WO1999000051A1

WO1999000051A1 - Improvements in or relating to matting

Info

Publication number: WO1999000051A1
Application number: PCT/GB1998/001687
Authority: WO
Inventors: Paul Jeremy Bleakley
Original assignee: Paul Jeremy Bleakley
Priority date: 1997-06-26
Filing date: 1998-06-25
Publication date: 1999-01-07
Also published as: GB9713379D0

Abstract

Matting comprises two superposed layers (1 and 3). Lower layer (1) is a moulded rubber base formed with a plurality of integral circular scraper protuberances which extend through respective complementary circular apertures (4) in upper layer (3) which is a carpet layer. The layers (1, 3) are bonded or attached to provide permanent or temporary fixing together. The protuberances (2) have a multi-directional scraping action and the 'open' aspect of the material allows moisture to move outwards promoting faster drying times. Protuberances (2) may be bonded rather than integral and the material of the layer may be different or the same.

Description

IMPROVEMENTS IN OR RELATING TO MATTING

The present invention relates to matting particularly, but not

exclusively, to matting for use in entrances to buildings such as shops

offices and other public buildings or domestic premises and to a method of

producing matting.

Most forms of commercial quality entrance matting are made up of

strips of material such as metal or PVC framing holding together strips of

scraper or absorbent material for the purpose of scraping and wiping grit,

mud and/or moisture from the footwear of pedestrian traffic. The frame is

generally of no practical purpose in the cleaning process and foot contact

with the working material is sometimes less than 50% on any step. In

many cases entrances may be multi-directional. In these circumstances,

these strips can form a slip hazard due to their smooth, hard nature when

approached from the ends of the strips as when entering from side doors.

Some existing forms of ribbed matting present a heel trap trip hazard,

especially when they become worn and buckle or breakdown mechanically.

According to one aspect of the present invention, there is provided

matting having a first layer comprising at least one aperture superposed on

and fixed to a second layer of material having at least one protuberance

extending through or into the at least one aperture and providing a surface

for cleaning footwear coming into contact therewith. According to another aspect of the invention, there is provided a

method of making matting including the steps forming a first layer of

material with at least one aperture, forming a second layer of material with

at least one protuberance having a surface for cleaning footwear coming

into contact therewith, superposing the two layers so that the protuberance

of the second layer extends through or into the aperture of the first layer

and fixing the two layers together.

In a preferred embodiment of the invention the protuberance is

integral with the first layer. Alternatively, the protuberance may be

separately formed and connected to the first layer. Usually, a plurality of

protuberances and a corresponding plurality of apertures would be provided.

These may be arranged to form a pattern as desired. When the

protuberance is integral with the layer, the layer may be formed by

moulding. Where the protuberance is connected the protuberance may be

bonded to the first layer by any suitable adhesive. The two layers may be

of the same or different material. The second (lower) layer may be attached

to a rubber, latex or polyvinyl chloride (PVC) backing sheet for stability.

The second layer is preferably rubber or soft plastics for flexibility and

durability. The cleaning surface of the or each protuberance may be ribbed

profiled, tufted or textured to form a scraper surface to provide grip as well

as the cleaning action. The first (upper) layer may comprise a non-absorbent scraper material and a series of drainage holes are provided to permit

passage of water through to the ground. The second (lower) layer may

have a profiled underside to allow the water to disperse.

According to a further aspect of the invention, there is provided

matting having a first rubber layer comprising an aperture formed therein,

and a rubber insert complementary in shape to the aperture inserted therein

the layer and insert, being cured together to form a homogeneous whole.

According to a still further aspect of the present invention, there is

provided a method of making matting including the steps of forming an

aperture in a first layer of uncured rubber, forming an insert having a shape

complementary to the shape of the aperture from second layer of uncured

rubber, introducing the insert into the aperture and curing them together to

form a homogeneous whole.

The insert may form a pattern or logo which will remain in the

product throughout its life. The insert may be replaceable.

According to a still further aspect of the invention, there is provided

a decorative inset for matting comprising a composite having a base layer

having an undersurface for attachment to the matting, a decorative layer

superposed on the base layer and an upper transparent or translucent wear

resistant layer superposed on the decorative layer the layers being fixed

together to form a composite whole. According to a still further aspect of the invention there is provided

a layer of a rigid or semi-rigid material defining one or more recesses and

one or more inserts inserted into corresponding recesses, the or each insert

providing a surface for cleaning footwear coming into contact therewith.

The rigid or semi-rigid material may be stone, resin, PVC, metal,

rubber or wood in tile, strip, roll or screed (polymeric or cementitious) form.

The or each insert may be permanently or temporarily fixed to the base of

the corresponding recess.

In order that the invention may be more clearly understood, one

embodiment thereof will now be described by way of example with

reference to the accompanying drawings, in which:-

Figure 1 diagrammatically shows a first embodiment of the

invention comprising two components,

Figure 2 diagrammatically shows a second embodiment of the

invention comprising three components.

Figure 3 diagrammatically shows a third embodiment of the

invention also comprising two components.

Figure 4 shows stages in the formation of a fourth embodiment

of the invention,

Figures 5a-5d shows stages in the formation of a fifth embodiment,

and Figure 6 shows a sixth embodiment of the invention.

Referring to figure 1 , the matting comprises a moulded rubber base

layer 1 formed with a plurality of integral circular scraper protuberances 2

and a superposed carpet layer 3 provided with circular apertures 4 which

correspond in size and number to the protuberances. The dimensions of the

layers are such that the scraper protuberances 2 preferably project through

and stand proud of the carpet layer 3 when the two layers are superposed

and in use. The two layers 1 and 3 may be bonded or attached to provide

permanent or temporary fixing together. The scraper protuberances 2 have

truly multi-directional scraping action and the 'open' aspect of the material

allows the moisture to move outwards from the main pass area easily to

promote faster drying times, whereas strips will confine the moisture in the

channels and thereby hinder the airflow required for drying. Saturated

matting is more of a hindrance than a help, studded mats -v-ribbed mats of

a similar material will have a higher performance value. As opposed to rigid

frame systems, this matting has a flexible quality and in sheet/tile form will

conform to the contour of the floor on which it is laid. It will therefore have

inherent safety qualities in this respect as it cannot rock or lift to cause a

trip hazard.

Referring to figure 2, a modified version of the embodiment of figure

1 is shown in which the protuberances 22 are bonded to a base layer 1 instead of being integral with it. In all other respects the embodiment is the

same as the embodiment of figure 1 equivalent parts bearing the same

reference numerals preceded by the numeral 2.

In both the embodiments of figures 1 and 2 the top and bottom layer

may be made of two or more different types of material in which case it

may be preferable to bond the bottom layer of the combined materials to a

rubber, latex or PVC backing sheet for stability. All of these variations offer

the ability to simply trim and customise to shape on site providing a distinct

advantage over most other systems especially ones with interconnecting

wiring or slotting methods.

The bottom layer will be, by preference, rubber or soft plastic for

flexibility and durability. Where the bottom layer protrudes through the top

layer, the top/wear surface of the protuberance will preferably be ribbed,

profiled, tufted or textured to form a scraper surface to provide both a

cleaning action and extra grip for safety. The texturing may be obtained by

applying a material such as magnesium powder. Protuberances may have

any alternative shape such as square or diamond.

For external use the holed upper surface may be of a non-absorbent

scraper material where a series of drainage holes are spaced between the

inserts to allow passage of water down through the whole matting whilst

the bottom surface of the matting will be profiled to allow the water to disperse.

Referring to figure 3, shapes such as letters 32 once cut from one

sheet of unvulcanised rubber and inserted into complementary shaped

apertures 34 cut into a second sheet 31 of unvulcanised rubber following

which the assembly is vulcanised. In the case of this rubber design, the

whole or part of the surface may be ribbed. Also customisation may be

introduced by profiling out the name or message required from two or more

pieces of rubber of differing shades dependent on the colour scheme

required. On vulcanisation the resultant product is a composite unit with

the design inset from the top surface to the bottom surface and cannot wear out ahead of the useful life of the mat. The rubber matting may have

a ramp surround section (as shown in figures 5b and 5d) similarly built-in

prior to vulcanising or connected after vulcanising by means of a lip and/or

channel. The overall product can be of any colour to suit the end user.

Referring to figures 4a to 4d composite decorative inset for matting

is shown. This comprises a top layer 45 of a transparent hardwearing

material (figure 4a), an intermediate sheet 46 bearing the desired image 47

(figure 4b) and a base layer 48 (figure 4c) which are bonded together to

form a composite 49 shown in figure 4d. The base layer provides a means

of attachment to matting either mechanically or by bonding.

Referring to figures 5a to 5d, an embodiment is shown in which a composite 59 of the type produced in accordance with figures 4a to 4d is

combined with a base layer 51 which also has a number of integral circular

protuberances 52. An upper layer 53 has a plurality of circular apertures

54 which receive the protuberances 52 and a rectangular aperture 55 which

received the composite 59. The two layers 51 and 53 are assembled in

unvulcanised form and vulcanised together, and provided with an integral

ramping surround 58.

Referring to figure 6, the base layer may be of stone or resin tiles

which may be prepared by way of recessing the upper surface to accept the

antislip - cleaning/scraping inserts 62 to be bonded onto the bases of the

recesses 64 to provide a permanent or temporary fixing. A further benefit

of this hole/recess and insert technique is that there is a notable change in

the texture of the floor surface thereby warning visually impaired people of

the proximity of the doorway.

The above described embodiments lend themselves to sheet, tile or

strip form and may be incorporated in many varying materials commonly

used in flooring namely rubber, plastics, carpeting in polypropylene, nylon,

wool, cotton and other natural fibres such as coir, sisal and the like, wood

sheet, metal sheet, stone and composite stone and resin, screeds, tiles

blocks and strips where it is to be laid flush with the floor surface or

recessed in a matwell. The embodiments are designed to provide substantial overall contact

with the foot, both to avoid hazards and to remove the maximum dirt and

moisture in doing so. The absence of ribs also provides for simpler

installation and less waste as cut pieces can be laid in any direction. There

being no substantial linear bulk, expansion due to large rises in temperature

will be minimal. Expansion is a major problem in PVC and rubber mats

causing the product to lift out of the matwell thereby causing serious trip

hazard with many recorded accidents. The embodiments have been

designed to obviate this serious problem.

The upper layer may be of vinyl with or without antislip additive and

the protuberances may be of any shape using any of the previously

mentioned materials. Similarly the upper surface may be of wood strip or

imitation wood strip or metal plate.

Adhesives for the purpose of fixing the layers will be as or similar to

the "F" range supplied by F. Ball & Company, Leek, Staffordshire, England

dependent upon the individual components in use. Epoxy type adhesives

or similar may also be used.

The flexible nature of the product will avoid all such problems of

buckling and component failure rendering it a more reliable alternative.

It will be appreciated that the above embodiment has been described

by way of example only and that many variations are possible without departing from the scope of the invention. For example, adjacent layers

may be releasably secured together to allow for changing or cleaning. The

base surface of the composite may be smooth or patterned to allow for

ventilation or to provide extra grip on soft floors.

Claims

CLAI S

1 . Matting having a first layer (3) comprising at least one aperture (4)

superposed on and fixed to a second layer (1 ) of material having at least

one protuberance (2) extending through or into the at least one aperture (4)

and providing a surface for cleaning footwear coming into contact

therewith.

2. Matting as claimed in claim 1 , in which the protuberance (2) is

integral with the second layer (1 ) .

3. Matting as claimed in claim 1 , in which the protuberance (2) is

separately formed and connected to the second layer (1 ).

4. Matting as claimed in claim 2, in which the second layer (1 ) is

moulded.

5. Matting as claimed in claim 3, in which the protuberance (2) is

connected to the second layer (1 ) by means of an adhesive.

6. Matting as claimed in any preceding claim, in which there are a

plurality of protuberances (2) and a plurality of apertures (1 ) .

7. Matting as claimed in any preceding claim, in which the first and

second layers are made of the same material.

8. Matting as claimed in any of claims 1 . to 6, in which the first and

second layers (3), (1 ) are made of different materials.

9. Matting as claimed in any preceding claim, in which the cleaning surface of the or each protuberance (2) may be ribbed, profiled, textured or

tufted.

10. Matting as claimed in any preceding claim, in which the first layer (3)

comprises a non-absorbent scraper material and a series of drainage holes

are provided to permit passage of water through to the ground.

1 1. A method of making matting including the steps of forming a first

layer (3) of material with at least one aperture (4), forming a second layer

(1 ) of material with at least one protuberance (2) having a surface for cleaning footwear coming into contact therewith, superposing the two

layers so that the protuberance of the second layer extends through or into

the aperture of the first layer and fixing the two layers together.

12. Matting having a first rubber layer (31 ) comprising an aperture (34)

formed therein, and a rubber insert (32) complementary in shape to the

aperture inserted therein the layer and insert, being cured together to form

a homogeneous whole.

13. A method of making matting including the steps of forming an

aperture (34) in a first layer (31 ) of uncured rubber, forming an insert

(32)having a shape complementary to the shape of the aperture from

second layer of uncured rubber, introducing the insert into the aperture and

curing them together to form a homogeneous whole.

14. A decorative inset for matting comprising a composite having a base

SUBSTrrUTE SHEET (RULE 26) layer (48) having an undersurface for attachment to the matting, a

decorative layer (46)superposed on the base layer and an upper transparent

or translucent wear resistant layer (45) superposed on the decorative layer

the layers being fixed together to form a composite whole.

15. A layer (61 ) of a rigid or semi-rigid material defining one or more

recesses (64) and one or more inserts (62) inserted into corresponding

recesses (64), the or each insert providing a surface for cleaning footwear

coming into contact therewith.