WO1998041134A1 - Method of producing a mat for wet areas - Google Patents

Method of producing a mat for wet areas Download PDF

Info

Publication number
WO1998041134A1
WO1998041134A1 PCT/FI1998/000221 FI9800221W WO9841134A1 WO 1998041134 A1 WO1998041134 A1 WO 1998041134A1 FI 9800221 W FI9800221 W FI 9800221W WO 9841134 A1 WO9841134 A1 WO 9841134A1
Authority
WO
WIPO (PCT)
Prior art keywords
mat
blank
producing
press means
wet areas
Prior art date
Application number
PCT/FI1998/000221
Other languages
Finnish (fi)
French (fr)
Inventor
Jukka Halonen
Original Assignee
Sandudd Oy
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 Sandudd Oy filed Critical Sandudd Oy
Priority to AU64024/98A priority Critical patent/AU6402498A/en
Publication of WO1998041134A1 publication Critical patent/WO1998041134A1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/14—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47K—SANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
    • A47K3/00—Baths; Douches; Appurtenances therefor
    • A47K3/001—Accessories for baths, not provided for in other subgroups of group A47K3/00 ; Insertions, e.g. for babies; Tubs suspended or inserted in baths; Security or alarm devices; Protecting linings or coverings; Devices for cleaning or disinfecting baths; Bath insulation
    • A47K3/002—Non-slip mats for baths
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/025—Foaming in open moulds, followed by closing the moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/022—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing characterised by the disposition or the configuration, e.g. dimensions, of the embossments or the shaping tools therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0072—Roughness, e.g. anti-slip
    • B29K2995/0074—Roughness, e.g. anti-slip patterned, grained
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/732—Floor coverings
    • B29L2031/7324—Mats

Definitions

  • the present invention relates to a method of producing a mat from foamed polymer material for use in wet areas .
  • Mats used in wet areas, particularly in shower spaces, are requested to have certain desirable properties. Obviously, most important of these are good resistance to moisture, fast drying, comfortable feel under the feet and sufficient friction to prevent slipping. From the prior art are known a plurality of different kinds of mats for wet areas, one of the most popular brands being marketed under the trade name SYMPATEX. These mats are made by soaking a glass-fiber fabric in a PVC suspension and then foaming the plastic. As a result, a mat offering a comfortable feel to the feet and a sufficient friction is obtained, however, with a drawback of water absorbance due to its open-pore cell structure.
  • the mat dries slowly and its drying requires the mat to be hanged in a proper place, where water can be drained off from the mat. If the mat is left, e.g., on the bathroom floor after its use in the shower, both the mat itself and the space between the mat and the floor will remain soaked with water, whereby no essential drying can occur. Thus used, the mat also becomes unhygienic.
  • the goal of the method according to the invention is achieved by virtue of a process comprising forming a blank containing polyolefin polymer, particularly polyethylene, a foaming agent and a cross- linking agent, heating said blank in an oven, whereby it undergoes foaming and crosslinking, and compressing the product in a press or similar mould into a desired shape, either during the heating step or immediately thereafter.
  • a mat made according to this method has the benefit of a closed-cell structure in its material, which prevents water from penetrating into the mat material.
  • the mat material is sufficiently soft to feel comfortable and warm as well to the feet. Because the material is nonabsorbent to water, it also stays more hygienic than most known types of mats owing to its significantly faster and easier drying. The material is also user-friendly, because there is no need to hang it for drying after each cycle of use .
  • Figure 1 is a top view of a portion of the mat implemented as an embodiment of the invention
  • Figure 2 is a sectional view along the line II-II of Fig. 1;
  • Figure 3 is a sectional view along the line III-III of Fig. 1.
  • the wet -area mat 1 shown in Fig. 1 is produced by virtue of the method according to the invention.
  • the mat surface has upward-projecting tops 2 with vertical and horizontal channels made thereinbetween in order to enhance water drainage off from the mat.
  • the tops 2 are drawn covering only a fraction of the mat surface. In practice, however, the entire surface of the mat is covered with upward-projecting tops.
  • the shape of the tops can be selected freely as they are nonessential to the function of the invention except for said drainage.
  • the mat blank is first prepared from a mixture containing a polyolefin polymer, a foaming agent also called an expanding agent and a crosslinking agent such as a peroxide.
  • a foaming agent also called an expanding agent
  • a crosslinking agent such as a peroxide.
  • One of the most suitable polyolefins grades for use in the invention is polyethylene.
  • the mixture thus prepared is heated in an oven adapted for the process.
  • the foaming agent can be selected from the group of compounds known to decompose at an elevated temperature and to release simultaneously gaseous components.
  • the volume of gases thus released will be manyfold as compared to the volume of the starting materials.
  • the gases normally released contain chiefly nitrogen, carbon dioxide and carbon monoxide.
  • the decomposition reactions of the crosslinking agent such as a peroxide and the foaming agent occur at different temperatures.
  • Crosslinking in the polymerization process refers to the intermolecular bonding of thin, linear polymer molecules to each other into a three-dimen- sionally solid network of linked polymer backbone chains.
  • the desired pattern of stops will be pressed on the mat blank (with the flow channels and the tops 2) .
  • the pressing equipment may comprise, e.g., two closely running rolls of which at least the one pressing the top side of the mat is contoured to form the desired top texture of the mac.
  • the mat is advantageously provided with holes 4 arranged at suitable spacings, e.g., into rows as shown in Fig. 1. Owing to the holes, water will be drained from the space between the mat and the floor and, correspondingly, moisture can escape to the environment from said space, thus permitting faster drying of the mat, whereby improved hygienics of the mat results.
  • the underside of the mat can be provided with a layer 3 of an antislip material thus assuring good stay of the mat in place.
  • an antislip backing can be made from any material of a high coefficient of friction that is suitable for use in wet areas.
  • An alternative approach is to contour the underside of the mat during its pressing step with "bumps" of a relatively small top area which, resultingly, will be subjected to a rather high surface pressure that increases the friction.

Landscapes

  • Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Epidemiology (AREA)
  • General Health & Medical Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Carpets (AREA)

Abstract

The invention relates to a method of producing a mat (1) for wet areas from a foamed polymer meterial. The invention is implemented by forming a blank containing polyolefin polymer, particularly polyethylene, a foaming agent and a cross-linking agent, heating said blank in an oven, whereby it undergoes foaming and cross-linking, and compressing the product in a press means or similar mould into a desired shape, either during the heating step or immediately thereinafter.

Description

Method of producing a mat for wet areas
The present invention relates to a method of producing a mat from foamed polymer material for use in wet areas .
Mats used in wet areas, particularly in shower spaces, are requested to have certain desirable properties. Obviously, most important of these are good resistance to moisture, fast drying, comfortable feel under the feet and sufficient friction to prevent slipping. From the prior art are known a plurality of different kinds of mats for wet areas, one of the most popular brands being marketed under the trade name SYMPATEX. These mats are made by soaking a glass-fiber fabric in a PVC suspension and then foaming the plastic. As a result, a mat offering a comfortable feel to the feet and a sufficient friction is obtained, however, with a drawback of water absorbance due to its open-pore cell structure. Hence, the mat dries slowly and its drying requires the mat to be hanged in a proper place, where water can be drained off from the mat. If the mat is left, e.g., on the bathroom floor after its use in the shower, both the mat itself and the space between the mat and the floor will remain soaked with water, whereby no essential drying can occur. Thus used, the mat also becomes unhygienic.
Also known in the art are wet-area mats made with an open-mesh structure from a harder grade of plastic. While these mats dry fast, they feel uncomfortable under the feet due to their hardness.
It is an object of the present invention to provide a method of producing a mat for wet areas, whereby a mat produced according to the method is free from the above- described problems. The goal of the method according to the invention is achieved by virtue of a process comprising forming a blank containing polyolefin polymer, particularly polyethylene, a foaming agent and a cross- linking agent, heating said blank in an oven, whereby it undergoes foaming and crosslinking, and compressing the product in a press or similar mould into a desired shape, either during the heating step or immediately thereafter. A mat made according to this method has the benefit of a closed-cell structure in its material, which prevents water from penetrating into the mat material. Furthermore, the mat material is sufficiently soft to feel comfortable and warm as well to the feet. Because the material is nonabsorbent to water, it also stays more hygienic than most known types of mats owing to its significantly faster and easier drying. The material is also user-friendly, because there is no need to hang it for drying after each cycle of use .
Some preferred embodiments of the invention are specified in dependent claims 2-6.
In the following the invention will be examined in greater detail with reference to the appended drawings, in which
Figure 1 is a top view of a portion of the mat implemented as an embodiment of the invention;
Figure 2 is a sectional view along the line II-II of Fig. 1; and
Figure 3 is a sectional view along the line III-III of Fig. 1.
The wet -area mat 1 shown in Fig. 1 is produced by virtue of the method according to the invention. The mat surface has upward-projecting tops 2 with vertical and horizontal channels made thereinbetween in order to enhance water drainage off from the mat. In Fig. 1, the tops 2 are drawn covering only a fraction of the mat surface. In practice, however, the entire surface of the mat is covered with upward-projecting tops. The shape of the tops can be selected freely as they are nonessential to the function of the invention except for said drainage.
In the method according to the invention, the mat blank is first prepared from a mixture containing a polyolefin polymer, a foaming agent also called an expanding agent and a crosslinking agent such as a peroxide. One of the most suitable polyolefins grades for use in the invention is polyethylene. The mixture thus prepared is heated in an oven adapted for the process. The foaming agent can be selected from the group of compounds known to decompose at an elevated temperature and to release simultaneously gaseous components. The volume of gases thus released will be manyfold as compared to the volume of the starting materials. The gases normally released contain chiefly nitrogen, carbon dioxide and carbon monoxide. The decomposition reactions of the crosslinking agent such as a peroxide and the foaming agent occur at different temperatures. It is essential that the properties of the starting material components are matched so that the reactions can be carried out in correct order at desired temperatures . Crosslinking in the polymerization process refers to the intermolecular bonding of thin, linear polymer molecules to each other into a three-dimen- sionally solid network of linked polymer backbone chains.
After or during the heating and crosslinking steps, the desired pattern of stops will be pressed on the mat blank (with the flow channels and the tops 2) . The pressing equipment may comprise, e.g., two closely running rolls of which at least the one pressing the top side of the mat is contoured to form the desired top texture of the mac. In addition to the running channels and tops, the mat is advantageously provided with holes 4 arranged at suitable spacings, e.g., into rows as shown in Fig. 1. Owing to the holes, water will be drained from the space between the mat and the floor and, correspondingly, moisture can escape to the environment from said space, thus permitting faster drying of the mat, whereby improved hygienics of the mat results.
Finally, the underside of the mat can be provided with a layer 3 of an antislip material thus assuring good stay of the mat in place. Such antislip backing can be made from any material of a high coefficient of friction that is suitable for use in wet areas. An alternative approach is to contour the underside of the mat during its pressing step with "bumps" of a relatively small top area which, resultingly, will be subjected to a rather high surface pressure that increases the friction.
To those versed in the art it is obvious that the invention is not limited by the exemplifying embodiments described above, but rather, may be varied within the scope and spirit of the appended claims.

Claims

Claims :
1. A method of producing a mat (1) for wet areas from a foamed polymer material, said method comprising forming a blank containing polyolefin polymer, particularly polyethylene, a foaming agent and a crosslinking agent, heating said blank in an oven, whereby it undergoes foaming and crosslinking, and compressing the product in a press means or similar mould into a desired shape, c h a r a c t e r i z e d in that said pressing into shape is made either during the heating step or immediately thereinafter, that an antislip material (3) is attached to the underside of the mat (1) thus formed in order to improve the nonslip properties of the mat and that the mat (1) with the antislip material attached thereto is provided with holes (4) .
2. A method as defined in claim 1, c h a r a c t e r i z e d in that the mat (1) is contoured with longitu- dinal and/or crosswise grooves in order to improve water drainage .
3. A method as defined in claim 1 or 2, c h a r a c t e r i z e d in that said press means comprises two closely running rolls having their surface (s) contoured with the desired shape of the mat texture.
4. A method as defined in any of foregoing claims 1-3, c h a r a c t e r i z e d in that the underside of the mat (1) is in the press means provided with bumps of a relatively small top area which under the resultingly high surface pressure act as friction-improving means.
PCT/FI1998/000221 1997-03-17 1998-03-12 Method of producing a mat for wet areas WO1998041134A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU64024/98A AU6402498A (en) 1997-03-17 1998-03-12 Method of producing a mat for wet areas

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FI971115 1997-03-17
FI971115A FI971115A (en) 1997-03-17 1997-03-17 Process for making a wet space mat

Publications (1)

Publication Number Publication Date
WO1998041134A1 true WO1998041134A1 (en) 1998-09-24

Family

ID=8548408

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/FI1998/000221 WO1998041134A1 (en) 1997-03-17 1998-03-12 Method of producing a mat for wet areas

Country Status (3)

Country Link
AU (1) AU6402498A (en)
FI (1) FI971115A (en)
WO (1) WO1998041134A1 (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004108371A1 (en) * 2003-06-02 2004-12-16 3M Innovative Properties Company Wet-slip resistant sheet and wet-slip resistant structure
DE102007001012A1 (en) * 2007-01-02 2008-07-10 Daniel Werner Shower mat e.g. for foot mat placed in bath, made of plastic having adhesive path and on underside of mat are two separate adhesive paths

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2154447A (en) * 1984-02-23 1985-09-11 Croydex Company Limited The Improved mat
GB2247168A (en) * 1990-08-09 1992-02-26 Holzapfel & Co Kg Geb Non-slip plastics mat and process for its manufacture

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2154447A (en) * 1984-02-23 1985-09-11 Croydex Company Limited The Improved mat
GB2247168A (en) * 1990-08-09 1992-02-26 Holzapfel & Co Kg Geb Non-slip plastics mat and process for its manufacture

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
WPI/DERWENT'S ABSTRACT, No. 87-252440, week 8736; & JP,A,62 172 041 (ASAHI CHEM IND CO LTD) 29-07-87. *

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004108371A1 (en) * 2003-06-02 2004-12-16 3M Innovative Properties Company Wet-slip resistant sheet and wet-slip resistant structure
DE102007001012A1 (en) * 2007-01-02 2008-07-10 Daniel Werner Shower mat e.g. for foot mat placed in bath, made of plastic having adhesive path and on underside of mat are two separate adhesive paths

Also Published As

Publication number Publication date
FI971115A0 (en) 1997-03-17
AU6402498A (en) 1998-10-12
FI971115A (en) 1998-09-18

Similar Documents

Publication Publication Date Title
AU2001278534B2 (en) Plastic floor covering and method for obtaining same
US4621013A (en) Thermoformable laminate structure
US6787215B1 (en) Cleat-forming woven fabric article for the manufacture of anti-creep floor mats
US4579764A (en) Molded carpet assembly with sound deadening foam backing
US8069587B2 (en) Molded insulated shoe footbed and method of making an insulated footbed
US3284274A (en) Cellular polymeric sheet material and method of making same
US7524778B2 (en) Composite sheet material
US20070193149A1 (en) Floor pad
WO1998041134A1 (en) Method of producing a mat for wet areas
US5906887A (en) Composite elastomeric article for adhesive cushioning and mounting means
US20070044350A1 (en) Ironing board
US4770648A (en) Water ski binding having an in situ molded base assembly
KR20100117985A (en) Non slip mat and manufacture method
US7491439B2 (en) Shelf liner with natural fibers
ATE66259T1 (en) PROCESS FOR MAKING A FLOOR OR WALL COVERING WITH IMPROVED STAIN RESISTANCE AND THE OBTAINED PRODUCT.
FI78259B (en) SKUMPLASTBANA.
JPS5812001B2 (en) Sugretakutsuzokoyoubanjiyouzairiyouno Seizouhou
JPH10155675A (en) Mat
US8124186B2 (en) Method of forming a shelf liner
EP1276924B1 (en) Cleat-forming woven fabric article for the manufacture of anti-creep floor mats
JPS62110992A (en) Production of floorings
AU2001255835B2 (en) Cleat-forming woven fabric article for the manufacture of anti-creep floor mats
JP3663497B2 (en) Method for producing suede-like foam rubber sheet
CA2068703C (en) Resilient composite open-cell foam structure
JP2004299576A (en) Automobile floor mat and its manufacturing method

Legal Events

Date Code Title Description
AK Designated states

Kind code of ref document: A1

Designated state(s): AL AM AT AU AZ BA BB BG BR BY CA CH CN CU CZ DE DK EE ES FI GB GE GH GM GW HU ID IL IS JP KE KG KP KR KZ LC LK LR LS LT LU LV MD MG MK MN MW MX NO NZ PL PT RO RU SD SE SG SI SK SL TJ TM TR TT UA UG US UZ VN YU ZW

AL Designated countries for regional patents

Kind code of ref document: A1

Designated state(s): GH GM KE LS MW SD SZ UG ZW AM AZ BY KG KZ MD RU TJ TM AT BE CH DE DK ES FI FR GB GR IE IT LU MC NL PT SE BF BJ CF CG CI CM GA GN ML MR NE SN TD TG

DFPE Request for preliminary examination filed prior to expiration of 19th month from priority date (pct application filed before 20040101)
121 Ep: the epo has been informed by wipo that ep was designated in this application
REG Reference to national code

Ref country code: DE

Ref legal event code: 8642

NENP Non-entry into the national phase

Ref country code: JP

Ref document number: 1998540165

Format of ref document f/p: F

NENP Non-entry into the national phase

Ref country code: CA

122 Ep: pct application non-entry in european phase