Photocatalytic play mat and method of production

Abstract

The invention relates to a photocatalytic play mat and its production method, which enables children to play in a safe and hygienic environment, featuring antibacterial and self-cleaning properties. This play mat is coated with photocatalytic materials, which interact with sunlight or artificial light to both clean the surface and improve the ambient air quality.

Description

[0001] DESCRIPTION

[0002] PHOTOCATALYTIC PLAY MAT AND METHOD OF PRODUCTION

[0003] TECHNICAL FIELD

[0004] The invention relates to a photocatalytic play mat and production method that enables children to play in a safe and hygienic environment, featuring antibacterial and self-cleaning properties. This play mat is coated with photocatalytic materials, interacting with sunlight or artificial light to both clean the surface and improve the ambient air quality.

[0005] PRIOR ART

[0006] Play mats are manufactured from various materials to enable children to play safely and comfortably. Their technologies rely on flexible, durable and easy-to-clean materials. Modem play mats generally feature the following technologies:

[0007] - Impact-Absorbing Structure: Play mats are equipped with impact-absorbing properties to prevent injuries in the event of children falling or bumping into them. Foam-based materials are commonly used for this purpose.

[0008] - Non-Slip Surface: To prevent slipping, many play mats have non-slip bases on their undersides. This prevents the mat from moving and allows children to play safely.

[0009] - Hypoallergenic and Non-Toxic Materials: To protect children's health, modem play mats are generally free from harmful chemicals such as BPA, phthalates, and formamide. Products that are harmless to health are developed using non-toxic inks and materials.

[0010] - Antimicrobial Coating: Some play mats are produced with antimicrobial coatings on their surfaces that prevent the growth of germs and bacteria. This may be ideal for use in environments where hygiene is paramount.

[0011] - Water Resistance and Easy Cleanability: Many play mats are waterproof and can be easily cleaned by wiping. These features simplify cleaning and maintenance tasks during daily use.

[0012] Most play mats feature colourful patterns, letters, numbers or educational graphics that appeal to children. Furthermore, the construction materials used in play mats are selected with children's safety, comfort and hygiene in mind. Here are the most commonly used construction materials: a) EVA (Ethylene Vinyl Acetate) Foam: EVA foam is a flexible, soft, and lightweight material. It has high shock-absorbing properties and is generally non-toxic. It is one of the most commonly used materials in children's play mats. Its flexible and durable structure protects children from the risk of falling and bumping. It is preferred because it is non-toxic, flexible, waterproof, and easy to clean. It can wear out over time and lose its softness with intensive use. Additionally, some EVA foams may contain toxic substances such as formamide. b) TPE (Thermoplastic Elastomer): TPE is a recyclable, flexible, and durable material. It has a rubber-like structure and is a non-toxic and environmentally friendly option. It is used as a flexible and environmentally friendly alternative in children's play mats. Being recyclable, flexible, non-toxic and hypoallergenic makes TPE a preferred material for environmentally conscious families. It may be more expensive than other materials. c) PVC (Polyvinyl Chloride): PVC is a durable, waterproof, and flexible type of plastic. Most PVC mats may have antibacterial properties, but some products may contain harmful phthalates and volatile organic compounds (VOCs). It is commonly used in play mats that require waterproofing and durability. It can be durable, waterproof, and antibacterial. There is a risk of toxicity as it may contain phthalates. It is also not an environmentally friendly material and may be difficult to recycle. d) Polyurethane (PU) Foam: Polyurethane is a flexible and shock-absorbing material. It is also durable and suitable for long-term use. Thanks to its soft and flexible structure, it provides a comfortable play area in children's play mats. It is flexible, durable and long-lasting. Its water-resistant structure makes it easy to clean. It may not be environmentally friendly as chemicals are used in the production process. Harmful chemicals may be released when the material deteriorates. e) Natural Rubber and Recyclable Materials: Natural rubber and recyclable materials are environmentally friendly options. They are preferred due to their flexible, durable and non-toxic structure. They are used in mats preferred by families who prioritise eco-friendliness and sustainability. They are produced from eco-friendly, non-toxic and natural materials. They have a natural texture and are recyclable. Natural rubber may cause allergic reactions in some people. They may also be more expensive than other materials.

[0013] The production process of mats using the known technique is outlined below:

[0014] - Foam Preparation: EVA or TPE foam material is produced in large sheets. These foams are prepared in the desired thickness and density. The softness and durability levels of play mats depend on the density of the foam used.

[0015] - Cutting and Shaping: Large sheets are cut to the desired dimensions. Depending on the shape and design of the mat, these sheets can be cut into various patterns and shapes.

[0016] - Coating and Printing: Colourful patterns or graphics that appeal to children are printed on the play mats. The printing process is usually done with non-toxic inks. In addition, the outer surface of the mat is usually coated with a waterproof and easy-to-clean layer.

[0017] - Final Processing and Testing: After the production process is complete, the play mats undergo safety and quality testing. It is ensured that they do not contain toxic substances and are safe for children.

[0018] However, some play mats manufactured using known techniques may contain harmful chemicals (PVC, phthalates or formamide). Overtime, they may wear out, tear, peel, crack and become less durable. The patterns or graphics on some play mats are made from low-quality prints, and these patterns or graphics may also peel or wear over time. This can affect the aesthetic appearance of the mat and reduce its appeal to children.

[0019] Play mats may lose their softness and shock-absorbing properties with frequent use. Some play mats may emit a strong chemical odour due to the chemicals used in their production. These odours are particularly noticeable when the mats are new and can be unpleasant. This situation carries the risk of inhaling the evaporating chemicals. Mats with a porous structure can trap dirt, dust and germs, which can make cleaning difficult. Mats with a non-slip underside may not stay in place on the floor and could slide, posing a risk to children. In humid environments, mould and bacteria can grow under or in the pores of play mats. Such microbial growth can pose health risks, especially when used in poorly ventilated areas. Furthermore, mould, bacteria, or moisture under the mat can cause unpleasant odours and create an unhygienic environment. Some play mats are made from materials that are difficult to recycle. PVC-based mats, in particular, contain chemicals that are harmful to the environment and are difficult to recycle at the end of their life . This is a disadvantage in terms of environmental sustainability. Play mats made from synthetic materials can cause high carbon emissions during the manufacturing process. When such synthetic materials are preferred over natural or recycled materials, the negative impact on the environment may increase. Play mats may fade when exposed to sunlight or heavy use. Mats used outdoors, in particular, may lose their colour and appearance more quickly if they are not resistant to UV rays.

[0020] With the known technology, some play mats cannot prevent the spread of noise generated by children playing because they do not provide adequate sound insulation. Soft foam materials generally provide good sound insulation, but thinner or harder materials may be weak in terms of sound insulation. Some play mats may be expensive but may not be durable. Products that lack quality materials and manufacturing processes may wear out quickly or lose their functionality. Consumers may find it difficult to strike a balance between quality and price. For this reason, there is a need for technologies that prioritise hygiene in the production of play mats, are free of toxic chemicals, are durable, prevent unpleasant odours, are environmentally friendly, antibacterial, and offer self-cleaning surfaces.

[0021] BRIEF DESCRIPTION OF THE INVENTION

[0022] The invention relates to an environmentally friendly photocatalytic play mat and production method that enables children to play in a safe and hygienic environment, featuring antibacterial and self-cleaning properties, being durable, preventing unpleasant odours, and made from recyclable materials. This play mat is coated with semiconductor photocatalytic materials such as titanium dioxide (-no^and interacts with sunlight or artificial light to both clean the surface and improve the ambient air.

[0023] Apart from titanium dioxide (TiO2), semiconductors such as zinc oxide (ZnO), cadmium sulphide (CdS), tungsten trioxide (WO3) and iron oxide (Fe2O3) can be used in photocatalytic applications. ZnO has high activity under UV light, similar to TiO2, while CdS is effective in visible light but toxic. WO3is preferred in harsh conditions due to its durability, while Fe2O3stands out for its low cost and visible light absorption. Additionally, graphene oxide (GO) and molybdenum disulphide (MoS2) enhance efficiency by increasing electron conduction. Bismuth vanadate (BiV04) and silver halides (AgX) are active in visible light, while ceria (CeO2) is used in applications requiring high temperature resistance. Material selection depends on the band gap, light absorption, and environmental conditions.

[0024] Our invention may be of great interest to parents who need a safe play area for their children at home, nurseries and kindergartens where children play in a hygienic and safe environment, and children's play centres that need to meet hygiene and cleanliness requirements in high-traffic areas. These photocatalytic play mats, which can be used both indoors and outdoors, can appeal to a wide customer base. Furthermore, the photocatalytic play mat's self-cleaning surface reduces the need for regular cleaning, saving time and money. In addition, our invention is an environmentally friendly product made from recyclable materials.

[0025] Features of the photocatalytic play mat:

[0026] - Antibacterial and Antimicrobial Protection: The photocatalytic coating prevents the growth of microorganisms, bacteria, and fungi on the mat surface, eliminating harmful microorganisms. This provides a hygienic play area, especially to protect children's sensitive immune systems.

[0027] - Self-Cleaning Surface: Thanks to the photocatalytic material, dirt and organic residues on the mat's surface are broken down when exposed to sunlight or artificial light during the day. This feature automatically keeps the mat clean and reduces the need for regular cleaning.

[0028] - Air Purification Function: The mat improves the air quality of the environment by breaking down harmful gases (such as nitrogen oxides and volatile organic compounds) in the surrounding air. This feature is particularly useful in enclosed spaces with limited air circulation. Thus, it provides clean air in the play area, supporting children's play in a healthier environment.

[0029] - Safe Materials: The mat is made from materials that are harmless to children's health, environmentally friendly, and recyclable. Photocatalytic coatings provide a safe and non-toxic play area for children.

[0030] - Easy to Clean and Durable: The photocatalytic material's self-cleaning feature reduces the need for regular cleaning. At the same time, the mat is durable and long-lasting against physical damage that children may cause during play. It provides resistance to UV light, wear and tear.

[0031] - Odour Removal: The photocatalytic coating has the ability to eliminate unpleasant odours. This feature helps to remove odours that accumulate in the play area, especially sweat and food odours. Play mats always smell clean and fresh for children.

[0032] DETAILED DESCRIPTION OF THE INVENTION

[0033] In our invention, the photocatalytic coating applied to the surface of the play mat prevents microbes, bacteria and harmful chemicals from remaining on the surface. This coating is activated by UV light and provides properties such as self-cleaning and air purification. Titanium dioxide (TiO2), binding resin and solvent are used as photocatalytic coating materials.

[0034] Titanium dioxide (TiO2) is the main component of photocatalytic coatings. This component activates under UV light and cleans by breaking down harmful organic substances, bacteria and microorganisms. At least one of acrylic and silicone-based binding resins is used to ensure that the titanium dioxide adheres to the surface of the play mat. Solvents are used to ensure that the coating is applied evenly to the surface. Water and alcohol-based solvents are preferred because they are environmentally friendly.

[0035] For the photocatalytic coating application, the surface of the play mat must first be cleaned and free of dust, dirt or grease. A clean and dry surface ensures better adhesion of the coating. Next, the photocatalytic coating material (a mixture of titanium dioxide and binding resin) is mixed with the solvent to obtain a homogeneous mixture. Photocatalytic coating is applied to large surfaces using a spray gun. This method ensures that the coating is distributed evenly. Spraying is an advantageous method for coating large surface areas in a short time. After the photocatalytic coating is applied, the surface is left to dry completely. The coating activates under UV light on the surface and begins to exhibit a photocatalytic effect.

[0036] Details of the five basic process steps described are as follows.

[0037] Material Selection and Preparation: A recyclable and non-toxic material is selected for the mat. This material is at least one of EVA (Ethylene Vinyl Acetate), TPE (Thermoplastic Elastomer) and natural rubber. Care is taken to ensure that the selected material is 95-100% pure, environmentally friendly and hypoallergenic.

[0038] Preparation of Photocatalytic Material: Titanium dioxide (TiO2) particles with an average size of 20-25 nm will be used. The coating solution is prepared with 2-5% TiO2, 1 -3% binder (by weight) and at least 92-97% pure water and at least one alcohol- based (ethanol, isopropyl alcohol) solvent. To ensure a homogeneous distribution, the mixture is stirred in an ultrasonic mixer at a frequency of 20 kHz for 30 minutes.

[0039] The use of a binder is critical for improving the adhesion of the coating to the surface and increasing its durability. For this purpose, organic binder resins (e.g., at least one of polyvinyl alcohol and acrylic polymers) are preferred on flexible surfaces, while inorganic binder resins (e.g., at least one of silica sol and aluminium) are preferred in coatings requiring high temperature resistance. Additionally, hybrid (organic and inorganic) binder resins can be used to provide both flexibility and durability. The binder amount is adjusted to between 1 % and 3% of the total weight of the solution; however, excessive binder use requires careful optimisation as it can negatively affect photocatalytic activity. Binders ensure that the coating bonds strongly to the surface while increasing durability and abrasion resistance. They also contribute to a more homogeneous application by controlling the viscosity of the solution.

[0040] Preparing the Foam Material for Coating: Before applying the photocatalytic coating, the surface of the play mat must be carefully prepared. First, dust, dirt and grease residues on the surface must be removed, as these contaminants can prevent the coating from adhering properly to the surface. For cleaning, the surface is wiped with at least one alcohol-based solution, such as 70% isopropyl alcohol and 90% ethanol, and dried with a microfibre cloth. When deeper cleaning is required, a water-based surface cleaning solution is used to ensure the surface is smooth and homogeneous. After cleaning, allow the surface to dry completely for 20-30 minutes, or accelerate the drying process using a low-temperature (40-50 °C) air blower. If the surface has microscopic irregularities or pores, it is recommended to lightly smooth the surface with fine sandpaper. This process ensures better adhesion of the coating to the surface and increases its long-term durability. Once surface cleaning and preparation are complete, a final check should be carried out before proceeding with the coating process to verify that there are no particle residues on the surface. This preparation process is a critical step in terms of the effectiveness and durability of the photocatalytic coating.

[0041] Photocatalytic Coating Application: The matt surface is first cleaned with at least one of 70% isopropyl alcohol and 90% ethanol and dried. The prepared TiO2solution (titanium dioxide (TiO2), binding resin and solvent) is applied to the surface from a distance of 15-20 cm using an HVLP (high volume low pressure) spray gun. During application, the coating thickness is adjusted to be between 10-50 microns. After the first coat has dried (15-20 minutes at room temperature), a second layer is applied to the surface. To ensure a more robust bond of the coating , the surface is subjected to heat treatment in an oven at 80-100 °C for 1 -2 hours.

[0042] Coating can also be achieved using alternative methods. As alternatives to the spraying method, at least one of the following can be used: dip coating, brush coating, roller coating, electrostatic coating, and sol-gel method. Dip coating is preferred for surfaces with complex geometries as it provides a homogeneous coating, but solution waste is high. Brush coating offers a cost-effective solution for small-scale production or spot applications, but it is limited in terms of homogeneity. Roller coating is suitable for providing fast and even coating on large, flat surfaces, but it is difficult to use on complex surfaces. Electrostatic coating provides a precise and homogeneous coating and reduces material waste, but it requires high technology. The sol-gel method offers a durable and long-lasting coating, but has high energy costs. Each method should be selected based on the product design, production scale, and targeted coating quality.

[0043] In the final stage, activating the photocatalytic coating with UV light is an important step in optimising the coating's performance. UV light activates photocatalytic materials (e.g., TiO2) and increases the rate at which they break down organic pollutants and microorganisms. This process ensures that the coating is ready for immediate use, verifies photocatalytic activity, and improves coating quality. Activation is typically applied under UV light at a wavelength of 365 nm for 10-30 minutes. This method supports the hygienic and effective delivery of product to users. Packaging: Packaged in 100% recyclable, airtight plastic bags to protect against moisture and dust.

Claims

CLAIMS1. An environmentally friendly photocatalytic play mat made from recyclable materials, featuring antibacterial properties, UV light activation, self-cleaning capabilities, durability, odour prevention, and designed to provide children with a safe and hygienic environment for play, characterised by; the coating solution titanium dioxide (TiO2), at least one of acrylic and silicone-based binding resins, and at least one of pure water, ethanol, and isopropyl alcohol as a solvent.

2. A production method for a photocatalytic play mat that enables children to play in a safe and hygienic environment, is antibacterial, has self-cleaning properties, is durable, prevents unpleasant odours, is made from recyclable materials, and is environmentally friendly, characterised by;- Cleaning dust, dirt, and oil residues on the surface of the play mat with at least one of 70% isopropyl alcohol and 90% ethanol and drying it with a microfibre cloth,- Allowing the surface to dry completely for 20-30 minutes after cleaning,- if there are microscopic irregularities or pores on the surface, lightly smoothing the surface with fine sandpaper,- Mixing a solution of 2-5% titanium dioxide and 1 -3% binding resin with 92-97% solvent,- To ensure a homogeneous distribution, mix the mixture in an ultrasonic mixer at a frequency of 20 kHz for 30 minutes.- Applying the prepared -no2solution (titanium dioxide (TiO2), binding resin and solvent) to the surface from a distance of 15-20 cm using an HVLP (high volume low pressure) spray gun,- Adjusting the coating thickness to between 10-50 microns during application,- Allowing the first coating to dry at room temperature for 15-20 minutes,- Applying a second layer to the surface,- Subjecting the surface to heat treatment in an oven at 80-100 °C for 1 -2 hours to ensure a stronger bond of the coating,- Applying UV light at a wavelength of 365 nm to the coating for 10-30 minutes to activate the photocatalytic materials,- Packaging in 100% recyclable, airtight plastic bags to protect the mat from moisture and dust.