forth in order to provide a more thorough understanding to persons skilled in the art. However, well known elements may not have been shown or described in detail to avoid unnecessarily obscuring the disclosure. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense.

[0046] As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the scope thereof. Accordingly, the scope of the invention is to be construed in accordance with the following claims.

Claims

Claims1 . A temporary floor protection fabric (10, 30, 40) comprising:(a) a top layer (12) comprising a non-woven polymeric material comprising polypropylene, the top layer having a plurality of channels (20) in its top surface (24), the top surface being hydrophilic and capable of absorbing water;(b) an intermediate cushioning layer (16) of spun bonded non-woven material comprising polypropylene;(c) an adhesive layer (14) bonding the top layer (12) to the intermediate cushioning layer (16), the adhesive layer comprising polypropylene; and(d) a waterproof bottom layer (18, 32) bonded to the intermediate cushioning layer (16), the bottom layer comprising polypropylene and polyethylene, the bottom layer having an anti-slip texture on its bottom surface (29, 34).

2. The temporary floor protection fabric according to claim 1 , wherein the top layer (12) comprises from 85 to 95 wt.% polypropylene.

3. The temporary floor protection fabric according to claim 1 or 2, wherein the top layer (12) further comprises calcium carbonate.

4. The temporary floor protection fabric according to claim 3, wherein the top layer (12) comprises from 2 to 10 wt.% calcium carbonate.

5. The temporary floor protection fabric according to any one of claims 1-4, wherein the top layer (12) further comprises from 2 to 6 wt.% polymer additives selected from the group consisting of antioxidants, antimicrobial agents, processing aids, UV stabilizers and antistatic agents.

6. The temporary floor protection fabric according to any one of claims 1-5, wherein the top layer (12) has a thickness in the range of 30 to 300 grams per square meter, alternatively 70 to 160 grams per square meter (gsm).

7. The temporary floor protection fabric according to any one of claims 1-6, wherein the intermediate cushioning layer (16) comprises from 85 to 99 wt.% polypropylene.

8. The temporary floor protection fabric according to claim 7, wherein the intermediate cushioning layer (16) comprises about 98 wt.% polypropylene.

9. The temporary floor protection fabric according to any one of claims 1-7, wherein the intermediate cushioning layer (16) comprises from 0.1 to 30 wt.% calcium carbonate, alternatively from 1 to 15 wt.% calcium carbonate.

10. The temporary floor protection fabric according to claim 8, wherein the intermediate cushioning layer (16) comprises about 2 wt.% calcium carbonate.

11. The temporary floor protection fabric according to any one of claims 1-10, wherein the intermediate cushioning layer (16) has a weight in the range of 10 to 300 gsm, alternatively 70 to 160 gsm.

12. The temporary floor protection fabric according to any one of claims 1-11 , wherein the adhesive layer (14) comprises from 0.1 to 50 wt.% polypropylene.

13. The temporary floor protection fabric according to any one of claims 1-11 , wherein the adhesive layer (14) comprises about 95 wt.% polypropylene.

14. The temporary floor protection fabric according to any one of claims 1-13, wherein the adhesive layer (14) comprises from 0.1 to 50 wt.% of polymer additives selected from the group consisting of ethylene-vinyl acetate (EVA), thermoplastic elastomers (TPE), polyethylene (PE) and styrene-butadiene rubber (SBR).

15. The temporary floor protection fabric according to any one of claims 1-14, wherein the adhesive layer (14) has a thickness in the range of 20 to 300 gsm, alternatively 20 to 60 gsm.

16. The temporary floor protection fabric according to any one of claims 1-15, wherein the bottom layer (18) comprises from 75 to 85 wt.% polypropylene and 15 to 25 wt.% polyethylene.

17. The temporary floor protection fabric according to any one of claims 1-15, wherein the bottom layer (18) comprises from 1 to 50 wt.% polypropylene and 1 to 50 wt.% polyethylene.

18. The temporary floor protection fabric (30) according to claim 1 , wherein the bottom layer (32) further comprises PVC.

19. The temporary floor protection fabric (30) according to claim 18, wherein the bottom layer (32) comprises from 4 to 10 wt.% PVC.

20. The temporary floor protection fabric (40) according to claim 1 , wherein the bottom layer (42) further comprises silicon.21 . The temporary floor protection fabric (40) according to claim 20, wherein the bottom layer (42) comprises from 4 to 10 wt.% silicon.

22. The temporary floor protection fabric according to any one of claims 1-21 , wherein the bottom layer (18, 32, 42) has a weight in the range of 20 to 300 gsm, alternatively 20 to 100 gsm.

23. A temporary floor protection fabric (50) comprising:(a) a top layer (12) comprising a non-woven polymeric material comprising polypropylene, the top layer having a plurality of channels (20) in its top surface (24), the top surface being hydrophilic and capable of absorbing water;(b) an intermediate cushioning layer (52) of needle-punched fabric comprising polyester;(c) an adhesive layer (14) bonding the top layer (12) to the intermediate cushioning layer (52), the adhesive layer comprising polypropylene; and(d) a waterproof bottom layer (54) bonded to the intermediate cushioning layer (52), the bottom layer comprising polyester with water-based glue applied to its bottom surface.

24. The temporary floor protection fabric (50) according to claim 23, wherein the intermediate cushioning layer (52) has a weight in the range of 50 to 200 gsm, alternatively 100 to 200 gsm.

25. The temporary floor protection fabric according to claim 23, wherein the water-based glue comprises polyvinyl acetate (PVA) or an acrylic emulsion.

26. The temporary floor protection fabric (50) according to claim 23, wherein the water-based glue is mixed with one or more of ethylene-vinyl acetate (EVA), thermoplastic elastomers (TPE), styrene-butadiene rubber (SBR and polyethylene (PE).

27. The temporary floor protection fabric (10, 30, 40, 50) according to any one of claims 1-26, having a tear strength in the range of 5 to 40 lbs as measured by ASTM test method D5034.

28. The temporary floor protection fabric (10, 30, 40, 50) according to any one of claims 1-27, having a tear strength of at least 30 lbs as measured by ASTM test method D5034.

29. The temporary floor protection fabric (10, 30, 40, 50) according to any one of claims 1-28, having an elongation of up to 40% as measured by ASTM test method D4533.

30. The temporary floor protection fabric (10, 30, 40, 50) according to any one of claims 1-29, wherein the channels (20) extend in multiple directions at an angle to each other.

31. The temporary floor protection fabric (10, 30, 40, 50) according to any one of claims 1-30, wherein the channels (20) extend in three or more directions.

32. The temporary floor protection fabric (10, 30, 40, 50) according to any one of claims 1-31 , wherein the top layer (12) has a plurality of groups (26) of the channels (20), each group comprising three sets of parallel channels (28A, 28B, 28C), the channels of a first set extending in a first direction, the channels of a second set extending in a second direction, and the channels of a third set extending in a third direction, where the first, second and third directions are at an angle to each other.

33. The temporary floor protection fabric (10, 30, 40, 50) according to claim 32, wherein the angle is about 120°.

34. The temporary floor protection fabric (10, 30, 40, 50) according to claim 30, wherein the angle is between 10° and 180°.

35. The temporary floor protection fabric (10, 30, 40, 50) according to any one of claims 1-34, wherein the temporary floor protection fabric is provided in a roll.

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