WARNING DOME DEVICE AND MANUFACTURE METHOD THEREOF

Abstract

A patterned warning mat according to the present disclosure having a base and a plurality of domes and patterns formed on the base. The warning mat is obtained by a process comprising the steps of providing an open-face mold having a plurality of textures and a plurality of dome indentations, preparing a liquid mixture capable of solidifying, pouring the mixture over the open-face mold, and allowing the mixture to solidify and form the warning mat. The domes and patterns on the warning mat respectively correspond to the dome indentations and textures of the open-face mold.

Claims

1. A method of producing a patterned warning mat configured to be placed on walkways, crosswalks, and other areas of pedestrian traffic for providing direction and warning to visually handicapped persons, the method comprising: a) providing an open-face mold having a plurality of textures and a plurality of dome indentations; b) preparing a liquid mixture capable of solidifying and chemical reaction; c) pouring the mixture over the open face open-face mold; and d) allowing the mixture to solidify and form the warning mat having: i. a base; ii. a plurality of dome formed on the base and corresponding to the dome indentations; and iii. a plurality of patterns formed on the base and corresponding to the textures of the open-face mold.

2. The method of producing a patterned warning mat of claim 1, further comprising providing an open-face mold having at least the first textures and the second textures, wherein the warning mat further includes: a plurality of first patterns corresponding to the first textures of the open-face mold; and a plurality of second patterns corresponding to the second textures of the open-face mold.

3. The method of producing a patterned warning mat of claim 1, further comprising: providing a mesh layer having a plurality of pores; laying out a mesh layer on the mixture in order for the mixture to pass through the mesh layer; immersing or saturating the mesh layer with the mixture in a liquid state; and allowing the mixture to solidify and form the warning mat further having the mesh layer in the base.

4. The method of producing a patterned warning mat of claim 1, further comprising: providing a mesh layer having a plurality of pores; laying out a mesh layer on the open-face mold, wherein the mesh layer includes a plurality of pores; pouring the mixture over the mesh layer, wherein the mixture passes through the pores of the mesh layer and accumulates on the textures of the open-face mold; immersing or saturating the mesh layer with the mixture in a liquid state; and allowing the mixture to solidify and form the warning mat further having the mesh layer in the base.

5. The method of producing a patterned warning mat of claim 1, wherein the step of preparing the mixture includes: mixing cement, resin, and bonding agents to form the mixture; and adding a color pigment to the mixture.

6. The method of producing a patterned warning mat of claim 1, further comprising: removing the warning mat from the open-face mold; and coloring the warning mat with a color pigment having a desired color, wherein the step of preparing the mixture includes mixing cement, resin, and bonding agents to form the mixture.

7. The method of producing a patterned warning mat of claim 1, wherein the step of preparing a mixture includes selectively making a polymer mixture or an acrylic mixture.

8. A patterned warning mat, configured to be placed on walkways, crosswalks, and other areas of pedestrian traffic for providing direction and warning to visually handicapped persons, obtained by a process comprising the steps of: a) providing an open-face mold having a plurality of textures and a plurality of dome indentations; b) preparing a liquid mixture capable of solidifying; c) pouring the mixture over the open-face mold; and d) allowing the mixture to solidify and form the warning mat having: i. a base; ii. a plurality of dome formed on the base and corresponding to the dome indentations; and iii. a plurality of patterns formed on the base and corresponding to the textures of the open-face mold.

9. The patterned warning mat obtained by the process of claim 8, wherein the process further includes providing an open-face mold having at least the first textures and the second textures, wherein the warning mat further includes: a plurality of first patterns formed on the base and corresponding to the first textures of the open-face mold; and a plurality of second patterns formed on the base and corresponding to the second textures of the open-face mold.

10. The patterned warning mat obtained by the process of claim 8, wherein the process further includes: providing a mesh layer having a plurality of pores; laying out a mesh layer on the mixture in order for the mixture to pass through the mesh layer and the mesh layer to be at least partially immersed in the mixture; and immersing or saturating the mesh layer with the mixture in a liquid state; and allowing the mixture to solidify and form the warning mat further having the mesh layer in the base.

11. The patterned warning mat obtained by the process of claim 8, wherein the process further includes: providing a mesh layer having a plurality of pores; laying out a mesh layer on the open-face mold, wherein the mesh layer includes a plurality of pores; pouring the mixture over the mesh layer, wherein the mixture passes through the pores of the mesh layer and accumulates on the textures of the open-face mold; immersing or saturating the mesh layer with the mixture in a liquid state; and allowing the mixture to solidify and form the warning mat further having the mesh layer in the base.

12. The patterned warning mat obtained by the process of claim 8, wherein the step of preparing the mixture includes: mixing cement, resin, and bonding agents to form the mixture; and adding a color pigment to the mixture.

13. The patterned warning mat obtained by the process of claim 8, wherein the process further includes: removing the warning mat from the open-face mold; and coloring the warning mat with a color pigment having a desired color, wherein the step of preparing the mixture includes mixing cement, resin, and bonding agents to form the mixture.

14. The patterned warning mat obtained by the process of claim 8, wherein the step of preparing a mixture includes selectively making a polymer mixture or an acrylic mixture.

15. A patterned warning mat, configured to be placed on walkways, crosswalks, and other areas of pedestrian traffic for providing direction and warning to visually handicapped persons, obtained by a process comprising the steps of: a) providing an open-face mold having a plurality of textures and a plurality of dome indentations; b) preparing a liquid mixture capable of solidifying, wherein a chemical reaction within the liquid mixture causes a temperature of the liquid mixture to be higher than a room temperature; c) pouring the mixture over the open-face mold; d) immersing or saturating a mesh layer in the mixture before solidification occurs; and e) allowing the mixture to solidify and form the warning mat having: i. a base; ii. a plurality of dome formed on the base and corresponding to the dome indentations; and iii. a plurality of patterns formed on the base and corresponding to the textures of the mold; and iv. the mesh layer immersed in the base.

16. The patterned warning mat obtained by the process of claim 15, wherein the step of immersing the mesh layer with the mixture includes: providing a mesh layer having a plurality of pores; laying out a mesh layer on the mixture in order for the mixture to pass through the mesh layer and the mesh layer to be at least partially immersed in the mixture; immersing or saturating the mesh layer with the mixture in a liquid state; and allowing the mixture to solidify and form the warning mat further having the mesh layer immersed in the base.

17. The patterned warning mat obtained by the process of claim 15, wherein the step of immersing the mesh layer with the mixture includes: laying out a mesh layer on the open-face mold, wherein the mesh layer includes a plurality of pores; and pouring the mixture over the mesh layer, wherein the mixture passes through the pores of the mesh layer and accumulates on the textures of the open-face mold; immersing or saturating the mesh layer with the mixture in a liquid state; and allowing the mixture to solidify and form the warning mat further having the mesh layer immersed in the base.

18. The patterned warning mat obtained by the process of claim 15, wherein the process further includes making an open-face mold having at least the first textures and the second textures, wherein the warning mat further includes: providing a mesh layer having a plurality of pores; a plurality of first patterns formed on the base and corresponding to the first textures of the open-face mold; a plurality of second patterns formed on the base and corresponding to the second textures of the open-face mold; immersing or saturating the mesh layer with the mixture in a liquid state; and allowing the mixture to solidify and form the warning mat further having the mesh layer in the base.

19. The patterned warning mat obtained by the process of claim 15, wherein the step of preparing the mixture includes: mixing cement, resin, and bonding agents to form the mixture; and adding a color pigment to the mixture.

20. The patterned warning mat obtained by the process of claim 15, wherein the process further includes: removing the warning mat from the open-face mold; and coloring the warning mat with a color pigment having a desired color, wherein the step of preparing the mixture includes mixing cement, resin, and bonding agents to form the mixture.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Non-limiting and non-exhaustive embodiments of the present disclosure are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various figures unless otherwise specified.

[0007] FIG. 1 illustrates a top view of an open-face mold according to one embodiment of the present disclosure.

[0008] FIG. 2 is an enlarged top view of the open-face mold according to the embodiment of the present disclosure illustrated in FIG. 1.

[0009] FIG. 3 is an enlarged top view of the open-face mold according to another embodiment of the present disclosure.

[0010] FIG. 4 is a perspective view of the mesh layer with liquid mixture poured thereon, according to one embodiment of the present disclosure.

[0011] FIG. 5 is a perspective view of the mesh layer with colored liquid mixture poured thereon, according to one embodiment of the present disclosure.

[0012] FIG. 6-7 are perspective view and enlarged perspective view of the textured warning mat according to one embodiment of the present disclosure.

[0013] FIGS. 8-9 are top view and perspective view of the textured warning mat according to another embodiment of the present disclosure.

[0014] FIG. 10 is a flow chart of the method of manufacturing a patterned warning mat according to one embodiment of the present disclosure.

[0015] FIG. 11 is a flow chart of the method of manufacturing a patterned warning mat according to another embodiment of the present disclosure.

DETAILED DESCRIPTION

[0016] The embodiment and various embodiments can now be better understood by turning to the following detailed description of the embodiments, which are presented as illustrated examples of the embodiments defined in the claims. It is expressly understood that the embodiments as defined by the claims may be broader than the illustrated embodiments described below. Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the embodiments.

[0017] The present disclosure relates to a textured warning mat having domes and configured to be placed on walkways, crosswalks, and other areas of pedestrian traffic for providing direction and warning to visually handicapped persons. The present disclosure also relates to a method of manufacturing said textured warning dome mat.

[0018] FIG. 1 illustrates a perspective view of an open-face mold 100 according to one embodiment of the present disclosure. FIG. 2 is an enlarged top view of the open-face mold 100. As illustrated in FIGS. 1 and 2, the open-face mold 100 includes first textures 110 and second textures 120 distributed over the surface of the open-face mold 100. The purpose of the first textures 110 and second textures 120 is to accommodate and contain liquid mixture poured over the open-face mold 100, so that once the liquid mixture solidifies its surface will have patterns corresponding to the shapes of the first textures 110 and the second textures 120.

[0019] The first texture 110 of the present embodiment is a sunken half-sphere space with a plurality of tiny openings in the middle. In the present embodiment, the first texture 110 is formed by first drilling a few openings on a metal sheet and then pressing or punching on the metal sheet to form the sunken half-sphere space. However, in different embodiments, the first texture 110 can be formed as part of a plastic open-face mold made using injection open-face molding method or other plastic open-face molding methods. On the other hand, the second texture 120 of the present embodiment is formed by a plurality of tiny openings distributed in substantially a diamond shape. The second texture 120 can be formed by drilling specific number of openings in a diamond shape. In other embodiments, the second texture 120 can be formed as part of a plastic open-face mold using injection open-face molding method or other plastic open-face molding methods.

[0020] Further, as illustrated in FIG. 2, the second texture 120 is located between four adjacent first textures 110. Similarly, the first texture 110 is located between four adjacent second textures 120.

[0021] Further, in the present embodiment, the open-face mold 100 is made of metal. However, in different embodiments, the open-face mold 100 can be made of plastics using injection open-face molding method or other suitable methods known in the art to have the shape and textures illustrated in FIGS. 1 and 2.

[0022] FIG. 3 illustrates an enlarged top view of an open-face mold 100 according to another embodiment of the present disclosure. The open-face mold 100 includes first textures 110, second textures 120, third textures 130, and fourth textures 140 distributed over the surface of the open-face mold 100. The purpose of the four different textures 110, 120, 130, 140 is to accommodate liquid mixture poured over the open-face mold 100, so that once the liquid mixture solidifies its surface will have patterns corresponding to the shapes of the corresponding textures 110, 120, 130, 140.

[0023] The first textures 110 and second textures 120 in FIG. 3 are substantially identical to the ones in FIG. 2 and thus will not be elaborated again. The third textures 130 includes a plurality of narrow and curved cuts formed on the surface of the open-face mold 100. The cuts of the third textures 130 can be formed by chemical etching process, mechanically scratching the surface of the open-face mold 100 using tools, or other known methods in the art to form cuts on metallic or plastic molds. The fourth textures 140 includes a plurality of narrow and substantially straight cuts formed on the surface of the open-face mold 100. The cuts of the third textures 140 can also be formed by chemical etching process, mechanically scratching the surface of the open-face mold 100 using tools, or other known methods known in the art to form cuts on metallic or plastic molds.

[0024] In the embodiment illustrated in FIG. 3, the open-face mold 100 includes four textures with different shapes and sizes. In different embodiments, the open-face mold 100 can have only first textures 110, second textures 120, third textures 130 on its surface or include even more textures different from the ones illustrated in FIG. 3.

[0025] FIGS. 4-5 are perspective views of the mesh layer 200 with liquid mixture poured thereon. As illustrated in FIGS. 4-5, the mesh layer 200 is a flexible and porous screen having a plurality of pores. In the present embodiment, a liquid mixture 300 is first poured over the open-face mold to subsequently accumulate in the textures 110, 120 on the open-face mold 100. However, before the mixture solidifies, the mesh layer 200 is laid over both the open-face mold 100 and the mixture 300. At this moment, the mixture 300 is still in the liquid state and thus will pass through the pores of the mesh layer 200 and immerse the mesh layer 200 in the process. Tools such as float or margin trowel can be used to evenly distribute and smooth the mixture over the open-face mold 100 and the mesh layer 200 before the mixture solidifies. Also, the area of the mesh layer 200 is preferably greater than that of the open-face mold 100, to ensure that the entire area of the open-face mold 100 is fully covered by the mesh layer 200.

[0026] The liquid mixture 300 is then allowed to solidify to eventually form a textured warning mat. The part of liquid mixture 300 that occupies the first textures 110 of the open-face mold 100 solidifies to have shape corresponding to the first textures 110. Similarly, the part of liquid mixture 300 that occupies the second textures 120 of the open-face mold 100 solidifies to have shape corresponding to the second textures 120. Further, the part of liquid mixture 300 that fills the pores of the mesh layer 200 eventually solidifies and form a thin base that preferably fully contains the mesh layer 200. In other words, the mesh layer 200 is preferably embedded within the cured liquid mixture 300. The solidification process preferably takes 5 to 10 minutes for the liquid mixture 300 to dry up and form the warning mat. However, in different embodiments, the process may take longer or less time depending on the ingredients used to create the liquid mixture 300.

[0027] In another embodiment, before a liquid mixture is poured over the open-face mold 100, the mesh layer 200 is first laid over the open-face mold 100 (not illustrated in FIGS. 4-5). Once the open-face mold 100 is covered by the mesh layer 200, a liquid mixture 300 is poured over at least the part of the mesh layer 200 above the open-face mold 100. Part of the liquid mixture 300 will pass through the pores of the mesh layer 200 and then accumulate in the first textures 110 and the second textures 120 of the open-face mold 100. The liquid mixture 300 eventually immerse the mesh layer 200. Tools such as float or margin trowel can be used to evenly distribute and smooth the mixture over the open-face mold 100 and the mesh layer 200 before the mixture solidifies.

[0028] The liquid mixture 300 is then allowed to solidify to eventually form a textured warning mat. The portion of liquid mixture 300 that occupies the first textures 110 of the open-face mold 100 solidifies to have shape corresponding to the first textures 110. Similarly, the portion of liquid mixture 300 that occupies the second textures 120 of the open-face mold 100 solidifies to have shape corresponding to the second textures 120. Further, the part of liquid mixture 300 also forms a thin base that preferably contains the mesh layer 200. In other words, the mesh layer 200 is immersed and embedded within the cured liquid mixture 300. The solidification process preferably takes 5 to 10 minutes for the liquid mixture 300 to dry up (or cool down) and form the warning mat. However, in different embodiments, the process may take longer or less time depending on the ingredients used to create the liquid mixture 300.

[0029] The liquid mixture 300 of the present embodiment includes cement, resin, and bonding agents (such as clay and water, oil, and sodium silicate), but is not limited thereto. In different embodiments, the liquid mixture 300 can also include glass and sand as well as other materials such as common mineral fillers, glass beads, skid resistant material, and color pigments.

[0030] In the embodiment illustrated in FIGS. 4-5, the liquid mixture 300 does not contain color pigments. To add color, the cured mixture 300 is removed from the open-face mold 100 and then colored/painted with the desired color pigments. However, in other embodiments such as the one illustrated in FIGS. 4-5, color pigments can be added to the liquid mixture 300 to eliminate the step of coloring/painting the cured mixture 300 after removal from the open-face mold 100. Also, the mixture can be a polymer mixture or an acrylic mixture, depending on the materials used to make the liquid mixture 300.

[0031] FIGS. 6-7 are respectively a perspective view and an enlarged perspective view of the textured warning mat according to one embodiment of the present disclosure. As illustrated in FIGS. 6-7, the warning mat includes a base 400, a first pattern 410, and a second pattern 420. The shape of the first patterns 410 substantially corresponds to that of the first textures 110 of the open-face mold 100 illustrated in FIGS. 1-2. Similarly, the shape of the second patterns 420 substantially corresponds to that of the second textures 120 of the open-face mold 100 illustrated in FIGS. 1-2. The first pattern 410 includes a dome structure 411 and a plurality of protrusions 412 on the dome structure 411. The dome structure 411 and protrusions 412 are both configured to provide auditory and tactile underfoot feedback for the visually impaired. In addition, the protrusions 412 are designed to increase the friction between the pedestrian's shoe and the warning mat to make the warning mat more skid-resistant.

[0032] As illustrated in FIG. 6, one of the first patterns 410 is removed to reveal the mesh layer 200 within the base 400. The mesh layer 200 gives flexibility to the warning mat so that it can be laid over uneven surface. Further, the bond between the cured mixture and the mesh layer 200 also maintains the integrity of the warning mat and keeps the warning mat from breaking down due to external forces.

[0033] In the embodiment illustrated in FIGS. 6-7, the warning mat has two surfaces on the two opposite sides of the base 400. The first surface is disposed with the first patterns 410 and the second patterns 420 and is the surface that physically interacts with the pedestrians. On the other hand, the second surface is the one adhered to the road using adhesives. In one embodiment, the adhesive is water-based acrylic adhesives. However, in different embodiments, rubber/resin adhesives, thermosetting rubber/resin adhesives, precured rubber/resin adhesives, solvent based adhesives, silicone adhesives, heat activated adhesives, thermal release adhesives, electrically conductive/anti-static adhesives, thermally conductive adhesives, or other suitable adhesives can be used to stick the textured warning mat of the present disclosure to wood, asphalt, and concrete.

[0034] Further, mechanical tools or chemical substances can be used to form patterns, similar to the cuts of the third textures 130 and fourth textures 140 illustrated in FIG. 3, on the surface of the textured warning mat removed from the open-face mold.

[0035] FIG. 8 is a top view of the open-face mold 100 according to yet another embodiment of the present disclosure. FIG. 9 is a partial perspective view of the warning mat according to the same embodiment as FIG. 8. The open-face mold 100 also includes a plurality of first textures 110 similar to the ones illustrated in FIG. 2. The open-face mold 100 also includes a plurality of third textures 130 distributed on the surface of the open-face mold 100. In the present embodiment, the third textures 130 are linear grooves that cross one another.

[0036] FIG. 10 is a flow chart of the method of manufacturing a patterned warning mat configured to be placed on walkways, crosswalks, and other areas of pedestrian traffic for providing direction and warning to visually handicapped persons, according to one embodiment of the present disclosure. The method includes step 501 of providing an open-face mold having a plurality of textures and a plurality of dome indentations. In the present embodiment, each of dome indentations has a base diameter of 23 mm (0.9 in) minimum to 36 mm (1.4 in) maximum, a top diameter of 50 percent of the base diameter minimum to 65 percent of the base diameter maximum, and a height of 5 mm (0.2 in). Further, the dome indentations have substantially a center-to-center spacing of 41 mm (1.6 in) minimum and 61 mm (2.4 in) maximum, and a base-to-base spacing of 17 mm (0.65 in) minimum, measured between the most adjacent domes. In other embodiments, the dome indentations can have other sizes or spacing depending on the government regulations on dome size and spacing.

[0037] In one embodiment, the textures on the open-face mold includes first textures on the dome indentations and second textures located between four dome indentations. The first and second textures can be openings such as the textures 110, 120 illustrated in FIG. 2. In a different embodiment, the textures can include cuts and holes configured to accommodate liquid mixture poured over the open-face mold, as the textures illustrated in FIG. 3. In yet another embodiment, the textures can be linear grooves such as the third texture 130 illustrated in FIG. 7 or any other etchings or textures with depth on the open-face mold.

[0038] The method further includes step 502 of preparing a liquid mixture capable of solidifying and chemical reaction. The liquid mixture includes cement, resin, and bonding agents (such as clay and water, oil, and sodium silicate), but is not limited thereto. In different embodiments, the liquid mixture can also include glass and sand as well as other materials such as common mineral fillers, glass beads, skid resistant material, and color pigments. Further, the process of mixing the above-mentioned materials may result in chemical reactions that generate heat as a result and causes a temperature of the liquid mixture to be higher than a room temperature.

[0039] The method further includes step 503 of pouring the mixture over the open face open-face mold. The mixture, still in a liquid state, accumulates in the textures of the open-face mold.

[0040] The method further includes step 504 of allowing the mixture to solidify and form the warning mat. The part of liquid mixture that occupies the patterns of the open-face mold solidifies to have shape corresponding to the patterns of the open-face mold. The solidification process preferably takes 5 to 10 minutes for the liquid mixture to solidify and form the warning mat. However, in different embodiments, the process may take longer or less time depending on the ingredients used to create the liquid mixture the liquid mixture.

[0041] After confirming the warning mat is taking shape and the solidification of mixture is complete, the method then executes step 505 of removing the warning mat from the open-face mold. As mentioned above, the liquid mixture that forms the warning mat may or may not include the pigment with desired color. Thus, in one embodiment, step 505 may further include adding desired color to the warning mat using pigment, after removal from the open-face mold.

[0042] FIG. 11 is a flow chart of the method of manufacturing a patterned warning mat according to another embodiment of the present disclosure. The method further including step 506 of immersing a mesh layer in the liquid mixture before the liquid mixture solidifies. The mesh layer is a flexible and porous screen having a plurality of pores. In one embodiment, the liquid mixture is first poured over the open-face mold to subsequently accumulate in the textures on the open-face mold. However, before the mixture solidifies, the mesh layer is laid over both the open-face mold and the mixture. At this moment, the mixture is still in the liquid state and thus will pass through the pores of the mesh layer to immerse the mesh layer in the process. Tools such as float or margin trowel can be used to evenly distribute and smooth the mixture over the open-face mold and the mesh layer before the mixture solidifies.

[0043] In another embodiment, before a liquid mixture is poured over the open-face mold 100, the mesh layer is first laid over the open-face mold. Once the open-face mold is at least substantially covered by the mesh layer, a liquid mixture is poured over the mesh layer above the open-face mold. Part of the liquid mixture will pass through the pores of the mesh layer and then accumulate in the textures of the open-face mold. The liquid mixture eventually immerse the mesh layer. Tools such as float or margin trowel can be used to evenly distribute and smooth the mixture over the open-face mold and the mesh layer before the mixture solidifies. Further, mechanical tools or chemical substances can be used to form cuts, similar to the third textures 130 and fourth textures 140 illustrated in FIG. 3, on the solidified and textured warning mat removed from the open-face mold.

[0044] In the foregoing description, reference is made to the accompanying drawings that form a part thereof, and in which is shown by way of illustration specific exemplary embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the concepts disclosed herein, and it is to be understood that modifications to the various disclosed embodiments may be made, and other embodiments may be utilized, without departing from the scope of the present disclosure. The foregoing detailed description is, therefore, not to be taken in a limiting sense.

[0045] Reference throughout this specification to one embodiment, an embodiment, one example, or an example means that a particular feature, structure, or characteristic described in connection with the embodiment or example is included in at least one embodiment of the present disclosure. Thus, appearances of the phrases in one embodiment, in an embodiment, one example, or an example in various places throughout this specification are not necessarily all referring to the same embodiment or example. Furthermore, the particular features, structures, databases, or characteristics may be combined in any suitable combinations and/or sub-combinations in one or more embodiments or examples. In addition, it should be appreciated that the figures provided herewith are for explanation purposes to persons ordinarily skilled in the field.