IMPROVED MAT FOR WET AREAS

Description

FIELD OF THE INVENTION

The present invention generally relates to the field of systems for improving floor mats for users in wet areas.

BACKGROUND OF THE INVENTION

Traditional mats used for wet areas, particularly in bathroom settings, typically retain water for extended periods of time. Water retention for long durations of time can lead to mold and mildew. Limited absorbency capabilities can bring about an unpleasant odor because of extensive drying time. Moreover, in communal bathrooms with more than one user, the spreading of germs is prevalent among the prolonged use of traditional bathmats due to the mats quickly becoming saturated with water. Existing bath mats pose a biohazard to users. Individuals who use a mat for wet areas are always looking for ways to enhance water absorption.

Conventional cotton fiber bathmat users are also more prone to slipping because of the weak absorption and inadequate durability. Without an anti-slip backing, a traditional mat used for wet areas does not stay in place and is unstable when stepped on. The instability of traditional mats is concerning, especially when exiting the shower or bath, when individuals may already be off-balance. Vulnerable populations, such as those with mobility issues and/or elderly individuals, are more susceptible to falling and injuries from mats without an anti-slip backing. Wet area mat users are increasingly looking for a mat that excels in slip prevention while still being easy to maintain.

One example of a prior art mat used in shower and bath areas is disclosed and discussed in U.S. Patent Application Publication Number 2021/0330110, published Oct. 28, 2021. It focuses on a method for reconfigurable absorption mats including multiple underlayment pieces joined together with a plurality of connectors for connecting more than one mat utilizing an interlocking system. However, this promotes an abundance of unnecessary pieces that requires meticulous assembly and is inconvenient for users. Similarly, Japanese Patent Application Publication No. 2010-184108 describes a method for a foot-wiping mat that uses several components, specifically wood pulp, which is known to have a warping effect when exposed to wet environments. These solutions, while partially effective, do not provide a convenient and practical mat for wet areas.

What is needed is a mat that utilizes a combination of diatomaceous earth-based (“stone”) material and a pulp fiber binding agent to enhance anti-slip surfaces, absorb water, and keep floors clean and dry for users in a convenient manner. See https://en.wikipedia.org/wiki/Diatomaceous_earth, which is incorporated herein by reference, for information related to diatomaceous earth material composition, properties, and formation.

What is also needed is a mat that is configured for efficient shipping, storage and retail shelf display, including having an underlayment that may be of one-piece design with a spine or joint that is capable of being folded for compact storage and packaging. In addition, the stone may be comprised of multiple pieces for ease of shipping, compactness of packaging, and to avoid breakage during shipment.

SUMMARY OF THE INVENTION

The present invention provides an improved apparatus and method for users to safely use a mat in a wet area and to protect flooring from damage in wet areas.

The present invention provides a system for enhancing a mat for wet areas. At its core, the invention comprises a TPR base underlay for enhanced safety made from thermoplastic rubber (TPR) and an absorbent top stone mat for providing water absorption and quick-drying capabilities made from a combination of diatomaceous earth and a pulp fiber binding agent. A plurality of strips are located on the top surface of the absorbent top stone mat to provide the user with a textured surface for improved traction. The TPR base underlay and the absorbent top stone mat are connected, for example, via a snap-fit system. In one exemplary embodiment, the top surface of the TPR base underlay or underlayment contains eight protrusions with jagged circumferences to be interlocked with the eight recessions with grooved circumferences on the bottom surface of the absorbent top stone mat component in the snap-fit system. The absorbent top stone mat that consists of a combination of diatomaceous earth and a pulp fiber binding agent is a two-piece design that is substantially rectangular in shape and has the ability to be fittingly received within a foldable one-piece underlayment formed of TPR. The underlayment may be folded down the middle in half such as by a spine or joint formed in the underlayment. In this manner, the underlayment may be folded and unfolded as needed and avoids the need for additional connecting members or pieces. The folding mechanism allows the absorbent top stone mat product to be transported, stored, and assembled conveniently. The design also enables the material to be more durable in use.

The system of the above embodiment may alternatively comprise a TPR base underlay that is segmented with openings. The TPR base underlay is substantially rectangular in shape and enhances safety for the user. The rubber material provides traction for the mat and reduces the risk of slips and falls in wet areas. The TPR base underlay has anti-slip properties to ensure that the mat stays in place. The substrate cushions the absorbent top stone mat and has shock absorption capabilities, and in the case of a hazardous situation, such as a fall or a heavy object dropping on the absorbent top stone mat, the substrate dampens the impact and protects the foundation of the absorbent top stone mat. The TPR base underlay also preserves the floor in wet areas from damage. The substrate is also easy to clean and maintain, helping the user to maintain a clean and hygienic shower or bath area. The durability and sustainability of the TPR base underlay allows for the implementation of an improved mat in wet-prone areas.

The system of the above embodiment may further comprise an absorbent top stone mat composed of diatomaceous earth and a pulp fiber binding agent with a plurality of strips on the top surface of the mat to provide the user with more traction during use. The composition of the absorbent top stone mat allows for enhanced water absorption and quick drying capabilities. The diatomaceous earth element is porous in nature and enables the mat to quickly soak up water and prevent the growth of mold and mildew. Additional antimicrobial components may be added to the composition comprising the stone mat components. The pulp fiber binding agent helps reinforce the diatomaceous earth and prevents the diatomaceous earth from breaking over time. The pulp fiber binding agent combined with the diatomaceous earth keeps the structural integrity of the absorbent top stone mat. The absorbent top stone mat comprising diatomaceous earth and a pulp fiber binding agent offers a sleek design that complements modern bathroom aesthetics. The combination of diatomaceous earth and a pulp fiber binding agent provides a porous, absorbent top stone mat that has antibacterial properties and rounded corners as an added safety feature.

In addition, as shown in FIGS. 5-10, the improved stone mat assembly may include reinforced elements disposed on the underside of the stone mat components to prevent or reduce warping. In use, the stone mat composite material may warp after repeated exposure to moisture. The severity of the warping may be dependent on the number of uses/exposures, the relative humidity in the area, the degree of moisture the mat is subjected to when used and the particular composition and materials used in fabricating the stone mat. The relative thickness of the stone mat may also affect the degree to which warping may occur. To eliminate or reduce the degree to which warping may occur, the stone mat may include one or more reinforcement elements. Also, the bar or elongated member may be bowed or bent or notched or ribbed or have other physical features that contribute to the overall rigidity or stiffness or strength of the element to assist in reducing warping of the stone mat. Much as “rebar” steel reinforcing rods are used to reinforce concrete, a reinforcement strip or bar or element or rod may be used to reinforce the stone mat to reduce warping.

Exemplary embodiments of the present invention are provided in more detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to facilitate a full understanding of the present invention, reference is now made to the accompanying drawings, in which like elements are referenced with like numerals. These drawings should not be construed as limiting the present invention, but are intended to be exemplary and for reference.

FIG. 1 is a schematic diagram of a top view of the TPR base underlay with a first section view BB on the bottom of the drawing and a second section view A-A on the right side of the drawing.

FIG. 2 is a schematic diagram of a bottom view of the TPR base underlay.

FIG. 3A is a schematic diagram of a top view of the absorbent stone mat.

FIG. 3B is a schematic diagram of a top view of an alternative absorbent stone mat to the mat of FIG. 3A.

FIG. 4 is a schematic diagram of a bottom view of the absorbent stone mat.

FIG. 5 is a top view of a first embodiment of a reinforced stone mat to prevent warping.

FIG. 6 is a top view of a first exemplary embodiment of a reinforced stone mat to prevent warping.

FIG. 7 is a top view of a second exemplary embodiment of a reinforced stone mat to prevent warping.

FIG. 8 is a top view of a third exemplary embodiment of a reinforced stone mat to prevent warping.

FIG. 9 is a top view of a fourth exemplary embodiment of a reinforced stone mat to prevent warping.

FIG. 10 is a top view of a fifth exemplary embodiment of a reinforced stone mat to prevent warping.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is not to be limited in scope by the specific embodiments described herein. It is fully contemplated that other various embodiments of and modifications to the present invention, in addition to those described herein, will become apparent to those of ordinary skill in the art from the foregoing description and accompanying drawings. Thus, such other embodiments and modifications are intended to fall within the scope of the following appended claims. Further, although the present invention has been described herein in the context of particular embodiments and implementations and applications and in particular environments, those of ordinary skill in the art will appreciate that its usefulness is not limited thereto and that the present invention can be beneficially applied in any number of ways and environments for any number of purposes. Accordingly, the claims set forth below should be construed in view of the full breadth and spirit of the present invention as disclosed herein.

As shown in FIG. 1, the TPR base underlay 100 is shown in a top view over a section B-B view and with a section A-A view along the side. The underlay 100 is configured to receive the stone mat components 204 disclosed in FIGS. 3 and 4 discussed below. Collectively the underlay 100 and the two stone mat portions 204 comprise the complete absorbent mat product. FIGS. 1 and 2 illustrate the schematic of an exemplary underlay component of the improved mat for wet areas referenced generally by reference 100. The substantially rectangular TPR base underlay 100 is bisected by a foldable midline axis 102, which divides the surface into two preferably but not necessarily symmetrical halves 104. Midline 102 is configured to be foldable so that the halves fold in on themselves to result in half the footprint of the underlay 100 when fully extended. Midline 102 may be made foldable by fabricating the underlay 100 out of a plastic material and with a midline being a reduced thickness to promote a controlled and desired fold in the underlay. These halves are referred to as the left half and the right half when viewed from this specific orientation. Each section contains specific features relevant to the design and function of the TPR base underlay. The TPR base underlay comprises, for example, eight protrusions 106, one or more of which may be provided or formed with jagged portions or circumferences and are symmetrically arranged along the periphery of the underlay halves when viewed from the top. The protrusions 106 are configured and located to mate with corresponding indentions or recesses 206 shown and described in FIG. 2 below. Of course one of ordinary skill in the art would appreciate that the protrusions and indentions may be reversed in an alternative design with the protrusions 106 on the stone mats 200 and the indentions 206 disposed on the underlay 100.

In one exemplary configuration, each protrusion 106 has a diameter of 15.4 millimeters and extends 3 millimeters above the surface of the TPR base underlay. Four protrusions are positioned in each corner of the halves. In the left half of the TPR base underlay, the distance between the protrusion in the top left corner and the protrusion in the top right corner is precisely 335 millimeters. This measurement is mirrored in the bottom left and bottom right protrusions, which are also 335 millimeters apart. Additionally, within the left half of the TPR base underlay, the vertical distance between the top left protrusion and the bottom left protrusion is 545 millimeters. This same vertical distance applies to the top right and the bottom right protrusions within the left half. The right half of the TPR base underlay mirrors these exact measurements, ensuring symmetrical arrangement and uniform functionality. Furthermore, with respect to the entire TPR base underlay, the horizontal distance between the protrusion located in the top right corner of the left half and the protrusion in the top left corner of the right half is approximately 56 millimeters. This same horizontal distance is maintained between the protrusion in the bottom right corner of the left half and the protrusion in the bottom left corner of the right half. The TPR base underlay has an essentially uniform thickness with the exception of the presence of protrusions 106. Along the foldable midline axis 102, the TPR base underlay measures approximately 1.5 millimeters thick, while the rest of the mat has a thickness of approximately 3 millimeters.

With reference still to FIG. 1, the system of the embodiment of the TPR base underlay further comprises a plurality of segments with openings. The openings in the TPR underlay facilitate air flow and allow moisture to escape. The implementation of the openings in the TPR base underlay prevents the buildup of mold, milder, and unpleasant odors in wet environments. The segmented openings in the TPR base underlay further allow the substrate to flex and create additional contact points with the floor. The additional contact points with the floor enhances grip strength and traction by improving the overall conformity to uneven surfaces. The segmented opening design enhances the anti-slip properties of the substrate. The openings that are segmented in the TPR base underlay also serve to absorb shock. When impacted by external forces, the openings permit the substrate to compress and flex more easily under the pressure. The design with openings lets the TPR base underlay distribute and disperse energy more effectively across its surface. This dissipation and absorption of shock reduces the overall impact force in any one area, providing a sturdier surface. The flooring upon which the TPR base underlay is placed on is supplementarily protected. The easy removability of the substrate from the overall apparatus allows for thorough cleaning. The low maintenance and non-porous material avoids dirt and liquid from penetrating its surface which allows the user to effortlessly clean as well.

As shown in FIG. 2, the TPR base underlay bottom view perspective illustrates the schematic of the underlay component. In one exemplary embodiment, the substantially rectangular TPR base underlay 100 measures approximately 779 millimeters in length and 598 millimeters in width. The TPR base underlay is composed of thermoplastic rubber. TPR comprises a unique blend of thermoplastic and elastomeric polymers. The use of TPR in the construction of the base underlay significantly enhances its performance and anti-slip characteristics.

One of ordinary skill in the art will appreciate that the present invention is not limited to the specific dimensions described herein. The invention can be readily adapted to various sizes, whether smaller or larger, without departing from the scope and spirit of the invention.

As shown in FIG. 3A, the absorbent top stone mat top view perspective illustrates the schematic of a stone mat components 200 collectively and 204 individually. In this exemplary embodiment, the substantially rectangular absorbent top stone mat combination 200 is precisely 780 millimeters in length and 600 millimeters in width. The absorbent top stone mat combination 200 is made up of two preferably equal sized stone mat components 204 are configured to fit within respective halves 104 of the underlay 100 and when in place form a conjoined space or edge gap 212 corresponding to the midline axis 112 of the underlay 100. Although having the halves 104 and stone mat components 204 of essentially equal size results in storage, packaging and shipping efficiencies and case in fabrication. However, the invention is not limited to such a preferred configuration. Each stone mat section 204 may contain specific features relevant to the design and function of the absorbent top stone mat. The individual stone mat components 204 in this example measures 390 millimeters in length. With the underlay 100 folded in half and the two stone mat components 204 laid on top of one another, packing materials may be used to help ensure convenient transit and prevent breakage when being transported. By having the stone mats in essence half the size of the overall stone mat combination 200, the likelihood of breakage during transit, packing and storage is significantly reduced. The collapsible design enables the material of the absorbent top stone mat to be more durable in use and allows the absorbent top stone mat to remain as one singular piece for easy assembly and storage as well.

As shown in FIG. 3A, the surface visible from the top view of the absorbent top stone mat components 204 include a plurality of strips 220. The plurality of strips 220 provides the user with a textured surface to ensure additional traction and improve the anti-slip characteristics of the apparatus. The plurality of strips are arranged in a diagonal configuration with respect to the absorbent top stone mat. In this example, each individual strip possesses a width of 15 millimeters.

With reference still to FIG. 3A, the absorbent top stone mat 200 comprises a combination of diatomaceous earth and a pulp fiber binding agent. The absorbent top stone mat 200 consists of roughly 60% diatomaceous earth and roughly 40% of a pulp fiber binding agent. The incorporation of pulp fivers serves as a binding agent, effectively integrating the diatomaceous earth particles into a unified composite material. The combination of diatomaceous earth and a pulp fiber binding agent results in a robust and cohesive substance capable of maintaining structural integrity.

FIG. 3B is a schematic diagram of a top view of an alternative absorbent stone mat to the mat of FIG. 3A, which comprises the same essential composition of materials as described above for FIG. 3A embodiment. As shown in FIG. 3B, the surface visible from the top view of the absorbent top stone mat components 204′ include a plurality of strips 220′ and a plurality of curve features 221′. The plurality of strips 220′ and plurality of curved features 221′ provide the user with a textured surface to ensure additional traction and improve the anti-slip characteristics of the apparatus. The plurality of strips and plurality of curved features are arranged in a complimentary configuration such that either component 204′ is rotatable so that the strips and curved features align with one another to present a matching pattern as shown about centerline 212.

As shown in FIG. 4, the absorbent top stone mat bottom view perspective illustrates the schematic of a stone mat combination 200 and stone mat components 204. The substantially rectangular absorbent top stone mat 200 is divided the surface into two symmetrical halves 204. These halves 204 are referred to as the left half and the right half when viewed from this specific orientation. The absorbent top stone mat comprises eight recessions or indentations or cavities 206 arranged when viewed from the bottom to correspond to the locations and configurations and sizes of protrusions 106 of the underlay such that the indentations 206 receive the protrusions 106 when the stone mat components 204 are placed onto the underlay 100. Each recession has a diameter of 16.568 millimeters. Four recessions 206 are positioned in each corner of the halves 204. The jagged circumferences of the protrusions 106 are designed to enhance the interlocking mechanism, e.g., snap-fit system, with the corresponding eight recesses 206 on the absorbent top stone mat components 204.

In operation, a user assembles the present invention via the interlocking mechanism between the absorbent top stone mat 200 and the TPR base underlay 100 forming a snap-fit system. In the alternative, the absorbent top stone mat 200 may be equipped with eight protrusions each designed to engage with the corresponding eight recesses on the TPR base underlay. Upon alignment, the user applies pressure to interlock the pieces, whereby the protrusions on the absorbent top stone mat insert into the recesses of the TPR base underlay, creating a snap-fit connection. The interlock system and jagged edges along the circumference of the protrusion ensures that the absorbent top stone mat and the TPR bas underlay remain securely attached during use.

FIGS. 5-10 illustrate a set of exemplary embodiments of reinforced versions of the stone mat component. In use, the stone mat composite material may warp after repeated exposure to moisture. The severity of the warping may be dependent on the number of uses/exposures, the relative humidity in the area, the degree of moisture the mat is subjected to when used and the particular composition and materials used in fabricating the stone mat. The relative thickness of the stone mat may also affect the degree to which warping may occur. To eliminate or reduce the degree to which warping may occur, the stone mat may include one or more reinforcement elements. Also, the bar or elongated member may be bowed or bent or notched or ribbed or have other physical features that contribute to the overall rigidity or stiffness or strength of the element to assist in reducing warping of the stone mat. Much as “rebar” steel reinforcing rods are used to reinforce concrete, a reinforcement strip or bar or element or rod may be used to reinforce the stone mat to reduce warping.

FIG. 5 is a top view of a first embodiment reinforced stone mat 500 having reinforcement elements to prevent warping. In this embodiment two parallel strips 506 are included on the underneath portion of stone mat 504. The reinforcement elements may be made of carbon fiber, stainless steel, stiff plastic or fiberglass, glass epoxy. For example, the element may be made of Carbon Fiber with the following characteristics: Tensile Stiffness-Standard (33-36 msi), Tensile Strength (120,000-175,000 psi), Comprehensive Strength (75,000-128,000 psi), Flexural Strength (89,000-174,000 psi), Flexibility-Rigid, Density (0.05-0.067 lbs./cu. in.

Alternatively, the element may be made of Glass Epoxy such as THK TOL +/−0.12′, MIL-I-24768/27 Type GEE-F, WT/SQFT 1.1250. The material used in making the reinforcement elements is preferable water or moisture resistant. Also, the elements should be strong or rigid enough to resist warping of the stone mat material. Also, the weight of the elements may be a design consideration, e.g., carbon fiber is lighter weight that stainless steel. Cost is another factor that may be considered when selecting the material for the reinforcement elements. Glue, adhesive, chemical bonding, heat, interference welding, friction and/or notches or other means may be used to receive and retain the reinforcement elements into the stone mat components. Grooves or recesses into which reinforcement elements are disposed may be formed during a molding process or by use of a CNC (Computer Numerical Control) machine or router or laser or other device or process suitable for making a notch or indentation or groove appropriate given the dimensions of the reinforcement element being used. These options and considerations apply equally to all embodiments 500/600/700/800/900/1000.

FIG. 6 is a top view of a second embodiment reinforced stone mat 600 having reinforcement elements to prevent warping. In this embodiment two parallel strips 606 and two parallel strips 608 are included along the sides and on the top and bottom of the underneath portion of stone mat 604.

FIGS. 7-10 show additional embodiments and as shown only one of the two stone mat components are included in each exemplary drawing. The reinforcement element(s) would be used on the underside (facing the underlayment) of both of the two components that make up the stone mat assembly.

FIG. 7 is a top view of a third embodiment reinforced stone mat component 704 having reinforcement elements to prevent warping. In this embodiment two parallel rods 706 may be inserted into two parallel receiving grooves or slots formed or machined or ground into the underneath portion of the mat component 704 of a stone mat. For example, the dimension on rigid bar(s) as used in the embodiments of FIGS. 7 and 9-10 on standard Stone may be 25 mm wide×3 mm thick×47 cm long. In the large stone configuration the dimension on rigid bar(s) on large Stone may be 25 mm wide×3 mm thick×57 cm long. The rod may be circular in cross-section along the length of the element or may be rectangular in cross-section giving the element a flatter profile for insertion in an appropriately dimensioned slot, groove, or recess.

FIG. 8 is a top view of a fourth embodiment reinforced stone mat component 804 having a single reinforcement element to prevent warping. In this embodiment a single, relatively wider, strip 806 is included along the underside and towards the middle of stone mat component 804. For example, the dimension on rigid bar only in the middle on standard Stone may be 75 mm wide×3 mm thick×47 cm long. In the large stone configuration the dimension on rigid bar only in the middle on large Stone may be 75 mm wide×3 mm thick×57 cm long.

FIG. 9 is a top view of a fifth embodiment reinforced stone mat 900 having an X-shaped reinforcement element(s) positioned to prevent warping. In this embodiment two intersecting strips 906, which may be of singular construction or may be multiple elements are included along the underside of stone mat component 904.

FIG. 10 is a top view of a sixth embodiment reinforced stone mat 1000 having reinforcement elements to prevent warping. In this embodiment four spaced apart strips 1006 are located generally at the four corners along the underneath portion of stone mat component 1004.

It should be noted that the present apparatus and method are not limited to the specific embodiments described herein, but are intended to apply to all similar systems and/or methods for accurately measuring and delivering supplement in a powdered form from a container to a mixing receptacle while avoiding spillage and waste. Modifications and alterations from the described embodiments will occur to those skilled in the art without departure from the spirit and scope of the present systems and/or methods.