Drying Mat Configured to Hold Accessory

Abstract

A drying mat has a first microfiber layer, a second microfiber layer, and a foam layer. The first microfiber layer and the second microfiber layer are joined to the foam layer with the first microfiber layer having a surface adjoining the foam layer and an opposite exposed surface and with the second microfiber layer having a surface adjoining the foam layer and an opposite exposed surface. The first microfiber layer exposed surface has two loops spaced apart from one another across the first microfiber layer exposed surface at a distance that corresponds to a dimension of a mount of an accessory to be used with the drying mat and that allows the loops to cooperate with each other to engage the mount of the accessory.

Description

BACKGROUND AND SUMMARY

The disclosure relates to a drying mat configured to hold one or more accessories in a releasably attachable manner. The accessory(ies) may be used for receiving wet items and allowing the wet items to dry. The accessory may receive the wet items in an arrangement that facilitates their drying. The disclosure of co-owned, pending application Ser. No. 13/858,261, filed on Apr. 8, 2013, is incorporated by reference herein.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1A is a perspective view of a drying mat.

FIG. 1B is a perspective view of the drying mat with an accessory installed thereon and a second like accessory shown above the mat prior to installation;

FIG. 2 is a top view of the drying mat.

FIG. 3 is a side view of the drying mat.

FIG. 4 is another side view of the drying mat.

FIG. 5 is an enlarged view of the drying mat from detail area 5 of FIG. 1A.

FIG. 6 is a cross-sectional view of one embodiment of the drying mat.

FIG. 7 is a cross-sectional view of another embodiment of the drying mat.

DETAILED DESCRIPTION

The drying mat 10 includes a top surface 20 and a bottom surface 30. The drying mat 10 includes a first microfiber layer 100, a second microfiber layer 130, and a foam layer 160 in a laminate or layered configuration. The drying mat may be used as dish mat to absorb water from wet items W. The wet items may be any type of item that typically found in a household kitchen, for instance, by way of limitation and not in any limiting sense, dishes, drinkware, forks, knives, spoons, cups, stemware, tumblers, glassware, strainer, colander, bakeware, cookware, pots, pans, baking sheets, baby bottles, bottles, jars, etc. The wet item W may also be fruit and vegetables. The drying mat may be used to absorb water from any washed and cleaned item placed on or in an accessory to be used with the drying mat. The drying mat is machine washable. The drying mat provides a highly absorbent and fast drying alternative to a conventional dish towel, plastic drain board, or rubberized mat.

The size of the drying mat 10 may vary depending upon its intended purpose. Typically, the first microfiber layer 100, the second microfiber layer 130, and the foam layer 160 will all generally have approximately the same overall length and width. The drying mat for dishes may have a size of approximately 12 inches to approximately 22 inches in width by approximately 14 inches to approximately 36 inches in length. Typical embodiments of the dish drying mat have a size of approximately 16 inches by approximately 18 inches or approximately 18 inches by approximately 24 inches. Typical embodiments of the kitchen counter-top drying mat have a size of approximately 18 inches by approximately 32 inches. The first microfiber layer 100 and the second microfiber layer 130 have a thickness of approximately 3 mm to approximately 7 mm. The foam layer 160 has a thickness of approximately 0.4 centimeters to approximately 0.8 centimeters. The drying mat 10 provides a water absorbent structure that will absorb up to approximately 4 to 5 times its own weight in water. For example, a 16 inch by 18 inch drying mat 10 weighs approximately 150 to 155 grams. As such, this particular drying mat 10 will absorb up to approximately 26 ounces of water.

The foam layer 160 may include a variety of different foam materials, such as polyester, polyether, polyvinyl alcohol, cellulose, natural foam, and synthetic foam materials. The foam layer 160 forms a porous structure to absorb water. One type of suitable foam material are foams from the demospongea class of foams. Such foams may have a density of approximately 18 to approximately 20 kg/m³. Such foams have a hydrophilic action that helps absorb water into the drying mat 10.

The first microfiber layer 100 and the second microfiber layer 130 comprise polyester and polyamide in a range of approximately 65% to approximately 95% polyester to approximately 35% to approximately 5% polyamide. One embodiment includes approximately 80% polyester and 20% polyamide. An increased amount in the polyamide content provides for a softer and more absorbent microfiber. The individual fibers of the microfiber used in the first and second microfiber layers 100, 130 generally have a thickness of 0.1 denier or less. The high number of individual fibers in the microfiber material forming the first microfiber layer 100 and the second microfiber layer 130 promote the absorption of water into the drying mat 10, as well as the ability of the drying mat 10 to dry quickly.

As shown in FIG. 6, adhesives or glues may be used to join and hold the first microfiber layer 100, the second microfiber layer 130, and the foam layer 160 together. In accordance with the embodiment shown in FIG. 6, a first surface 105 of the first microfiber layer 100 forms the top surface 20 of the drying mat 10. A second surface 108 of the first microfiber layer 100 is glued via a first adhesive layer 120 to a first surface 165 of the foam layer 160. A first surface 135 of the second microfiber layer 130 forms the bottom surface 30 of the drying mat 10. A second surface 138 of the second microfiber layer 130 is glued via a second adhesive layer 140 to a second surface 168 of the foam layer 160. As such, the foam layer 160 is in between the first and second microfiber layers 100,130. A suitable adhesive, for the first and second adhesive layers 120,140, is a composite material glue, such as a polyurethane adhesive. Preferably, the adhesive is a non-water based adhesive. Typically, approximately 30 g/m² to approximately 50 g/m² of adhesive is applied to the first and second microfiber layers 100,130 for the first and second adhesive layers 120,140. Although the term “adhesive layer” is used, the term adhesive layer encompasses the intermittent spraying or partial coating of the adhesive to the microfiber layers or foam layer, as well as the spot application of the adhesive to the microfiber layers or to the foam layer. In other embodiments, the adhesive layer may fully or nearly fully coat the microfiber layers or the foam layer.

As shown in FIG. 7, the drying mat may also be produced using flame lamination. The flame lamination process creates a bond between the foam layer 160 and the microfiber layer or layers 100,130. The foam layer 160 is passed over an open flame, which produces a thin layer of molten polymer at a surfaces 165,168 of the foam. The thin layer of molten polymer acts as an adhesive for bonding or attaching the foam layer 160 to the respective surfaces 108,138 of the microfiber layer 100,130. When urged against the microfiber layers 100,130, the molten polymer may flow into or between the pattern, weave, and/or fibers of the microfiber. After the molten polymer cools, the foam layer is bonded to the microfiber. The flame used for the flame lamination may be approximately 350 degrees F. to approximately 450 degrees F. The foam layer 160 may be passed over the flame at a rate of approximately 20 meters per minute to approximately 30 meters per minute. The temperature and/or rate of the passing of the foam layer 160 over the flame may be increased or decreased depending upon the specific composition of the foam layer 160 and/or the microfiber layers 100 and 130. The temperature and/or rate of passing of the foam layer 160 over the flame will vary depending on the density, weight, and specific material of the foam layer 160. A temperature of approximately 350 degrees F. at a rate of approximately 25 meters per minute forms a molten polymer surface for the foam layer 160 suitable for bonding to the microfiber layers 100 and 130. Other temperatures and rates will provide suitable results.

The first microfiber layer 100 and the second microfiber layer 130 may also be bonded to the foam layer 160 using heated compression or a flame type compression with an adhesive applied between the first microfiber layer 100 and the foam layer 160 to form the first adhesive layer 120, and the adhesive is applied between the second microfiber layer 130 and the foam layer 160 to form the second adhesive layer 140. Heat and compression may be applied to join the first microfiber layer 100, the second microfiber layer 130, and the foam layer 160.

The first microfiber layer 100 and the second microfiber layer 130 may also be attached to the foam layer 160 by binding or sewing. The first surface 105 of the first microfiber layer 100 forms the top surface 20 of the drying mat, while the first surface 135 of the second microfiber layer 130 forms the bottom surface 30 of the drying mat. The foam layer 160, the first microfiber layer 100, and the second microfiber layer 130 are layered together and held together by stitching through the foam layer and microfiber layers. The stitching may pass through all of the foam layer 160, the first microfiber layer 100, and the second microfiber layer 130. In other embodiments, portions of the stitching may also pass through the foam layer 160 and the first microfiber layer 100, while other portions of the stitching pass through the foam layer 160 and the second microfiber layer 130. As such, in certain embodiments, the foam layer 160 is bound to the first microfiber layer 100, and the foam layer 160 is bound to the second microfiber layer 130. The sewing or binding of the various layers may be in different patterns and styles. The stitching may be at the perimeter of the drying mat. The stitching may occur in patterns across the width and length of the drying mat. The stitching may occur at specific points, locations, or regions of the drying mat. The sewing of the stitching may occur at points at specific intervals, such as, for example, the stitching of the thread may occur at points at every several inches of the drying mat. In still further embodiments, the various microfiber layer(s) and the foam layer(s) may be held together by combinations of binding, sewing, adhesives, and flame lamination.

A binding 200 may be used to affix or connect together the perimeter portions or edges of the first microfiber layer 100, the second microfiber layer 130, and the foam layer 160. The binding 200 may be applied using an over-edging machine at a rate of approximately 5 stitches per inch. The binding 200 may be a polyester, microfiber, polyamide, satin, cotton, synthetic, nylon, or other durable material. The binding 200 is attached to the microfiber layers 100 and 160 via stitching 210.

The first microfiber layer 100 and the second microfiber layer 130 may include a textured pattern. The textured pattern increases the surface area of the layer of microfiber 100 and 130 as compared to a flat sheet of microfiber. The increased surface area promotes water absorption into the microfiber layers 100 and 130, as well as the drying of the microfiber layers 100 and 130. The textured pattern may be a honeycomb pattern that forms a grid or matrix of squares 300 in the top and bottom surface 20 and 30 of the first microfiber layer 100 and the second microfiber layer 130. A central region of each square 300 includes a depression 250, which provides a hollow void interior to the square 300. All or essentially all of the squares 300 include the depression 250. The squares 300 adjacent to the binding 200 may have their depressions 250 fully or partially covered or blocked by the binding 200. The depressions 250 generally extend into the top and bottom surface 20 and 30. The depressions 250, through gravity and wicking action of the microfiber material, receive and direct beads of water and moisture into the interior of the drying mat 10 and toward the foam layer 160. Each depression 250 includes sidewalls 310 leading to an interior surface 320 of the depression 250. The sidewalls 310 connect either the top surface 20 or the bottom surface 30, respectively, with the interior surface 320 of the depression 250. The honeycomb pattern comprises approximately 50,000 to approximately 150,000 depressions 250 per square meter of the first and second microfiber layers 100 and 130. Each depression 250 may be approximately 0.3 mm to approximately 2 mm in depth. Each depression 250 is approximately 3 mm by approximately 3 mm in width. The width of the depressions 250 may range from approximately 2 mm to approximately 25 mm. Although a honeycomb pattern is shown in FIGS. 1-7, other patterns or plain surface types of microfiber material may be used for the first and second microfiber layers 100 and 130. For example, a waffle pattern, a terry pattern, a circular knit pattern, a flat loop pattern, a suede pattern or a herringbone pattern may be used in forming the drying mat 10. Also, a non-woven microfiber material may be used in forming the microfiber layers 100 and 130. The honeycomb pattern may also form a matrix of rectangles instead of the squares 300. Patterns of microfiber containing circular, ovular, geometric, or non-geometric shapes and designs of depressions may also be utilized. Microfiber materials having patterns, which increase surface area for the drying mat 10, such as the honeycomb pattern, are well suited for use in the drying mat 10. The increased surface area promotes absorption of water into the drying mat 10 and the drying of the drying mat 10.

The drying mat 10 may use combination of one or more different types or patterns of microfiber, such as, for example, a waffle pattern, a terry pattern, a circular knit pattern, a flat loop pattern, a suede pattern or a herringbone pattern. As such, the first microfiber layer 100 and the second microfiber layer 130 may use the same or different types of microfiber. For example, the first microfiber layer 100 and the second microfiber layer 130 may both use a waffle pattern. Or, for example, the first microfiber layer 100 may use a waffle pattern, while the second microfiber layer 130 may use a terry pattern.

As shown in the drawings, the drying mat 10 may include an accessory 400 that enhances use of the drying mat. To enhance use of the accessory 400 with the drying mat 10, the exposed surfaces of the drying mat 105,135, for instance, the first microfiber layer 100 and/or second microfiber layer 130, has two loops spaced 410 apart from one another across the exposed surface of the drying mat. Each of the loops 410 may have a length 412 and a width 414 transverse to the length. The width edges 414 of the loops 410 may be arranged on the exposed surface of the drying mat to set length dimensions of the loops and an amount of projection of the loop above the exposed surface of the drying mat, for instance, from a position where the widths are spaced apart by the length, thereby allowing the loops to be generally flush to the exposed surface of the drying mat to a configuration where the widths are together, thereby allowing the loops to project from the exposed surface of the drying mat by half of the length. A pair of loops may be provided on the first microfiber layer 100 and also on the second microfiber layer 130 to allow either side of the drying mat to be used. The loops 410 may be mechanically secured to the drying mat by being riveted, pinned, adhered or stitched, for instance, stitched across their widths edges, or the loops may be releasably attachable to the exposed surface of the drying mat, for instance, with a hook and loop material to allow the location and size of the loops on the exposed surface of the drying mat to be changed by the user as may be desired.

The loops 410 may cooperate with each other and the accessory 400 and/or a mount 420 of the accessory to allow the accessory to be releasably attached to the drying mat. The loops 410 may be formed from a stretchable material, for instance, an elastic material, and arranged on the exposed surface of the drying mat at a distance so as to stretchingly engage the mount 420 and/or the accessory 400. In addition to or in the alternative, the mount 420 and/or the accessory 400 may be formed from a material that is resiliently pliable and capable of springingly engaging the loops and/or when arranged relative to the loops to springingly engage the loops. The loops 410 may be spaced apart from one another at an accessory mounting distance 422 that corresponds to a dimension 424 of the mount and/or accessory that is to be used with the drying mat and allows the loops to cooperate with each other to secure the mount and/or accessory to the drying mat. For instance, the mount may be movable between a first position in which the mount dimension 424 has a first value and a second position in which the mount dimension has a second value smaller than the first value and slight smaller than the accessory mounting distance 422. When the mount moves from the first position to the second position, the inherent springing force in the accessory or mount may urge the mount or accessory toward the first position, thereby enabling the mount to engage the loops 410. To install the mount 420 and/or accessory in the loops 410, the mount may be moved from the first position to the second position, for instance, the mount may be compressed. The second position may be slightly less than the accessory mounting distance 422 between the loops. Once the mount is engaged in the loops, the mount may be released. The material of the mount 420 may urge the mount outward to engage the loops 410. The loops 410 may be made from a stretchable material to facilitate the engagement of the mount 420 in the loops. To remove the mount 420 from the loops 410, the mount may be compressed to the second position to allow the mount to clear the loops. The mount may then be released to allow the mount to return to the first position. By way of example and not in any limiting fashion, the mount and accessory may be monolithically formed from a plastic material. The mount 420 and accessory 400 may have a generally flat configuration, corresponding to the first position, which may be desirable for storage and/or shipping. To install the accessory on the mat, the mount may be moved to a second position by bending the accessory and/or mount so that opposite ends of the mount 420 are brought closer to each other. The mount may then be engaged in the loops and released. When in the loops, the mount tends to move to the first position, e.g., the flat configuration, but the loops constrain the mount thereby holding the mount and the accessory in position on the exposed surface of the drying mat. In one example, the loops may be spaced apart from one another and parallel to one another along their lengths and stitched to the exposed surface of the drying mat across their width edges at opposite ends of the length. The mount may fit between each loop and the exposed surface of the drying mat. The loop may also wrap around the mount and/or accessory

The exposed surface of the drying mat may also include a second pair loops. The second pair loops may be arranged on the drying mat in a manner similar to the first pair loops. For instance, the second pair loops may be spaced apart from one another and parallel to each other along their lengths. The second pair of loops may be spaced apart from one another to cooperate with each other to engage a mount of an accessory to be used with the drying mat. The accessory may be separate from the accessory of the first pair of loops or may be the same accessory, in which case the accessory may be provided with a second mount to be engaged by the second pair of loops. The second pair of loops may be arranged on the drying mat so as to cooperate with the first pair of loops to allow the use of an accessory that utilizes the first and second pairs of loops to secure the accessory to the drying mat. The second pair loops may be spaced apart from the first loops in the direction extending along the lengths of the first pair of loops. The second pair of loops may have their lengths collinearly arranged with the lengths of the first pair of loops. The second pair of loops may have may be arranged on the drying mat in a manner to accommodate the dimensions and arrangement of the second mount of the accessory.

It should be understood from the foregoing that, while particular embodiments of the invention have been illustrated and described, various modifications can be made thereto without departing from the spirit and scope of the present invention. Therefore, it is not intended that the invention be limited by the specification; instead, the scope of the present invention is intended to be limited only by the appended claims.

Claims

1. A drying mat comprising:

a first microfiber layer;

a second microfiber layer; and

a foam layer;

wherein the first microfiber layer and the second microfiber layer are joined to the foam layer with the first microfiber layer having a surface adjoining the foam layer and an opposite exposed surface and the second microfiber layer having a surface adjoining the foam layer and an opposite exposed surface, the first microfiber layer exposed surface having at least two loops spaced apart from one another across the first microfiber layer exposed surface at a distance that corresponds to a dimension of an accessory to be used with the drying mat and allows the loops to cooperate with each other to engage the accessory.

2. The drying mat according to claim 1, wherein the drying mat is approximately 12 inches to approximately 22 inches in width by approximately 14 inches to approximately 36 inches in length.

3. The drying mat according to claim 1, wherein at least one of the loops of the first microfiber layer exposed surface is fixed in position on the exposed surface of the first microfiber layer.

4. The drying mat according to claim 1, wherein the distance corresponds to a compressed dimension of the accessory.

5. The drying mat according to claim 1, wherein the second microfiber layer exposed surface has at least two loops spaced apart from one another across the second microfiber layer exposed surface at a distance that corresponds to a dimension of an accessory to be used with the drying mat and allows the loops to cooperate with each other to engage the accessory.

6. The drying mat according to claim 1, wherein at least one of the loops of the second microfiber layer exposed surface is fixed in position on the exposed surface of the first microfiber layer.

7. The drying mat according to claim 1, wherein at least one of the loops of the first microfiber layer exposed surface and second microfiber layer exposed surface is stretchable.

8. A drying mat comprising:

a first microfiber layer;

a second microfiber layer; and

a foam layer;

wherein the first microfiber layer and the second microfiber layer are joined to the foam layer with the first microfiber layer having a surface adjoining the foam layer and an opposite exposed surface and the second microfiber layer having a surface adjoining the foam layer and an opposite exposed surface; and

wherein the first microfiber layer exposed surface has a first pair of loops, each of the loops of the first pair of loops has a length and a width transverse to the length, and the loops are spaced apart from one another and parallel to one another along their lengths and cooperate with each other to engage an accessory to be used with the drying mat.

9. The drying mat according to claim 8, wherein each of the loops of the first pair of loops is fixed to the exposed surface of the first microfiber layer on opposite ends of the length across the width.

10. The drying mat according to claim 8, further comprising a second pair of loops of the exposed surface of the first microfiber layer, each of the second pair of loops of the exposed surface of the first microfiber layer has a length and a width transverse to the length, and the second pair of loops are spaced apart from one another and parallel along their lengths, and the second pair of loops are spaced apart from one another and parallel to one another along their lengths and cooperate with each other to engage an accessory to be used with the drying mat.

11. The drying mat according to claim 10, wherein each of the second pair of loops is fixed to the exposed surface of the first microfiber layer on opposite ends of the length across the width.

12. The drying mat according to claim 10, wherein the second pair of loops spaced apart from the first pair of loops in a direction extending along the length of the first pair of loops.

13. The drying mat according to claim 12, wherein one loop of the second pair of loops has its length arranged collinearly with the length of one loop of the first pair of loops.

14. The drying mat according to claim 13, wherein the other loop of the second pair of loops has its length arranged collinearly with the length of the other loop of the first pair of loops.

15. A method comprising:

providing a drying mat with a first microfiber layer comprising a first surface and a second surface, a second microfiber layer comprising a first surface and a second surface, a foam layer comprising a first surface and a second surface wherein the first surface of the foam layer is applied to the second surface of the first microfiber layer and the second surface of the foam layer is applied to the second surface of the second microfiber layer, the first microfiber layer first surface has at least two loops spaced apart from one another across the first microfiber layer first surface at an accessory mounting distance; and

providing an accessory to be used with the drying mat, the accessory having a dimension that corresponds to the accessory mounting distance of the first microfiber first layer first surface, the accessory being configured to engage the loops such that the loops cooperate with each other to engage the accessory.

16. The method claim 15, further comprising installing the accessory on the drying mat by inserting the accessory into the loops.

17. The method of claim 16, wherein the step of providing the accessory includes providing the accessory with a compressible mount.

18. The method claim 17, wherein the step of installing the accessory on the drying mat by inserting the mount into the loops includes compressing the mount such that the mount dimension corresponds to the accessory mounting distance and the mount engages the loops.

19. The method of claim 16, wherein the step of providing the accessory includes providing an accessory that comprises a holder for at least one of following: a dish, drinkware, fork, knife, spoon, cup, stemware, tumbler, glassware, strainer, colander, bakeware, cookware, pot, pan, baking sheet, baby bottle, bottle, and jar.

20. The method of claim 16, wherein the step of providing the drying mat including providing the drying mat with at least two additional loops spaced apart from one another across the first microfiber layer first surface at the accessory mounting distance; and the step of installing the accessory on the drying mat by inserting the accessory into the loops includes inserting the accessory into the two additional loops.