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WO2007100813A1 - Floor mat assembly - Google Patents

Floor mat assembly Download PDF

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Publication number
WO2007100813A1
WO2007100813A1 PCT/US2007/005058 US2007005058W WO2007100813A1 WO 2007100813 A1 WO2007100813 A1 WO 2007100813A1 US 2007005058 W US2007005058 W US 2007005058W WO 2007100813 A1 WO2007100813 A1 WO 2007100813A1
Authority
WO
WIPO (PCT)
Prior art keywords
mat
edging
section
edge
perimeter section
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2007/005058
Other languages
French (fr)
Inventor
Eric Bozouklian
Bernard Vincent
David G. Sebesta
Sylvain Masson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
3M Innovative Properties Co
Original Assignee
3M Innovative Properties Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 3M Innovative Properties Co filed Critical 3M Innovative Properties Co
Publication of WO2007100813A1 publication Critical patent/WO2007100813A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/10Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47GHOUSEHOLD OR TABLE EQUIPMENT
    • A47G27/00Floor fabrics; Fastenings therefor
    • A47G27/04Carpet fasteners; Carpet-expanding devices ; Laying carpeting; Tools therefor
    • A47G27/0406Laying rugs or mats
    • A47G27/0431Reinforcement or stiffening devices, e.g. edge binders, anticurl devices for corners
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47LDOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
    • A47L23/00Cleaning footwear
    • A47L23/22Devices or implements resting on the floor for removing mud, dirt, or dust from footwear
    • A47L23/26Mats or gratings combined with brushes ; Mats
    • A47L23/266Mats
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements

Definitions

  • the present disclosure is directed to sectional floor matting, in particular, to edging for sectional floor matting.
  • Carpets and rugs have long been used to cover the ground, floor, and other surfaces.
  • Floor coverings are not only functional in that they protect the floor, collect and retain dirt, mud and water, but they are also aesthetical. Depending on the material, the floor covering may also provide a cushion, softening the surface and thus easing stress on the user.
  • Floor coverings have evolved to include modular systems that can be designed on the spot for the specific application. For example, twelve 1 foot by 1 foot (about 30.5 cm by 30.5 cm) interlocking mats can be combined to form a 12 square foot mat (about 1.1 m 2 ), either 2 foot by 6 foot (about 61 cm by 183 cm) or, 3 foot by 4 foot (about 91.5 cm by 122 cm).
  • Such interlocking sectional matting is a popular system for customizing floor mats. Additionally, with such sectional matting systems, it is possible to replace only the worn or damaged mat sections when needed, rather than having to replace the entire mat.
  • 3M Company has a sectional matting product line that is well recognized.
  • Various NOMADTM floor mats are available, with a variety of physical properties, such as thickness, mat density, material, mat section size, etc.
  • the mats are configured to interlock, providing various shapes and sizes of matting.
  • the mats are placed into a recessed well in the floor, so that the top surface of the mats is approximately level with the ground.
  • tapered or ramped edging is placed around the perimeter of the mat, to reduce the chance a user may trip on the edge of the mat.
  • the edging is generally glued to the mat, to inhibit the mat and edging from becoming separated. Typically, when either the mat or the edging is worn or damaged, both the edging and the mat section are replaced.
  • the present invention provides a floor mat system that increases the benefits associated with using sectional matting.
  • An aspect of the present disclosure is directed to a sectional floor mat system to allow varying sizes of floor mats to be created from smaller floor mats. Edging pieces or sections are removably engaged with the floor mats to inhibit tripping on the edge of the mat.
  • An exemplary embodiment of the floor mat system of the present disclosure is a sectional system that includes at least one mat and sufficient edging to border at least one of the side edges of the at least one mat. In many embodiments, there is sufficient edging to border all side edges of the at least one mat. When multiple mats are in the system, in many embodiments, there is sufficient edging to boarder all exposed edges of the mats when connected together.
  • the disclosure is directed to a perimeter section for a mat, the perimeter section capable of being removably engaged to a side edge of the mat.
  • the perimeter section comprises a transition portion having a varying (e.g., tapered) thickness, where the maximum thickness is substantially the same as the mat thickness. In many embodiments, the thickness decreases as the perimeter section extends outward from the mat.
  • the perimeter section includes an engagement portion for at least partially penetrating into the mat. This engagement portion may penetrate up into or down into the mat.
  • the disclosure is also to a mat system, the system being a combination of at least one mat and at least one perimeter or edging section that releaseably attaches to the mat.
  • the mat system includes at least one floor mat having a side edge, a top surface and a bottom surface, with a plurality of voids extending into the floor mat, and an edging section configured to abut the side edge of the floor mat, the edging section having an engagement mechanism configured to extend into at least one void to releasably engage the floor mat.
  • the engagement mechanism could extend into a plurality of voids, and optionally through one or more voids. This extension could be down from the attachment portion of the edging section into the top surface of the mat or up from the attachment portion into the bottom surface of the mat.
  • Another aspect of this disclosure is the combination of a floor mat having a side edge, a top surface and a bottom surface, with a plurality of voids extending into the floor mat, and an edging section configured to abut the side edge of the floor mat, the edging section having an engagement mechanism configured to extend into at least one void to releasable engage the floor mat.
  • kits that includes a mat section, and a perimeter section capable of being removably engaged adjacent to the edge of the mat, the perimeter section having a varying thickness, wherein the maximum thickness of the perimeter section is substantially the same as the mat thickness at its edge, and the perimeter section thickness decreases as the perimeter section extends outwardly from the edge of the mat section.
  • Also provided is a method of assembling a modular mat by providing a mat section and removably attaching a perimeter section to the edge of the mat, the perimeter section having a varying thickness, wherein the thickness of the perimeter section is substantially the same as the mat thickness at the edge, and the perimeter section thickness decreases as the perimeter section extends outwardly from the edge of the main section.
  • FIG. 1 is a perspective view of a floor mat system assembled from multiple floor mats and edging sections;
  • FIG. 2 is a top view of a first embodiment of an edging section engaged with a floor mat
  • FIG. 3 is a perspective view of the edging section of FIG. 2;
  • FIG. 4 is a top plan view of the edging section of FIG. 2;
  • FIG. 5 is a side plan view of the edging section of FIG. 2;
  • FIG. 6 is a bottom plan view of the edging section of FIG. 2;
  • FIG. 7 is a top plan view of a second embodiment of an edging section engaged with a floor mat
  • FIG. 8 is a side plan view of the edging section of FIG. 7;
  • FIG. 9 is a top plan view of a third embodiment of an edging section engaged with a floor mat
  • FIG. 10 is a side plan view of the edging section of FIG. 9.
  • FIGS. 1 l(a), 1 l(b), 11 (c), and 1 l(d) are various embodiments of engagement mechanisms suitable for use with any of the edging sections of this disclosure.
  • FIG. 1 a floor mat system, composed of a plurality of floor mats and a plurality of edging, is illustrated generally at 10.
  • System 10 is composed of a plurality of floor mats 12 (specifically, nine floor mats 12) and an edging system 14 that circumscribes the plurality of mats 12.
  • edging system 14 has a plurality of side edging sections or pieces 16 (specifically, twelve edging pieces 16, three of which are specifically referenced as 16A, 16B, 16C), which will be described in detail below.
  • FIG. 2 illustrates a partial piece of mat 12 with a generic edging section 16 connected thereto.
  • edging sections 16A and 16C illustrated in FIG. 1 are corner pieces, each including an end angled at 45 degrees, to facilitate forming a corner. Two angled ends joined form a 90 degree corner.
  • Edging section 16B of FIG. 1 and edging section 16, as illustrated in FIG. 2 and FIGS. 3 through 6, is a piece suitable for positioning between two corner edging sections.
  • a single edging section 16 may extend the entire side edge, having an angled end on each end. Such an embodiment could be formed "in situ", being cut to length on site during installation.
  • mat 12 has a first edge 22, a second edge 24 and a third edge 26 opposite second edge 24.
  • Mat 12 in this embodiment being a rectangle such as a square, includes a fourth edge which is not shown in FIG. 2.
  • the width of mat is the distance between edge 24 and edge 26.
  • mat 12 is connected to edging section 16 proximate a wall 32, which is further described below.
  • edging section 16 has a first end edge 34 and a second end edge 36 opposite first end edge 34.
  • the length of edging section 16 is the distance between end edge 34 and end edge 36.
  • the length of edging section 16 may be the same, more, or less than the width of mat 12; for example, a corner edging section (such as sections 16A, 16C of FIG. 1) may be longer than the width of mat 12.
  • Edging section 16 also has an outer edge 38 and opposite outer edge 38 is wall 32. Together, edges 34, 36, 38 and wall 32 define a transition portion 40.
  • Transition portion 40 includes a top surface 35, which is a beveled or angled surface that facilitates the progression from the ground, floor or other surface on which edging section 16 is placed and the top of mat 12. Transition portion 40 is a ramp from a surface below the top of mat 12 (e.g., the floor) to the top of mat 12. Transition portion 40 is that portion of edging section 16 that circumscribes mat 12 and is visible in FIG. 1.
  • Edging section 16 also includes attachment portion 42, FIG. 3, which engages and retains edging section 16 to mat 12.
  • Attachment portion 42 has a lower portion 45 with an end edge 44 which is preferably aligned with end edge 34, and an end edge 46, which is preferably aligned with end edge 36.
  • Attachment portion 42 also has inner edge 48 opposite transition portion 40.
  • Wall 32 differentiates between transition portion 40 and attachment portion 42, providing a step from lower portion 45 of attachment portion 42 to transition portion 40, particularly, to top surface 35; see FIG. 3 and 5.
  • edging section 16 is defined by ends 34/44, ends 36/46, edge 38 and edge 48.
  • Attachment portion 42 includes an engaging mechanism 50, which engages and retains mat 12.
  • engaging mechanism 50 comprises a plurality of posts 52 that extend upward from lower portion 45.
  • Engaging mechanism 50 can be described as at least one but preferably a plurality of posts, nubs, spikes, or other such protruding features that extend up from lower portion 45 and have a distal or free end opposite lower portion 45.
  • Engaging mechanism 50 is configured to extend or penetrate up into, and optionally through, mat 12.
  • Engaging mechanism 50 may extend at a right angle to lower portion 45, or may be tilted or angled in relation thereto.
  • engaging mechanism 50 extends generally level with the maximum height of transition portion 40, at wall 32; it is understood that in alternate embodiments, transition portion 40 may extend higher than engaging mechanism 50, or even, though not preferred, engaging mechanism 50 may extending higher than the maximum of transition portion 40.
  • Mat 12 generally includes a plurality of passages, cells, or other voids that extend though the thickness of mat 12.
  • Engaging mechanism 50 is configured to pass through, at least partially, these voids to hold mat 12 relative to attachment portion 42 and edging section 16.
  • Engaging mechanism 50 passes through mat 12 from the bottom surface of mat 12 toward the top surface of mat 12. The thickness of mat 12 and the length or height of engaging mechanism 50 will affect the amount that mechanism 50 extends into mat 12.
  • engaging mechanism 50 comprises a plurality of posts 52 extending as two rows parallel to wall 32, although it is understood that any number of rows or any configuration of posts 52 could be suitable.
  • posts 52 from one row are offset from posts 52 of the other row. No matter what the configuration of posts 52, they should be shaped, sized, and arranged so a sufficient number of posts 52 pass into the voids of mat 12 in order to adequately retain mat 12 with edging section 16.
  • engaging mechanism 50 can be seen extending into voids in mat 12.
  • edge 22 of mat 12 is illustrated adjacent and preferably seated against wall 32 (FIG. 3) of edging section 16.
  • a portion of mat 12 is present over attachment portion 42.
  • attachment portion 42 extends at least 1/2 inch (about 1.27 cm), preferably at least 1 inch (about 2.54 cm), and more preferably at least 1.3 inches (about 3.3 cm) past wall 32 and is covered by mat 12.
  • edging section 56 has a first end edge 64 and a second end edge 66 opposite first end edge 64.
  • the length of edging section 56 is the distance between end edge 64 and end edge 66.
  • the length of edging section 56 may be the same, more, or less than the width of mat 12; for example, a corner edging section may be longer than the width of mat 12.
  • Edging section 56 also has an outer edge 68 and opposite outer edge 68 is an internal wall 62. Together, edges 64, 66, 68 and wall 62 define a transition portion 60.
  • Transition portion 60 includes a top surface 65, which is a beveled or angled surface. Transition portion 60 is that portion of edging section 56 that circumscribes mat 12.
  • Edging section 56 also includes attachment portion 7O 5 which engages and retains mat 12 with edging section 56.
  • Attachment portion 70 has top portion 72 with end edge 74 which is preferably aligned with end edge 64, and end edge 76, which is preferably aligned with end edge 66.
  • Attachment portion 70 also has inner edge 78.
  • a wall 62 differentiates between transition portion 60 and attachment portion 70; see FIG. 8.
  • Attachment portion 70 includes engaging mechanism 75, which engages and retains mat 12.
  • engaging mechanism 75 extends or penetrates down from top portion 72.
  • Engaging mechanism 75 can be described as at least one but preferably a plurality of posts, nubs, spikes, or other such features that extend down from top portion 72 and have a free distal end.
  • Engaging mechanism 75 is configured to extend down into, and optionally through, voids in mat 12.
  • attachment portion 70 When edging section 56 is engaged with a mat 12, attachment portion 70, particularly top portion 72, is present over a portion of mat 12. Typically, attachment portion 70 extends no more than about 4 inches (about 10.2 cm), preferably no more than about 2 inches (about 5 cm) over mat 12 or even no more than about 1.5 cm (about 4 cm) over mat 12.
  • Edging sections 16, 56 are configured for use with mats 12 that have a generally straight edge 22 to abut against wall 32, 62.
  • FIG. 9 illustrates an embodiment of an edging section for use with a mat 12' that includes engagement elements 20 extending out from edge 22' of mat 12'.
  • These engagement elements 20, for example, are configured to engage with a second mat 12' (not shown), in order to provide a larger overall mat, such as in FIG. 1 which illustrates nine mats connected together, such as by engagement elements 20.
  • FIG. 1 illustrates nine mats connected together, such as by engagement elements 20.
  • One example of such a mat 12' with engagement elements 20 is shown in registered Community design No. 000050638, Applicant of which is 3M Innovative Properties Company.
  • edging section 86 An embodiment of edging suitable for use with mat 12' is illustrated in FIGS. 9 and 10 as edging section 86.
  • edging section 86 has end edges and edges similar to edging section 56, described above.
  • edging section 86 has transition portion 90 generally similar to transition portion 60, which includes a top surface 95, and also includes an attachment portion 100 generally similar to attachment portion 70, which includes inner edge 108.
  • Edging section 86 includes an internal wall 92, generally similar to internal wall 62, with modifications as described below.
  • Attachment portion 100 is the portion of edging section 86 which engages and retains mat 12'.
  • Attachment portion 100 includes engaging mechanism 105 extending from top portion 102, which engages and retains mat 12' in a manner similar to engaging mechanism 75 of edging section 56.
  • Engaging mechanism 105 is " configured to extend down into, and optionally through, voids in mat 12'. When engaged with mat 12', attachment portion 100 is present over a portion of mat 12'.
  • Edging section 86 differs from edging section 56 in that wall 92, differentiating between transition portion 90 and attachment portion 100, is adapted to receive a portion of mat 12' therein.
  • Wall 92 includes a recess 94, recessed away from attachment portion 100 include transition portion 90.
  • Recess 94 is shaped and sized to receive engagement element 20 extending out from edge 22' of mat 12'.
  • FIGS. 1 l(a) through 1 l(d) various embodiments of engagement mechanism, as alternates to engaging mechanisms 50, 75, 105, are illustrated.
  • Engagement mechanism 50 best seen in FIG. 5, has a blunt distal end, configured for passing generally unhindered into and out from a void in mat 12.
  • Engagement mechanisms 75, 105 have a rounded distal end, for passing generally unhindered into and out from a void in mat 12.
  • FIG. 1 l(a) shows an alternate engagement mechanism, having a tapered or pointed distal end, which would pass unhindered into and out from a void in a mat.
  • FIGS. 1 l(b), 1 l(c) and 1 l(d) show alternate engagement mechanisms that engage with a portion of the mat in which it is inserted.
  • FIGS. 1 l(b), 1 l(c) and 1 l(d) has an increased diameter at its distal end.
  • FIG. 1 l(b) illustrates an engagement mechanism having a rounded, bulbous feature at its distal end.
  • FIG. 1 l(c) illustrates an engagement mechanism having a tapered, blunt distal end.
  • FIG. 11 (d) illustrates a branched engagement mechanism, in this embodiment having a bifurcated stem with bulbous features at the distal ends.
  • each of the engagement mechanisms of FIGS. 1 l(b), 1 l(c) and 1 l(d) has a shelf or lip that defines the side of the increased diameter opposite the distal end.
  • Each of the engagement mechanisms of FIGS. 1 l(b), 1 l(c) and 1 l(d) is configured to provide either or both frictional or physical engagement with mat 12.
  • Frictional engagement could be provided by the outer edges of the engagement mechanisms contact the walls of the void into which the engagement mechanism is positioned.
  • Physical engagement could be provided by passing the engagement mechanism through the void, and having the shelf of the increased diameter region engage with and catch the bottom side of mat 12, inhibiting removal of the engagement mechanism from the void. Branched designs facilitate withdrawing the engagement mechanism from the void when desired.
  • any engagement mechanism may have, for example, surface features that increase the engagement of the engagement mechanism in the void, such as barbs or ribs.
  • Each of generic edging sections 16, 56, 86 has been illustrated having side edges being orthogonal to the extension of edging section 16, 56, 86 respectively; specifically, for example, end edges 34/44, 36/46 of edging section 16 are at 90 degree angle to edge 38. Additionally, end edges 34/44, 36/46 align with edges 24, 26 of mat 12.
  • edging section 16B is configured for positioning between two corner edging pieces 16A, 16C.
  • edging section 16B is configured for positioning between two corner edging pieces 16A, 16C.
  • the previous discussion and figures of generic edging sections 16, 56, 86 has been to edging sections for positioning at a non-corner mat.
  • the configuration of any of edging sections 16, 56, 86 can be modified so that the pieces are suited for use as a corner piece.
  • an end of edging section 16, 56, 86 i.e., end edge 34/44 or 36/46, or end edge 64/74 or 66/76) could be configured at a 45 degree angle, so that two so-formed pieces could be joined to form a 90 degree corner.
  • a piece separate from an edging section could be used as a corner piece.
  • edging sections 16, 56, 86 have been illustrated as having the same length as the width of the mat to which they are attached, edging sections 16, 56, 86 could be longer, to engage more than one mat, or shorter, to engage less than one mat. For example, one edging section could be configured to engage three adjacent mats.
  • top surface 35, 65, 95 of transition portion 40, 60, 90 has been illustrated as a beveled edge or chamfer, top surface 35, 65, 95 could be curved or arched, such as a fillet, stepped, or ribbed.
  • Edging section 16, 56, 86 and other embodiments can be made from any suitable material, including polymers (plastics), metal, wood, composites, clay, and the like.
  • the most preferred material for edging sections, however, is polymeric materials.
  • Edging section 16, 56, 86 can be a unitary piece or assembled from multiple pieces. A polymeric unitary piece can be readily injection molded using conventional techniques. Polymeric materials can also be readily colored.
  • engaging mechanism 50, 75, 105 might be a metal or a polymeric material different than lower portion 45 or top portion 12, 102.
  • Edging section 16, 56, 86 having different engaging mechanisms 50, 75, 105 could be made by extruding the transition and attachment portions and subsequently attaching engaging mechanisms 50, 75, 105.
  • top surface 35, 65, 95 could have an anti-slip or other fricative surface integral therewith or applied subsequently.
  • edging sections 16, 56 or 86 are combined with mats 12 or 12' to form a mat system.
  • Generic edging sections 16, 56, 86, as described above, are edging pieces suitable for use in the center or non-end of an assembled mat system. These sections 16, 56, 86 may be used in combination with edging pieces configured as corner pieces (e.g., sections 16A, 16C), or these sections 16, 56, 86 may be used in combination with pieces that do not contact the side edges of mats 12, 12' but only form the corners.
  • mats 12, 12' are square mats; other shapes are suitable. Examples of shapes include rectangles, parallelograms, rhombus, hexagons, triangles, and other polygons, including irregular polygons such as bowties, L-shaped, or U-shaped. Mats 12, 12' could have curved surfaces.
  • the resulting mat system could have any shape, such a square, rectangle, parallelogram, rhombus, hexagon, triangle, and other polygons including irregular polygons. Circular or arced shapes are possible.
  • the ends of the edging pieces would be appropriately angled or otherwise shaped to form the desired corner angle. Internal corners, of any angle, are foreseen.
  • edging sections 16, 56, 86 may be placed on only a portion of the sides of mats 12, 12', leaving one or more edges of mats 12, 12' unedged.
  • the maximum height of transition portion 40, 60, 90 of edging sections 16, 56, 86 which generally defines the height of edging section 16, 56, 86, may be the thickness of mat 12, 12', such as for installations where mats 12, 12' are placed on the same surface as edging sections 16, 56, 86. Alternately, mats 12, 12' may be partially recessed into a well, or depression, so that edging sections 16, 56, 86 do not need to be the full thickness of mat 12, 12'.
  • the mat systems that can be created with mats 12, 12', and other embodiments, and edging sections 16, 56, 86, and other embodiments, are countless. Various shapes, sizes, colors, textures, materials, etc. can be used in conjunction to create a mat system.
  • the mat system if made from a plurality of mats, may include more than one type of mat; the outer perimeter or other high traffic areas may utilize, e.g., more durable or more porous mats.
  • the outer perimeter or other high traffic areas may utilize, e.g., more durable or more porous mats.

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  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Carpets (AREA)

Abstract

A sectional floor mat system of floor mats and edging pieces or sections that are removably engaged with the floor mats. The floor mat system includes at least one mat and sufficient edging to border at least one of the side edges of the at least one mat. In many embodiments, there is sufficient edging to border all side edges of the at least one mat, when multiple mats, if present, and connected together. The edging pieces of the invention, and other variations thereof, when combined with mats, provide a floor covering system that is easy for the user to set-up, disassemble as needed, and inhibit tripping on the edges of mats.

Description

FLOOR MAT ASSEMBLY
Cross Reference To Related Applications
This application claims the benefit of U.S. Provisional Patent Application Nos. 60/777,358, filed February 28, 2006, and 60/777,359, filed February 28, 2006, the disclosures of which are incorporated by reference herein in their entirety.
Field of the Disclosure
The present disclosure is directed to sectional floor matting, in particular, to edging for sectional floor matting.
Background of the Disclosure
Carpets and rugs have long been used to cover the ground, floor, and other surfaces. Floor coverings are not only functional in that they protect the floor, collect and retain dirt, mud and water, but they are also aesthetical. Depending on the material, the floor covering may also provide a cushion, softening the surface and thus easing stress on the user.
Floor coverings have evolved to include modular systems that can be designed on the spot for the specific application. For example, twelve 1 foot by 1 foot (about 30.5 cm by 30.5 cm) interlocking mats can be combined to form a 12 square foot mat (about 1.1 m2), either 2 foot by 6 foot (about 61 cm by 183 cm) or, 3 foot by 4 foot (about 91.5 cm by 122 cm). Such interlocking sectional matting is a popular system for customizing floor mats. Additionally, with such sectional matting systems, it is possible to replace only the worn or damaged mat sections when needed, rather than having to replace the entire mat.
3M Company has a sectional matting product line that is well recognized. Various NOMAD™ floor mats are available, with a variety of physical properties, such as thickness, mat density, material, mat section size, etc. The mats are configured to interlock, providing various shapes and sizes of matting. In one installation design, the mats are placed into a recessed well in the floor, so that the top surface of the mats is approximately level with the ground. In another installation design, where there is no recessed well, tapered or ramped edging is placed around the perimeter of the mat, to reduce the chance a user may trip on the edge of the mat. The edging is generally glued to the mat, to inhibit the mat and edging from becoming separated. Typically, when either the mat or the edging is worn or damaged, both the edging and the mat section are replaced.
The present invention provides a floor mat system that increases the benefits associated with using sectional matting.
Summary of the Disclosure
An aspect of the present disclosure is directed to a sectional floor mat system to allow varying sizes of floor mats to be created from smaller floor mats. Edging pieces or sections are removably engaged with the floor mats to inhibit tripping on the edge of the mat.
An exemplary embodiment of the floor mat system of the present disclosure is a sectional system that includes at least one mat and sufficient edging to border at least one of the side edges of the at least one mat. In many embodiments, there is sufficient edging to border all side edges of the at least one mat. When multiple mats are in the system, in many embodiments, there is sufficient edging to boarder all exposed edges of the mats when connected together.
In one particular aspect, the disclosure is directed to a perimeter section for a mat, the perimeter section capable of being removably engaged to a side edge of the mat. The perimeter section comprises a transition portion having a varying (e.g., tapered) thickness, where the maximum thickness is substantially the same as the mat thickness. In many embodiments, the thickness decreases as the perimeter section extends outward from the mat. The perimeter section includes an engagement portion for at least partially penetrating into the mat. This engagement portion may penetrate up into or down into the mat.
In another particular aspect, the disclosure is also to a mat system, the system being a combination of at least one mat and at least one perimeter or edging section that releaseably attaches to the mat. In one more specific embodiment, the mat system includes at least one floor mat having a side edge, a top surface and a bottom surface, with a plurality of voids extending into the floor mat, and an edging section configured to abut the side edge of the floor mat, the edging section having an engagement mechanism configured to extend into at least one void to releasably engage the floor mat. The engagement mechanism could extend into a plurality of voids, and optionally through one or more voids. This extension could be down from the attachment portion of the edging section into the top surface of the mat or up from the attachment portion into the bottom surface of the mat.
Another aspect of this disclosure is the combination of a floor mat having a side edge, a top surface and a bottom surface, with a plurality of voids extending into the floor mat, and an edging section configured to abut the side edge of the floor mat, the edging section having an engagement mechanism configured to extend into at least one void to releasable engage the floor mat.
Yet another aspect of this disclosure is a kit that includes a mat section, and a perimeter section capable of being removably engaged adjacent to the edge of the mat, the perimeter section having a varying thickness, wherein the maximum thickness of the perimeter section is substantially the same as the mat thickness at its edge, and the perimeter section thickness decreases as the perimeter section extends outwardly from the edge of the mat section.
Also provided is a method of assembling a modular mat by providing a mat section and removably attaching a perimeter section to the edge of the mat, the perimeter section having a varying thickness, wherein the thickness of the perimeter section is substantially the same as the mat thickness at the edge, and the perimeter section thickness decreases as the perimeter section extends outwardly from the edge of the main section.
These and other embodiments and aspects are within the scope of this disclosure.
Brief Description of the Drawings
FIG. 1 is a perspective view of a floor mat system assembled from multiple floor mats and edging sections;
FIG. 2 is a top view of a first embodiment of an edging section engaged with a floor mat;
FIG. 3 is a perspective view of the edging section of FIG. 2;
FIG. 4 is a top plan view of the edging section of FIG. 2; FIG. 5 is a side plan view of the edging section of FIG. 2;
FIG. 6 is a bottom plan view of the edging section of FIG. 2;
FIG. 7 is a top plan view of a second embodiment of an edging section engaged with a floor mat;
FIG. 8 is a side plan view of the edging section of FIG. 7;
FIG. 9 is a top plan view of a third embodiment of an edging section engaged with a floor mat;
FIG. 10 is a side plan view of the edging section of FIG. 9; and
FIGS. 1 l(a), 1 l(b), 11 (c), and 1 l(d) are various embodiments of engagement mechanisms suitable for use with any of the edging sections of this disclosure.
Detailed Description
Referring to the figures, various embodiments of floor mat edging according to the present invention are provided. In FIG. 1, a floor mat system, composed of a plurality of floor mats and a plurality of edging, is illustrated generally at 10. System 10 is composed of a plurality of floor mats 12 (specifically, nine floor mats 12) and an edging system 14 that circumscribes the plurality of mats 12. In this embodiment, edging system 14 has a plurality of side edging sections or pieces 16 (specifically, twelve edging pieces 16, three of which are specifically referenced as 16A, 16B, 16C), which will be described in detail below.
FIG. 2 illustrates a partial piece of mat 12 with a generic edging section 16 connected thereto. It is noted that edging sections 16A and 16C illustrated in FIG. 1 are corner pieces, each including an end angled at 45 degrees, to facilitate forming a corner. Two angled ends joined form a 90 degree corner. Edging section 16B of FIG. 1 and edging section 16, as illustrated in FIG. 2 and FIGS. 3 through 6, is a piece suitable for positioning between two corner edging sections. In some embodiments, a single edging section 16 may extend the entire side edge, having an angled end on each end. Such an embodiment could be formed "in situ", being cut to length on site during installation.
Returning to FIG. 2, mat 12 has a first edge 22, a second edge 24 and a third edge 26 opposite second edge 24. Mat 12, in this embodiment being a rectangle such as a square, includes a fourth edge which is not shown in FIG. 2. The width of mat, at least for these purposes, is the distance between edge 24 and edge 26. At first edge 22, mat 12 is connected to edging section 16 proximate a wall 32, which is further described below.
Referring to FIG. 2 and also to FIGS. 3 through 5, edging section 16 has a first end edge 34 and a second end edge 36 opposite first end edge 34. The length of edging section 16 is the distance between end edge 34 and end edge 36. The length of edging section 16 may be the same, more, or less than the width of mat 12; for example, a corner edging section (such as sections 16A, 16C of FIG. 1) may be longer than the width of mat 12. Edging section 16 also has an outer edge 38 and opposite outer edge 38 is wall 32. Together, edges 34, 36, 38 and wall 32 define a transition portion 40. Transition portion 40 includes a top surface 35, which is a beveled or angled surface that facilitates the progression from the ground, floor or other surface on which edging section 16 is placed and the top of mat 12. Transition portion 40 is a ramp from a surface below the top of mat 12 (e.g., the floor) to the top of mat 12. Transition portion 40 is that portion of edging section 16 that circumscribes mat 12 and is visible in FIG. 1.
Edging section 16 also includes attachment portion 42, FIG. 3, which engages and retains edging section 16 to mat 12. Attachment portion 42 has a lower portion 45 with an end edge 44 which is preferably aligned with end edge 34, and an end edge 46, which is preferably aligned with end edge 36. Attachment portion 42 also has inner edge 48 opposite transition portion 40. Wall 32 differentiates between transition portion 40 and attachment portion 42, providing a step from lower portion 45 of attachment portion 42 to transition portion 40, particularly, to top surface 35; see FIG. 3 and 5.
As seen in FIG. 6, the overall shape of edging section 16 is defined by ends 34/44, ends 36/46, edge 38 and edge 48.
Attachment portion 42 includes an engaging mechanism 50, which engages and retains mat 12. In this embodiment, engaging mechanism 50 comprises a plurality of posts 52 that extend upward from lower portion 45. Engaging mechanism 50 can be described as at least one but preferably a plurality of posts, nubs, spikes, or other such protruding features that extend up from lower portion 45 and have a distal or free end opposite lower portion 45. Engaging mechanism 50 is configured to extend or penetrate up into, and optionally through, mat 12. Engaging mechanism 50 may extend at a right angle to lower portion 45, or may be tilted or angled in relation thereto. In this particular embodiment, engaging mechanism 50 extends generally level with the maximum height of transition portion 40, at wall 32; it is understood that in alternate embodiments, transition portion 40 may extend higher than engaging mechanism 50, or even, though not preferred, engaging mechanism 50 may extending higher than the maximum of transition portion 40.
Mat 12 generally includes a plurality of passages, cells, or other voids that extend though the thickness of mat 12. Engaging mechanism 50 is configured to pass through, at least partially, these voids to hold mat 12 relative to attachment portion 42 and edging section 16. Engaging mechanism 50 passes through mat 12 from the bottom surface of mat 12 toward the top surface of mat 12. The thickness of mat 12 and the length or height of engaging mechanism 50 will affect the amount that mechanism 50 extends into mat 12.
In this particular embodiment, best seen in FIGS. 3 and 4, engaging mechanism 50 comprises a plurality of posts 52 extending as two rows parallel to wall 32, although it is understood that any number of rows or any configuration of posts 52 could be suitable. In this embodiment, posts 52 from one row are offset from posts 52 of the other row. No matter what the configuration of posts 52, they should be shaped, sized, and arranged so a sufficient number of posts 52 pass into the voids of mat 12 in order to adequately retain mat 12 with edging section 16. Returning to FIG. 2, engaging mechanism 50 can be seen extending into voids in mat 12.
In FIG. 2, edge 22 of mat 12 is illustrated adjacent and preferably seated against wall 32 (FIG. 3) of edging section 16. Although not readily visible, a portion of mat 12 is present over attachment portion 42. Typically, attachment portion 42 extends at least 1/2 inch (about 1.27 cm), preferably at least 1 inch (about 2.54 cm), and more preferably at least 1.3 inches (about 3.3 cm) past wall 32 and is covered by mat 12.
A second embodiment of edging suitable for use with mat 12 is illustrated in FIGS. 7 and 8. In this embodiment, edging section 56 has a first end edge 64 and a second end edge 66 opposite first end edge 64. The length of edging section 56 is the distance between end edge 64 and end edge 66. The length of edging section 56 may be the same, more, or less than the width of mat 12; for example, a corner edging section may be longer than the width of mat 12. Edging section 56 also has an outer edge 68 and opposite outer edge 68 is an internal wall 62. Together, edges 64, 66, 68 and wall 62 define a transition portion 60. Transition portion 60 includes a top surface 65, which is a beveled or angled surface. Transition portion 60 is that portion of edging section 56 that circumscribes mat 12.
Edging section 56 also includes attachment portion 7O5 which engages and retains mat 12 with edging section 56. Attachment portion 70 has top portion 72 with end edge 74 which is preferably aligned with end edge 64, and end edge 76, which is preferably aligned with end edge 66. Attachment portion 70 also has inner edge 78. A wall 62 differentiates between transition portion 60 and attachment portion 70; see FIG. 8.
Attachment portion 70 includes engaging mechanism 75, which engages and retains mat 12. In this embodiment, engaging mechanism 75 extends or penetrates down from top portion 72. Engaging mechanism 75 can be described as at least one but preferably a plurality of posts, nubs, spikes, or other such features that extend down from top portion 72 and have a free distal end. Engaging mechanism 75 is configured to extend down into, and optionally through, voids in mat 12.
When edging section 56 is engaged with a mat 12, attachment portion 70, particularly top portion 72, is present over a portion of mat 12. Typically, attachment portion 70 extends no more than about 4 inches (about 10.2 cm), preferably no more than about 2 inches (about 5 cm) over mat 12 or even no more than about 1.5 cm (about 4 cm) over mat 12.
Edging sections 16, 56 are configured for use with mats 12 that have a generally straight edge 22 to abut against wall 32, 62. FIG. 9 illustrates an embodiment of an edging section for use with a mat 12' that includes engagement elements 20 extending out from edge 22' of mat 12'. These engagement elements 20, for example, are configured to engage with a second mat 12' (not shown), in order to provide a larger overall mat, such as in FIG. 1 which illustrates nine mats connected together, such as by engagement elements 20. One example of such a mat 12' with engagement elements 20 is shown in registered Community design No. 000050638, Applicant of which is 3M Innovative Properties Company.
An embodiment of edging suitable for use with mat 12' is illustrated in FIGS. 9 and 10 as edging section 86. In this embodiment, edging section 86 has end edges and edges similar to edging section 56, described above. Turning to FIG. 10, edging section 86 has transition portion 90 generally similar to transition portion 60, which includes a top surface 95, and also includes an attachment portion 100 generally similar to attachment portion 70, which includes inner edge 108. Edging section 86 includes an internal wall 92, generally similar to internal wall 62, with modifications as described below.
Attachment portion 100 is the portion of edging section 86 which engages and retains mat 12'. Attachment portion 100 includes engaging mechanism 105 extending from top portion 102, which engages and retains mat 12' in a manner similar to engaging mechanism 75 of edging section 56. Engaging mechanism 105 is" configured to extend down into, and optionally through, voids in mat 12'. When engaged with mat 12', attachment portion 100 is present over a portion of mat 12'.
Edging section 86 differs from edging section 56 in that wall 92, differentiating between transition portion 90 and attachment portion 100, is adapted to receive a portion of mat 12' therein. Wall 92 includes a recess 94, recessed away from attachment portion 100 include transition portion 90. Recess 94 is shaped and sized to receive engagement element 20 extending out from edge 22' of mat 12'. By using edging section 86 with mat 12', mat 12' can be positioned without the concern of engagement element 20 inhibiting abutment of edge 22' against wall 92.
Turning to FIGS. 1 l(a) through 1 l(d), various embodiments of engagement mechanism, as alternates to engaging mechanisms 50, 75, 105, are illustrated. Engagement mechanism 50, best seen in FIG. 5, has a blunt distal end, configured for passing generally unhindered into and out from a void in mat 12. Engagement mechanisms 75, 105 have a rounded distal end, for passing generally unhindered into and out from a void in mat 12. FIG. 1 l(a) shows an alternate engagement mechanism, having a tapered or pointed distal end, which would pass unhindered into and out from a void in a mat. FIGS. 1 l(b), 1 l(c) and 1 l(d) show alternate engagement mechanisms that engage with a portion of the mat in which it is inserted.
Each of the engagement mechanisms of FIGS. 1 l(b), 1 l(c) and 1 l(d) has an increased diameter at its distal end. FIG. 1 l(b) illustrates an engagement mechanism having a rounded, bulbous feature at its distal end. FIG. 1 l(c) illustrates an engagement mechanism having a tapered, blunt distal end. FIG. 11 (d) illustrates a branched engagement mechanism, in this embodiment having a bifurcated stem with bulbous features at the distal ends. In addition to the increased diameter at the distal end, each of the engagement mechanisms of FIGS. 1 l(b), 1 l(c) and 1 l(d) has a shelf or lip that defines the side of the increased diameter opposite the distal end.
Each of the engagement mechanisms of FIGS. 1 l(b), 1 l(c) and 1 l(d) is configured to provide either or both frictional or physical engagement with mat 12. Frictional engagement could be provided by the outer edges of the engagement mechanisms contact the walls of the void into which the engagement mechanism is positioned. Physical engagement could be provided by passing the engagement mechanism through the void, and having the shelf of the increased diameter region engage with and catch the bottom side of mat 12, inhibiting removal of the engagement mechanism from the void. Branched designs facilitate withdrawing the engagement mechanism from the void when desired.
Although each of the engagement mechanism illustrated herein are smooth- walled, extending between its connection to the edging section and its distal end, it is understood that other configurations would be useful. For example, any engagement mechanism may have, for example, surface features that increase the engagement of the engagement mechanism in the void, such as barbs or ribs.
It is to be understood that features discussed in respect to edging section 16, edging section 56 or edging section 86 can be present on each or any of the others, and that unless the character of the edging section will be substantively changed, elements are interchangeable among edging sections 16, 56, 86.
Each of generic edging sections 16, 56, 86 has been illustrated having side edges being orthogonal to the extension of edging section 16, 56, 86 respectively; specifically, for example, end edges 34/44, 36/46 of edging section 16 are at 90 degree angle to edge 38. Additionally, end edges 34/44, 36/46 align with edges 24, 26 of mat 12.
Returning to FIG. 1, edging section 16B is configured for positioning between two corner edging pieces 16A, 16C. Similarly, the previous discussion and figures of generic edging sections 16, 56, 86 has been to edging sections for positioning at a non-corner mat. It should be understood that the configuration of any of edging sections 16, 56, 86 can be modified so that the pieces are suited for use as a corner piece. For example, an end of edging section 16, 56, 86 (i.e., end edge 34/44 or 36/46, or end edge 64/74 or 66/76) could be configured at a 45 degree angle, so that two so-formed pieces could be joined to form a 90 degree corner. In another embodiment, a piece separate from an edging section could be used as a corner piece.
Although edging sections 16, 56, 86 have been illustrated as having the same length as the width of the mat to which they are attached, edging sections 16, 56, 86 could be longer, to engage more than one mat, or shorter, to engage less than one mat. For example, one edging section could be configured to engage three adjacent mats.
Although top surface 35, 65, 95 of transition portion 40, 60, 90, respectively, has been illustrated as a beveled edge or chamfer, top surface 35, 65, 95 could be curved or arched, such as a fillet, stepped, or ribbed.
Edging section 16, 56, 86 and other embodiments can be made from any suitable material, including polymers (plastics), metal, wood, composites, clay, and the like. The most preferred material for edging sections, however, is polymeric materials. Edging section 16, 56, 86 can be a unitary piece or assembled from multiple pieces. A polymeric unitary piece can be readily injection molded using conventional techniques. Polymeric materials can also be readily colored.
It may be desirable to have two or more materials present in edging section 16, 56, 86; for example, engaging mechanism 50, 75, 105 might be a metal or a polymeric material different than lower portion 45 or top portion 12, 102. Edging section 16, 56, 86 having different engaging mechanisms 50, 75, 105 could be made by extruding the transition and attachment portions and subsequently attaching engaging mechanisms 50, 75, 105. Additionally or alternately, top surface 35, 65, 95 could have an anti-slip or other fricative surface integral therewith or applied subsequently.
In use, edging sections 16, 56 or 86 are combined with mats 12 or 12' to form a mat system. Generic edging sections 16, 56, 86, as described above, are edging pieces suitable for use in the center or non-end of an assembled mat system. These sections 16, 56, 86 may be used in combination with edging pieces configured as corner pieces (e.g., sections 16A, 16C), or these sections 16, 56, 86 may be used in combination with pieces that do not contact the side edges of mats 12, 12' but only form the corners.
It is to be understood, however, that even though numerous characteristics and advantages of the mat system and edging pieces of the present disclosure have been set forth in the foregoing description, together with details of the structure and function of the disclosure, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the disclosure to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. For example, it is not necessary that mats 12, 12' are square mats; other shapes are suitable. Examples of shapes include rectangles, parallelograms, rhombus, hexagons, triangles, and other polygons, including irregular polygons such as bowties, L-shaped, or U-shaped. Mats 12, 12' could have curved surfaces. Additionally or alternatively, the resulting mat system could have any shape, such a square, rectangle, parallelogram, rhombus, hexagon, triangle, and other polygons including irregular polygons. Circular or arced shapes are possible. For mat systems that have corners, the ends of the edging pieces would be appropriately angled or otherwise shaped to form the desired corner angle. Internal corners, of any angle, are foreseen. In some embodiments, edging sections 16, 56, 86 may be placed on only a portion of the sides of mats 12, 12', leaving one or more edges of mats 12, 12' unedged. The maximum height of transition portion 40, 60, 90 of edging sections 16, 56, 86, which generally defines the height of edging section 16, 56, 86, may be the thickness of mat 12, 12', such as for installations where mats 12, 12' are placed on the same surface as edging sections 16, 56, 86. Alternately, mats 12, 12' may be partially recessed into a well, or depression, so that edging sections 16, 56, 86 do not need to be the full thickness of mat 12, 12'. The mat systems that can be created with mats 12, 12', and other embodiments, and edging sections 16, 56, 86, and other embodiments, are countless. Various shapes, sizes, colors, textures, materials, etc. can be used in conjunction to create a mat system. For example, the mat system, if made from a plurality of mats, may include more than one type of mat; the outer perimeter or other high traffic areas may utilize, e.g., more durable or more porous mats. These, and other variations, are within the scope of this invention.

Claims

What is claimed:
1. A perimeter section for a mat, the perimeter section capable of being removably engaged to the mat, the perimeter section comprising: a first end and an opposite second end, an outer edge and an inner edge, the section further comprising: a transition portion extending from the first end to the second end and having a varying thickness from the outer edge to the inner edge, wherein the thickness decreases towards the outer edge; and an engagement portion at the inner edge for at least partially penetrating into the mat.
2. The perimeter section of claim 1, wherein the engagement portion extends into a plurality of voids in the mat.
3. The perimeter section of claim 2, wherein the engagement portion penetrates up into the mat.
4. The perimeter section of claim 2, wherein the engagement portion penetrates down into the mat.
5. The perimeter section of claim 1, wherein the thickness decreases linearly toward the outer edge.
6. The perimeter section of claim 1, wherein each of the first end and the second end is perpendicular to the inner edge and the outer edge.
7. The perimeter section of claim 1, wherein one of the first end and the second end forms an angle of 45 degrees to the outer edge.
8. The perimeter section of claim I5 wherein the engagement portion comprises a plurality of posts.
9. The perimeter section of claim 8, wherein the posts comprise a stem and an increased diameter distal end.
10. In combination: a mat section having a thickness and at least one edge; and at least one perimeter section capable of being removably engaged to the at least one edge, the perimeter section having a first end and an opposite second end, an outer edge and an inner edge, the section further comprising: a transition portion extending from the first end to the second end and having a varying thickness from the outer edge to the inner edge, wherein the thickness decreases towards the outer edge; and an engagement portion at the inner edge for at least partially penetrating into the mat.
11. The combination of claim 10, wherein the mat comprises a plurality of voids.
12. The combination of claim 11 , wherein the engagement portion of the perimeter section extends into the plurality of voids in the mat.
13. The combination of claim 12, wherein the engagement portion of the perimeter section penetrates up into the mat.
14. The combination of claim 12, wherein the engagement portion of the perimeter section penetrates down into the mat.
15. The combination of claim 10, wherein the thickness of the perimeter section decreases linearly toward the outer edge.
16. The combination of claim 10, wherein each of the first end and the second end of the perimeter section is perpendicular to the inner edge and the outer edge.
17. The combination of claim 10, wherein one of the first end and the second end of the perimeter section forms an angle of 45 degrees to the outer edge.
18. The combination of claim 10, wherein the engagement portion comprises a plurality of posts.
19. The combination of claim 18, wherein the posts comprise a stem and an increased diameter distal end.
20. The combination of claim 10 comprising at least four interlockable mats.
PCT/US2007/005058 2006-02-28 2007-02-26 Floor mat assembly Ceased WO2007100813A1 (en)

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