Abstract
An improved mat system comprising a top stone mat and a bottom rubber mat featuring a snap-fit mechanism for secure assembly and variable thickness for enhanced durability and stability. The improved stone mat may also include one or more reinforcement elements to prevent or reduce warping and may include one or more complimentary sets of decorative features that also provide a textured surface to prevent slipping.
Claims
1. A modular system combinable to provide a mat for wet areas, the system comprising: a base underlay having a top surface and bottom surface and substantially made from thermoplastic rubber (TPR), the bottom surface positioned opposite a supporting surface such as a floor; at least two absorbent top mats adapted to be fittingly placed on the top surface of the base underlay and comprised of stone material capable of water absorption and quick-drying, wherein the stone material comprises a combination of diatomaceous earth and a pulp fiber binding agent; a plurality of surface features formed into one or more of the at least two absorbent top mats and adapted to provide a combined decorative aspect and a textured surface aspect for improved traction in a wet condition such as encountered when bathing or showering.
2. The system of claim 1, wherein the plurality of surface features comprise a plurality of strips located on the top surface of the absorbent top stone mat to provide a textured surface for improved traction.
3. The system of claim 1, wherein the base underlay and the at least two absorbent top stone mats are connected by a snap-fit system.
4. The system of claim 1, wherein the top surface of the base underlay contains a set of features configured to receive or interlock with a set of opposite features located on the bottom surfaces of the at least two absorbent top stone mats.
5. The system of claim 4, wherein the set of features and the set of opposite features comprise a set of protrusions to be received within a set of recessions.
6. The system of claim 1, wherein the base underlay is a foldable one-piece underlayment and the plurality of absorbent top stone mats is configured as a two-piece design that is substantially rectangular in shape and has the ability to be fittingly received within the top surface of the foldable one-piece underlayment.
7. The system of claim 6, wherein the foldable one-piece underlay may be folded down the middle in half by a spine, crease or joint formed in the underlay.
8. The system of claim 7, wherein the underlay may be folded and unfolded as needed and avoids the need for additional connecting members or pieces.
9. The system of claim 7, wherein the foldable underlay and the plurality of absorbent top stone mats provide a modular system adapted to facilitate system transport and storage.
10. The system of claim 1, wherein the base underlay has a set of openings and a set of interior connectors configured to enhance structural integrity while reducing material cost and weight.
11. The system of claim 10, wherein the base underlay comprises a rubber material adapted to provide enhanced traction for the mat against a variety of supporting floor surface types to reduce risk of slips and falls in wet areas.
12. The system of claim 1, wherein the base underlay has anti-slip properties to ensure that the mat stays in place.
13. The system of claim 1, wherein the plurality of top stone mats comprise diatomaceous earth.
14. The system of claim 1, wherein the plurality of top stone mats comprise antimicrobial components.
15. The system of claim 1, wherein the plurality of top stone mats comprise at least one reinforced element disposed on the underside of the stone mat adapted to prevent or reduce warping.
16. The system of claim 15, wherein the at least one reinforced element is bowed or bent or notched or ribbed or has other physical features that contribute to the overall rigidity or stiffness or strength of the reinforced element to assist in reducing warping of the stone mat.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] 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.
[0014] 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.
[0015] FIG. 2 is a schematic diagram of a bottom view of the TPR base underlay.
[0016] FIG. 3A is a schematic diagram of a top view of the absorbent stone mat.
[0017] FIG. 3B is a schematic diagram of a top view of an alternative absorbent stone mat to the mat of FIG. 3A.
[0018] FIG. 4 is a schematic diagram of a bottom view of the absorbent stone mat.
[0019] FIG. 5 is a top view of a first embodiment of a reinforced stone mat to prevent warping.
[0020] FIG. 6 is a top view of a first exemplary embodiment of a reinforced stone mat to prevent warping.
[0021] FIG. 7 is a top view of a second exemplary embodiment of a reinforced stone mat to prevent warping.
[0022] FIG. 8 is a top view of a third exemplary embodiment of a reinforced stone mat to prevent warping.
[0023] FIG. 9 is a top view of a fourth exemplary embodiment of a reinforced stone mat to prevent warping.
[0024] FIG. 10 is a top view of a fifth exemplary embodiment of a reinforced stone mat to prevent warping.
DETAILED DESCRIPTION OF THE INVENTION
[0025] 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.
[0026] 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.
[0027] 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.
[0028] 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.
[0029] 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.
[0030] 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.
[0031] 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.
[0032] 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.
[0033] 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.
[0034] 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.
[0035] 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.
[0036] 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.
[0037] 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.
[0038] 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.
[0039] 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.
[0040] 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.
[0041] 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.
[0042] 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 wide3 mm thick47 cm long. In the large stone configuration the dimension on rigid bar(s) on large Stone may be 25 mm wide3 mm thick57 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.
[0043] 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 wide3 mm thick47 cm long. In the large stone configuration the dimension on rigid bar only in the middle on large Stone may be 75 mm wide3 mm thick57 cm long.
[0044] 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.
[0045] 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.
[0046] 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.
