Abstract
A selectively repositionable mat having a liquid-absorbing layer backed by a moisture impermeable backsheet having peripheral margins including oppositely disposed, laterally extending side margins each comprising a longitudinally extending V-fold containing a pressure-sensitive adhesive applied between two opposed surface portions of the underside of the backsheet. The V-fold can open to the outside when configured as the top part of a Z-fold disposed above the backsheet or can open to the inside when configured as a single fold disposed below the backsheet, but is desirably configured so as to permit repositionable attachment of the mat to an underlying surface or substrate for which the selectively releasable, pressure-sensitive adhesive demonstrates sufficient tackiness to hold the mat in place relative to the substrate during normal use.
Claims
1. A selectively repositionable mat having a liquid-absorbing layer backed by a liquid-impermeable backsheet having a top side, bottom side, and peripheral margins including oppositely disposed, laterally extending side margins each comprising a longitudinally extending V-fold comprising a pressure-sensitive adhesive applied between two opposed surface portions of the bottom side.
2. The selectively repositionable mat of claim 1 wherein the V-fold opens to the outside and is configured as part of a Z-fold disposed on the top side the backsheet.
3. The selectively repositionable mat of claim 1 wherein the V-fold or opens to the inside and is configured as a single fold disposed below the bottom side of the backsheet.
4. The selectively repositionable mat of claim 1 wherein the backsheet has two oppositely disposed, longitudinally extending side edges and wherein the pressure-sensitive adhesive disposed inside the V-fold is selectively releasable by grasping and pulling the opposed side edges laterally prior to use of the mat.
5. The selectively repositionable mat of claim 1 wherein the pressure-sensitive adhesive exhibits tackiness sufficient to hold the mat in a substantially fixed position relative to an underlying surface or substrate.
6. The selectively repositionable mat of claim 1 wherein the two opposed surface portions of the bottom side are pressured into facing contact with the pressure-sensitive adhesive disposed between them and are releasably held in that position prior to use.
7. The selectively repositionable mat of claim 1 wherein the liquid-absorbing layer and backsheet further comprise fire retardant compositions.
8. The selectively repositionable mat of claim 1 further comprising a cover layer disposed over the liquid-absorbent layer, wherein the cover layer protects and permits the passage of liquid into the liquid-absorbent layer.
9. The selectively repositionable mat of claim 1 wherein the liquid absorbent layer and backsheet are made of materials resistant to degradation when contacted by an absorbed liquid.
10. A method for making a selectively repositionable mat having a liquid-absorbing layer backed by a liquid-impermeable backsheet having a top side, bottom side, and peripheral margins including oppositely disposed, laterally extending side margins each comprising a longitudinally extending V-fold comprising a pressure-sensitive adhesive applied between two opposed surface portions of the bottom side, wherein the V-fold is formed in a high-speed web comprising a plurality of the subject mats joined in end-to-end relation by passing the laterally extending side margins of the backsheet over and around a longitudinally extending folding guide; and wherein the pressure-sensitive adhesive is applied inside the V-fold formed in the moving web.
11. The method of claim 10 wherein the pressure-sensitive adhesive is sprayed through a nozzle disposed in fluid communication with a longitudinally extending applicator rail.
12. The method of claim 10 wherein the pressure-sensitive adhesive is sprayed through a nozzle disposed in fluid communication with the folding guide.
13. The method of claim 11 wherein the folding guide and the applicator rail are substantially parallel.
14. The method of claim 10 wherein the V-fold opens outwardly as the pressure-sensitive adhesive is applied.
15. The method of claim 10 wherein the V-fold opens inwardly as the pressure sensitive adhesive is applied.
16. The method of claim 10 wherein the pressure-sensitive adhesive is applied to a surface inside the V-fold.
17. The method of claim 14 wherein the pressure-sensitive adhesive is applied to a plurality of surfaces disposed inside the V-fold.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The absorbent mats of the invention are further described and explained in relation to the following drawings wherein:
[0016] FIG. 1 is a plan view, partially broken away, of a web comprising plurality of absorbent mats of the invention connected in end-to-end relation and moving longitudinally from left to right, with dashed lines depicting the predetermined cut lines between adjacent mats;
[0017] FIG. 2 is an enlarged detail view of a portion of one of the absorbent mats of FIG. 1, with first and second longitudinal fold lines disposed along each side of the mat;
[0018] FIG. 3 is a transverse cross-sectional elevation view of an absorbent mat of the invention depicting the full width of the backsheet in relation to the width of the mat;
[0019] FIG. 4 is a transverse cross-sectional view of an absorbent mat of the invention as in FIG. 3 but having a longitudinally extending first fold line created by folding the outer edge of the backsheet upwardly and inwardly to create a longitudinally extending, inwardly opening V-fold on each side of the mat;
[0020] FIG. 5 is a transverse cross-sectional view of an absorbent mat of the invention as in FIG. 4 but having a longitudinally extending second fold line created by folding the inwardly lying outer edge of the backing sheet upwardly and outwardly to create a longitudinally extending, outwardly opening V-fold on each side of the mat;
[0021] FIG. 6 is a transverse cross-sectional view of an absorbent mat of the invention as in FIG. 5 wherein the longitudinally extending V-folds on each side of the absorbent mat as described in relation to FIGS. 4 and 5 are pressed downwardly so that the two V-folds on each side cooperate to form a compressed Z-fold in which facing and contacting bottom surface portions of the backsheet are held in place by a layer of selectively releasable, pressure-sensitive adhesive;
[0022] FIG. 7 is simplified diagrammatic view of one illustrative embodiment of a longitudinally extending portion of the backing sheet moving from left to right that is folded back over itself around a stationary folding guide that also dispenses a spray of pressure-sensitive adhesive into the fold, thereby enabling the facing surface portions to be pressed into facing and contacting releasable engagement with each other as shown in FIG. 6 after the backsheet passes the folding guide;
[0023] FIG. 8 is a cross-sectional elevation view taken transversely along line 8-8 of FIG. 7 showing an adhesive spray directed outwardly against the facing surfaces on each side of the fold;
[0024] FIG. 9 is simplified diagrammatic view of another illustrative embodiment of a longitudinally extending portion of the backing sheet moving from left to right that is folded back over itself around a stationary folding guide, together with a separate applicator guide spaced apart from the folding guide that dispenses a spray of pressure-sensitive adhesive into the fold, thereby enabling the facing surface portions to be pressed into facing and contacting releasable engagement with each other as shown in FIG. 6 after the backsheet passes the folding guide and applicator rail;
[0025] FIG. 10 is a cross-sectional elevation view taken transversely along line 10-10 of FIG. 9 showing an adhesive spray directly inwardly against the facing surfaces on each side of the fold;
[0026] FIG. 11 is simplified diagrammatic view of another illustrative embodiment of a longitudinally extending portion of the backsheet moving from left to right that is folded back over itself around a stationary folding guide, together with a separate applicator guide spaced apart from the folding guide that dispenses a spray of pressure-sensitive adhesive into the fold, thereby enabling the facing surface portions to be pressed into facing and contacting releasable engagement with each other as shown in FIG. 6 after the backsheet passes the folding guide and applicator rail;
[0027] FIG. 12 is a cross-sectional elevation view taken transversely along line 12-12 of FIG. 11 showing an adhesive spray directed downwardly against the surface on one side of the fold;
[0028] FIG. 13 is simplified diagrammatic view of another illustrative embodiment of a longitudinally extending portion of the backsheet moving from left to right that is folded back over itself around a stationary folding guide, together with a separate applicator guide spaced apart from the folding guide that dispenses a spray of pressure-sensitive adhesive into the fold, thereby enabling the facing surface portions to be pressed into facing and contacting releasable engagement with each other as shown in FIG. 6 after the backsheet passes the folding guide and applicator rail;
[0029] FIG. 14 is a cross-sectional elevation view taken transversely along line 14-14 of FIG. 13 showing an adhesive spray directed upwardly against the surface on one side of the fold;
[0030] FIG. 15 is a cross-sectional view of an absorbent pad as in FIG. 6, with the Z-fold being pulled open from the outer edges to expand the Z-folds and expose the releasable pressure-sensitive adhesive disposed inside the outwardly opening V-fold on each side of the absorbent mat prior to use in sticking the outer portions of the bottom surface of the backsheet to an underlying support surface;
[0031] FIG. 16 is a cross-sectional view of the absorbent mat of FIG. 15 with the Z-folds fully extended on both sides of the absorbent mat and with the pressure-sensitive adhesive being pressed downwardly onto an underlying support surface to hold the mat in place;
[0032] FIG. 17 is an alternate embodiment of the absorbent mat of the invention in which the outside edges of the backsheet are folded downward around a longitudinally extending folding guide and into facing relation to the bottom surface of the backsheet to form a single, longitudinally extending, inwardly opening V-fold on each side of the backsheet into which selectively releasable, pressure-sensitive adhesive is sprayed;
[0033] FIG. 18 shows the absorbent mat of FIG. 17 with the resultant fold being pressed together and closed against the bottom of the backsheet on each side edge of the pad for packaging, shipping and storage, with arrows 130, 132 indicating the direct in which the mat edges are unfolded to the position shown in FIG. 19; and
[0034] FIG. 19 shows the mat of FIG. 18 with the folds on each side edge being reopened prior to use by grasping the outside edges of the backing sheet and pulling them laterally outward to expose the pressure-sensitive adhesive for use in releasably attaching the bottom surface of the pad to an underlying support surface.
[0035] When examining the accompanying drawings, it should be appreciated that the drawing figures are created for illustrative purposes and are simplified and not drawn to scale, so that relative sizes and proportions of various components and structural features of the invention can vary substantially from those depicted while still remaining within the scope of the invention as defined by the appended claims.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] FIGS. 1 and 2 depict a continuous web 20 comprising a plurality of mats 24, 26 disposed in end-to-end relation and moving from left to right as indicated by arrow 22. Dashed cut lines 28, 30, 32 are depicted between successive pairs of mats, with cut line 30 being disposed between mats 25, 27. Cut lines 28, 30, 32 can be real or virtual, depending upon the method used to separate the pads prior to packaging. Such cut lines can be scored to facilitate subsequent mechanical separation, or separation can be achieved using a rotating blade, hot wire, or other conventionally known means. Web 20 desirably moves at a relatively high rate of speed, such as 600 feet per minute or more, and can be supported on or between moving belts, rollers, or the like (not shown) as needed to perform the various operational steps needed to produce such mats 24, 26.
[0037] Each mat 24, 26 further comprises a liquid-absorbing portion 25, 27 that is supported on and attached to backsheet 35. Backsheet 35 is desirably a thin, flexible, liquid-impermeable polymeric sheet or film made from an extrudable polymer such as polyethylene or polypropylene, or from another polymer, copolymer or terpolymer chosen for making mats intended for particular uses or applications. Liquid-absorbing portion 25, 27 can comprise one or more layers of the same or different materials selected for their collective ability to receive liquid deposited on the exposed surface during use and then retain the liquid inside mat 24, 26 until it dries or until the mat is removed. Depending upon the structure and composition of liquid-absorbing portion 25, 27 of mats 24, 26, liquid can be captured inside a hydrophilic gel, wicked away from the surface toward backsheet 35, or otherwise channeled and distributed throughout the mats. Liquid-absorbing portion 25, 27 can be applied to backsheet 35 by known deposition or buildup methods, and as shown in FIGS. 1-2, can be covered by a woven or porous protective layer that will permit the passage of liquids into the absorbent material but will also protect the absorbent layer from being ripped or torn, such as by animal claws, during use.
[0038] Referring to FIG. 2, mat 24 disposed between cut lines 28, 30 of web 20 desirably further comprises longitudinally extending lateral side edges 34, 38 of backsheet 35, and longitudinally extending fold lines 36, 40. Fold lines 36, 40 are disposed inwardly of side edges 34, 38 and between side edges 34, 38 and liquid absorbing portion 25 of mat 25. Referring to FIG. 6, a cross-sectional elevation view is depicted that is taken along line 6-6 of FIG. 2. FIG. 6 better illustrates that mat 24 desirably comprises liquid-absorbing layer 25 centrally disposed upon an upwardly facing surface of polymeric backsheet 35. Liquid-absorbing layer 25 satisfactorily further comprises one or more absorbent materials 44 selected from cellulosic fluff, super-absorbing polymer, or other known fibrous or granular components or materials, used alone or in combination, that are generally known to be effective absorbents of liquids of the type intended for a particular intended application for mat 24. Protective cover 42 is desirably a thin netting or porous material as previously discussed that will readily permit the passage of liquids into absorbent materials 44 while holding absorbent materials 44 in place on backsheet 35. Protective cover 42 is desirably held in place over absorbent materials 44 by an adhesive material (not shown) that is sprayed or otherwise applied to the upwardly facing surface of backsheet 35.
[0039] Referring again to FIG. 6, a Z-fold is depicted on each of the laterally disposed sides of backsheet 35 beyond the side edges of liquid-absorbing layer 25. As depicted, each Z-fold is formed on the upwardly facing surface of backsheet 35. The detailed structure and method of forming each Z-fold is further described in relation to FIGS. 3-5 and 15-16 of the drawings.
[0040] Referring first to FIG. 3, mat 24 as previously described is depicted with the full width of backsheet 35 shown laterally in one plane, with outside edges of backsheet 35 extending well beyond the side edges of liquid-absorbing layer 25. In FIG. 4, the opposed, laterally extending side edges 34, 38 of backsheet 35 are folded upwardly and inwardly toward the upwardly facing surface of backsheet 35 as indicated by arrows 50, 52, respectively, causing the upwardly facing surface of backsheet 35 to be folded over itself and creating a first longitudinally extending fold line 46, 48 on each side of mat 24. In FIG. 5, laterally extending side edges 34, 38 of backsheet 35 are refolded back to the outside of mat 24 as indicated by arrows 54, 56, thereby creating a V-fold that opens outwardly on each lateral side of mat 24 around second longitudinally extending fold lines 36, 40, respectively. Taken in combination, the initial folds made to create fold lines 46, 48, together with the outwardly opening V-folds made by refolding side edges 34, 38 outwardly to create second fold lines 36, 40, a Z-fold is thereby created on the upwardly facing side of backsheet 35. Upon completion of the second (reverse) fold, mat 24 has the configuration shown in FIG. 6.
[0041] In accordance with the present invention, with reference to FIG. 5, a selectively releasable pressure-sensitive adhesive is desirably applied at least between facing opposed surface portions 82 and 86 (which are also part of the downwardly facing surface of backsheet 35 as depicted in FIG. 3) before completing the fold to the position shown in FIG. 6. The presence of pressure-sensitive adhesive inside the V-folds opening outwardly around second fold lines 36, 40 is seen in FIG. 15, as discussed below in relation to subsequent opening of that fold prior to installation of mat 24.
[0042] A satisfactory method for depositing a selectively releasable pressure-sensitive adhesive inside a V-fold in backsheet 35 is further described in relation to the simplified diagrammatic representations depicted in FIGS. 7-14. It should be understood that the portion of backsheet 35 depicted in FIGS. 7-14 is a longitudinally extending segment taken from the right side of the full-width web of backsheet 35 and is moving continuously from left to right as indicated by arrows 22, with the right edge 38 of backsheet 35 refolded outwardly to create second longitudinally extending fold line 40.
[0043] FIGS. 7 and 8 disclose a method of the invention whereby backsheet 35 is folded around longitudinally extending folding guide 60 that remains stationary relative to moving backsheet 35 and also comprises a fluid flow channel and nozzle from which a selectively releasable pressure-sensitive adhesive is sprayed outwardly onto opposed surface portions 84, 88 that are also shown in FIGS. 4-6. A satisfactory spray pattern 72 is shown in FIGS. 7 and 8, although other similarly effective spray patterns or non-spraying methods of depositing pressure-sensitive adhesive inside the V-fold can also be used within the scope of the invention. It is apparent from FIGS. 4-6 and 8 that surface portions 84, 88 are both part of the underside (downwardly facing surface) of backsheet 35.
[0044] FIGS. 9 and 10 disclose another embodiment of a satisfactory method of the invention whereby backsheet 35 is folded around longitudinally extending, stationary (although adjustable) folding guide 64 to form longitudinally extending fold line 40 as previously described. In this embodiment, however, a separate applicator rail 62 is provided that is disposed in spaced-apart relation to folding guide 64 and is also stationary relative to the moving backsheet 35 and comprises a fluid flow channel and nozzle from which a selectively releasable pressure-sensitive adhesive is sprayed inwardly onto surface portions 84, 88 of backsheet 35. A satisfactory spray pattern 74 is shown in FIGS. 9 and 10, although other similarly effective spray patterns or non-spraying methods of depositing pressure-sensitive adhesive inside the V-fold can also be used within the scope of the invention.
[0045] FIGS. 11 and 12 disclose another embodiment of a satisfactory method of the invention whereby backsheet 35 is folded around longitudinally extending, stationary (although adjustable) folding guide 64 to form longitudinally extending fold line 40 as previously described. In this embodiment, however, a separate applicator rail 62 is provided that is disposed in spaced-apart relation to folding guide 64 and is also stationary relative to the moving backsheet 35 and comprises a fluid flow channel and nozzle from which a selectively releasable pressure-sensitive adhesive is sprayed downwardly onto surface portion 88 of backsheet 35. A satisfactory spray pattern 76 is shown in FIGS. 11 and 12, although other similarly effective spray patterns or non-spraying methods of depositing pressure-sensitive adhesive inside the V-fold can also be used within the scope of the invention.
[0046] FIGS. 13 and 14 disclose another embodiment of a satisfactory method of the invention whereby backsheet 35 is folded around longitudinally extending, stationary (although adjustable) folding guide 64 to form longitudinally extending fold line 40 as previously described. In this embodiment, however, a separate applicator rail 62 is provided that is disposed in spaced-apart relation to folding guide 64 and is also stationary relative to the moving backsheet 35 and comprises a fluid flow channel and nozzle from which a selectively releasable pressure-sensitive adhesive is sprayed upwardly onto surface portion 84 of backsheet 35. A satisfactory spray pattern 78 is shown in FIGS. 13 and 14, although other similarly effective spray patterns or non-spraying methods of depositing pressure-sensitive adhesive inside the V-fold can also be used within the scope of the invention.
[0047] Referring again to FIG. 6, because the selectively releasable, pressure-sensitive adhesive is disposed inside a V-fold of mat 24 of the invention, no pressure-sensitive adhesive is exposed, and no separate release strip or cover member is needed to protect the adhesive during the remainder of the manufacturing and packaging process during which web 20 (FIGS. 1-2) is separated into individual mats that are folded and packaged for shipment, storage or distribution, and sale prior to being unpackaged for use by a consumer.
[0048] Referring next to FIGS. 15-16, when mat 24 is ready for use, the V-folds on each side of mat 24 are desirably opened by pulling edges 34, 38 of backsheet 35 upwardly and outwardly as indicated by arrows 90, 92 and 94, 96, respectively, to open the outwardly facing V-folds. Although not clearly depicted in the drawings, side edges 34, 38 will desirably overhang first longitudinally extending fold lines 46, 48, respectively, so that side edges 34, 38 can be readily grasped by the user to overpressure the adhesion and cohesion of pressure-sensitive adhesive 98 to open the folds. No other peeling or removal of release strips or covers is required as is the case with other conventional mats or pads. Once the folds are pulled fully open, as shown in FIG. 16, pressure-sensitive adhesive 98 faces downwardly on the underside of mat 24, permitting mat 24 to be releasably secured in a non-skid position to support surface 100. Mat 24 can then remain in place until such time as repositioning or removal for disposal is required.
[0049] When repositioning or removal of mat 24 is required, it is again helpful if a graspable portion of the outside edges 34, 38 of backsheet 35 is provided for use in lifting mat 24 away from support surface 100 to pull the pressure-sensitive adhesive 98 away from the support surface. This is most easily done by lifting mat 24 from one side at a time and rolling or folding the respective side edge inwardly toward the center of mat 24 so that any debris lying on the surface of mat 24 is captured inside the roll or fold.
[0050] Another embodiment of the invention is disclosed in relation to FIGS. 17-19. In this embodiment, Mat 110 comprises a liquid-absorbing layer 118 disposed on backsheet 112 having oppositely disposed, outside edges 114, 116. A pressure-sensitive adhesive as previously described is deposited inside a single V-fold made around oppositely disposed, longitudinally extending fold lines 123, 125 by folding side edges 114, 116 downwardly as indicated by arrows 120, 122, respectively, to form a single, inwardly facing V-fold on the underside of backsheet 112 as shown in FIG. 18. Referring again to FIG. 17, a longitudinally extending folding guide 124 is provided that also comprises a fluid flow path through which a spray 128 of pressure-sensitive adhesive is applied to the facing surfaces inside the fold. Following packaging, shipping, storage and sale, mat 110 is desirably removed from its packaging and unfolded to the position shown in FIG. 18, after which a user desirably grasps outside edges 114, 116 of backsheet 112 and opens the V-fold on each side of the downwardly facing surface of backsheet 112 as indicated by arrows 130, 132 to expand the folds to the use position as seen in FIG. 19. Referring to FIG. 19, mat 110 is desirably installed by pressing downwardly on downwardly facing pressure-sensitive adhesive strips 135 as indicated by arrows 138, 140 to releasably secure mat 110 to support surface 136 pending repositioning or disposal as previously described above.
[0051] Other alterations and modifications of the invention will likewise become apparent to those of ordinary skill in the art upon reading this specification in view of the accompanying drawings, and it is intended that the scope of the invention disclosed herein be limited only by the broadest interpretation of the appended claims to which the inventors and/or Applicant are legally entitled.
