NON-SLIP CUTTING MAT AND METHOD OF FORMATION

Abstract

A polymeric non-slip cutting mat that includes an integral layup forming a body and having a base layer of a polymeric material, at least one print layer of a polymeric material with a friction-inducing characteristic and decorative indicia disposed thereon, and a bonding print layer having a polymeric bonding agent and interposed between the base layer and the at least one print layer with the decorative indicia disposed thereon.

Claims

1. A non-slip cutting mat assembly comprising: an integral layup forming a body with an upper surface and a lower surface opposing the upper surface of the body, the integral layup having: a base layer of a polymeric material and defining the upper surface of the body; at least one print layer of a polymeric material, with decorative indicia disposed thereon, and defining the lower surface of the body, the polymeric material having a friction-inducing characteristic; and a bonding print layer having a polymeric bonding agent and interposed between the base layer and the at least one print layer with the decorative indicia disposed thereon.

2. The non-slip cutting mat assembly according to claim 1, wherein: the base layer is of a polypropylene material and the base layer defines an outer perimeter of the body.

3. The non-slip cutting mat assembly according to claim 1, wherein: the polymeric material of the least one print layer is of a silicone rubber material.

4. The non-slip cutting mat assembly according to claim 1, wherein: the decorative indica makes up at least 50% of an area defined by an outer perimeter of the body.

5. The non-slip cutting mat assembly according to claim 1, wherein: the body is flexible and operably configured to repeatedly bend in an overlapping relationship with itself without plastic deformation.

6. The non-slip cutting mat assembly according to claim 1, wherein the body further comprises: a body thickness separating the upper surface of the body and the lower surface of the body, the body thickness less than approximately 2 cm.

7. The non-slip cutting mat assembly according to claim 1, wherein: the base layer is of a transparent material over an area defined by an outer perimeter of the body.

8. A method of forming a non-slip cutting mat comprising the steps of: providing a substrate forming a base layer of a polymeric material and defining an upper surface of a body of an integral layup; applying a polymeric bonding agent to the base layer to form an integral layup; curing the integral layup at a temperature and for a period of time sufficient to cure the integral layup without plastic deformation; applying at least one print layer of a polymeric material, with decorative indicia disposed thereon, on the integral layup, the at least one print layer defining a lower surface of the body of the integral layup and the polymeric material having a friction-inducing characteristic; and curing the integral layup at a temperature and for a period of time sufficient to cure the integral layup without plastic deformation.

9. The method of forming a non-slip cutting mat according to claim 8, wherein: the integral layup is cured at a temperature ranging between 100° F. and 180° F.

10. The method of forming a non-slip cutting mat according to claim 8, wherein: the integral layup is cured for a period of time ranging between 5 minutes and 72 hours.

11. The method of forming a non-slip cutting mat according to claim 8, wherein: the integral layup is cured after the application of every at least one print layer of a polymeric material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and explain various principles and advantages all in accordance with the present invention.

[0016] FIG. 1 is a perspective view image of a non-slip cutting mat assembly, in accordance with one embodiment of the present invention;

[0017] FIG. 2 is an exemplary schematic diagram depicting a preferred layup of the non-slip cutting mat assembly shown in FIG. 1;

[0018] FIG. 3 is a perspective view of several exemplary embodiments of the non-slip cutting mat assembly shown in FIG. 1;

[0019] FIG. 4 is a block diagram of a method of formation of a non-slip cutting mat, in accordance with the present invention; and

[0020] FIG. 5 is a schematic diagram depicting a preferred layup of the non-slip cutting mat assembly, in accordance with the present invention.

DETAILED DESCRIPTION

[0021] While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward. It is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms.

[0022] The present invention provides a novel non-slip cutting mat assembly 100, hereafter “the cutting mat assembly 100”, and method of formation. Embodiments of the invention provide the cutting mat assembly 100, as best seen in FIGS. 1-2, include an integral layup 200 forming a body 102, wherein the body has multiple layers enabling a cutting mat that is both functional, safe, and ornamental. The body includes an upper surface 104, for cutting by the user, and a lower friction-inducing surface 106, for supporting the mat on a support surface. The lower surface can be seen opposing the upper surface of the body.

[0023] In one embodiment, the body can be seen having a base layer 202 of a polypropylene or other thermoplastic polymer composition, at least one print layer 206a-n of a polymeric material and with decorative indicia disposed thereon (wherein “n” represents any number greater than 1), and a bonding print layer 204 having a polymeric bonding agent and interposed between the base layer 202 and the at least one print layer 206a-n with the decorative indicia disposed thereon.

[0024] The print layer forming the lower surface is positioned, when desired for use, facing downward and is of or forms a friction-inducing material or gripping surface that has non-slip characteristics. The base layer 104 forming the upper surface of the body is positioned facing upward when in use and may be comprised of a polypropylene or other thermoplastic polymer composition.

[0025] FIG. 2 provides a more detailed breakdown of the layers of the cutting mat assembly 100. A base layer 202 is comprised of a polypropylene or other thermoplastic polymer composition operably configured to be cut repeatedly with sharp objects, under forces ranging up to approximately 100 lbf, without completely penetrating the base layer thickness. When in use, the base layer 202 faces upward toward the user and functions as the cutting surface for dicing of produce and various other foodstuffs. An exemplary body 102 thickness range separating the upper surface 104 of the body 102 and the lower surface 106 of the body 102 is approximately between 0.1 millimeters and 2.0 centimeters. This exemplary thickness range provides for flexibility of the cutting mat assembly 100 in that it is operably configured to be bent repeatedly without plastic or permanent deformation. In preferred embodiments, the body 102 is flexible and operably configured to repeatedly bend at least 100 times in an overlapping relationship with itself without plastic deformation, wherein plastic deformation is defined as the permanent distortion that occurs when a material is subjected to tensile, compressive, bending, or torsion stresses that exceed its yield strength and cause it to elongate, compress, buckle, bend, or twist. A thickness greater than 2.0 centimeters may be characterized as a cutting board, as opposed to a cutting mat, but would nevertheless fall within the scope of the present invention, unless specifically limited, as the characterization may be merely one of semantics. Deviations in thickness falling outside the exemplary thickness range will affect the degree of flexibility of the cutting mat assembly 100. The cutting mat assembly 100 may comprise any level of thickness while retaining the slip-resistant and transparent features of the present invention. To that end, the coupling and formation techniques described herein may also be applicable to a more rigid first layer more akin to that of a cutting board. In preferred embodiments, the base layer 202 defines an outer perimeter 108 of the body 102.

[0026] In preferred embodiments of the present invention, the base layer 202 is of a sheet-cut composition. In other embodiments, the base layer 202 may be comprised of a mold or outline with injected polypropylene or other thermoplastic polymer composition filling the voids therein. The general shape, form, or outline of the base layer 202 and the cutting mat assembly 100 may vary in accordance with the desired customization of the Inventor.

[0027] In an exemplary embodiment, the base layer 202 is of a transparent or translucent material over an area defined by the outer perimeter 108 of the body 102 such that when the cutting mat assembly 100 is in use, the decorative indicia on the at least one print layer 206a-n remains visible to users. The base layer 202 may be nontransparent or opaque in other embodiments, wherein the decorative indicia on the at least one print layer 206a-n are only visible when the cutting mat assembly 100 is turned over.

[0028] The cutting mat assembly 100 further comprises a bonding print layer 204 having a polymeric bonding agent and interposed between the base layer 202 and the at least one print layer 206a-n with the decorative indicia disposed thereon. The polymeric bonding agent is designed to permanently bond silicone or other types of rubber to poly materials such as, by way of example and without limitation, polypropylene. In preferred embodiments, the bonding print layer 204 is substantially comprised of a polysiloxane composition, generally known as silicone, or another substantially equivalent material. The bonding print layer 204 may span the entire area of the base layer 202 and the at least one print layer 206a-n or may be less than the area. The area may be defined by the perimeter 108 of the base layer 202 or the at least one print layer 206a-n. The at least one print layer 206a-n are thereafter laid on top of the bonding print layer 204. All layers may be coupled together to be integral, i.e., permanent or semi-permanent and requiring a sufficient external force to separate prematurely. In one embodiment, this integral formation may be done through a curing polymerization process whereby a specific high temperature and pressure is applied to the body 102 for a certain period of time, causing all layers to become coupled but falling short of deforming the layers, e.g., of curling, warping, sinking, or shrinking the layers. The length and temperature of the curing processes varies depending on the thickness of the material or substrate used for the base layer 202, the at least one print layer 206a-n, and the bonding print layer 204, and the viscosity and Shore Hardness Value (“SHV”) of the at least one print layer 206a-n and the bonding print layer 204. Generally, a greater thickness, viscosity, or SHV increases the length of time the integral layup 200 must be cured and the temperature at which the integral layup 200 must be cured. The curing time and temperature must be closely monitored and controlled to avoid plastic deformation of the integral layup 200, e.g., curling or warping. In preferred embodiments, the formation of the body may be through a screen-printing process known by those of skill in the art. See, e.g., Machita et al., U.S. Pat. No. 4,981,074; Baele, U.S. Patent Application Publication No. 2003/0021886; Amao et al., U.S. Pat. No. 4,864,361, the entirety of which is incorporated herein by reference.

[0029] The at least one print layer 206a-n is of a polymeric material having a friction-inducing characteristic designed to prevent the cutting mat assembly 100 from substantially moving when in use. In exemplary embodiments, the polymeric material of the least one print layer 206a-n is of a silicone rubber material, or another substantially equivalent material, having a coefficient of friction ranging approximately from 0.5 to more than 1, e.g., 1.5. Lower durometers will have higher coefficients. The texture of the at least one print layer 206a-n may be varied to increase or modify the co-efficient of friction accordingly.

[0030] The bonding layer 204 and the at least one print layer 206a-n may have an SHV ranging from SHV A 30 up to, and not exceeding, SHV A 80. The specific SHV of each layer depends on the level required to achieve the desired nonslip quality of the cutting mat assembly 100 and on the level required to achieve adequate resistance to abrasion. The bonding layer 204 and the at least one print layer 206a-n may fall within a varied numerical SHV range where a different SHV grade is utilized or applied thereto.

[0031] The bonding print layer 204 and the at least one print layer 206a-n may each have an exemplary thickness range approximately between 0.05 millimeters and 1.0 millimeters. This exemplary thickness range provides for flexibility of the cutting mat assembly 100 in that it is operably configured to be bent repeatedly without plastic or permanent deformation. In other embodiments of the present invention, the bonding print layer 204 and the at least one print layer 206a-n may have thicknesses falling below or above this exemplary thickness range. Deviations in thickness falling outside the exemplary thickness range will affect the degree of flexibility of the cutting mat assembly 100.

[0032] As best seen in the block diagram of FIG. 3, the specific decorative indicia disposed on the at least one print layer 206a-n may be a color, design element, picture, logo, wording, etc., or a plurality or combination of any or all the foregoing. The decorative indicia may be selectively varied and customized during the screen-printing process to suit the taste of the user or manufacturer. In one embodiment, a solid design layer 302 may feature one single solid color characterizing the principal design characteristics. In an alternate embodiment, a pattern design layer 304 may feature a customized pattern or design characterizing the principal design characteristics. The solid design layer 302 and the pattern design layer 304 may each comprise functional prints intended to perform a function, aesthetic prints intended to appeal to the aesthetic taste of users, or both. In one embodiment, the decorative indica makes up at least 50% of an area defined by the outer perimeter 108 of the body 102.

[0033] The present invention further provides a novel method 400 for the formation of a non-slip cutting mat assembly 100. As referenced in the block diagram of FIG. 4, the method 400 comprises a sequence of consecutive steps for combining and curing a variety of layers to form the integral layup 200 designed to be used as a cutting surface. The method 400 begins with Steps 401 and 402, whereby Step 402 entails providing a substrate forming the base layer 202 of a polymeric material and defining the upper surface 104 of the body 102 of the integral layup 200. Step 403 comprises applying the polymeric bonding agent to the base layer 202 to form the integral layup 200. The polymeric bonding agent is designed to permanently bond silicone or other types of rubber to poly materials such as, by way of example and without limitation, polypropylene.

[0034] A further Step 404 further comprises curing the integral layup 200 at a temperature and for a period of time sufficient to cure the integral layup 200 without plastic deformation of the integral layup 200. Curing causes all layers to become coupled without deforming the layers, e.g., of curling, warping, sinking, or shrinking the layers. The length and temperature of the curing process varies depending on the thickness of the material or substrate used for each of the layers, and the viscosity and SHV of the layers. In an exemplary embodiment, the integral layup 200 is cured at an optimum temperature ranging between 100° F. and 180° F. and for a period of time ranging between 5 minutes and 72 hours. Step 405 entails applying the at least one print layer 206a-n of a polymeric material, with decorative indicia disposed thereon, on the integral layup 200, the at least one print layer 206a-n defining the lower surface 106 of the body 102 of the integral layup 200 and the polymeric material having a friction-inducing characteristic. In exemplary embodiments, the polymeric material of the least one print layer 206a-n is of a silicone rubber material having a coefficient of friction ranging approximately from 0.5 to more than 1, e.g., 1.5. Lower durometers will have higher coefficients. The texture of the at least one print layer 206a-n may be varied to increase or modify the co-efficient of friction accordingly.

[0035] Step 406 comprises curing the integral layup 200 at a temperature and for a period of time sufficient to cure the integral layup 200 without plastic deformation of the integral layup 200. Curing causes all layers to become coupled without deforming the layers, e.g., of curling, warping, sinking, or shrinking the layers. The length and temperature of the curing process varies depending on the thickness of the material or substrate used for each of the layers, and the viscosity and SHV of the layers. In an exemplary embodiment, the integral layup 200 is cured at an optimum temperature ranging between 100° F. and 180° F. and for a period of time ranging between 5 minutes and 72 hours. Where multiple print layers 206a-n are applied, the integral layup 200 may be cured once after the application of all the print layers 206a-n on the integral layup 200 or after the application of each print layer 206a-n on the integral layup 200.

[0036] FIG. 5 provides a schematic diagram depicting a preferred layup of the non-slip cutting mat assembly 100 and, specifically, depicting the integral layup 200, the base layer 202, the bonding print layer 204, and the at least one print layer 206a.