INTEGRATED MAT ASSEMBLY AND METHOD OF USE
A mat assembly includes a center section and four ramps that create a unitary mat assembly for any desired use. The center section includes a top plate that provides the desired kind of mat surface for use and a sponge layer underlying the top plate to provide the center section with a cushioned feel during use. Each ramp includes a flange that extends from an end portion of the ramp, the flange configured to be joined between the top plate and sponge insert. The ramps can be joined to each other using a connector or a mitered connection.
A unitary mat assembly is provided that includes a cushioned center section and ramps integrally connected to the periphery of the center section, and more particularly, a unique ramp configuration that minimizes any lifting of the ramp ends during use of the mat assembly and possible tripping hazards and provides a robust attachment between the ramp and center section without visibly showing the attachment details.
BACKGROUND ARTFloor mat designs widely vary in the prior art. One type uses connectors on peripheral edges of the mat so that mats can be linked together to provide more mat coverage. Another type of mat is a unitary one, i.e., a single mat, which is provided with a ramp structure along its periphery and does not use peripheral connectors to link to another mat.
As such, a need exists to provide an improved unitary mat assembly that avoids tripping hazards, damage to the ramp portions of the mat, and the like. The present invention responds to this need by providing an improved mat assembly that employs a separate ramp section that is configured to securely attach to the center section of the mat assembly and retain its ramp configuration during use of the mat assembly.
SUMMARY OF THE INVENTIONOne object of the invention is to provide an improved unitary mat assembly.
Another object is to provide a mat assembly which resists the edges of the mat assembly turning up and causing a tripping hazard.
Yet another object of the invention is the use of the improved mat assembly to cover an area and provide cushioned support to a mat user.
In one embodiment, the mat assembly includes a center section having a peripheral portion, the center section comprising a sponge layer and a top layer, a center portion of each of the top layer and the sponge layer secured together.
Also provided as part of the mat assembly are a plurality of ramps. Each ramp has an inclined or angled top portion, a bottom portion, and a connecting flange. One end of the inclined top portion terminates at a free end of the ramp, the free end extending longitudinally along the ramp. The ramp can also have a plurality of channels extending longitudinally along the ramp, wherein adjacent channels are separated by a member extending between the inclined top portion and bottom portion of the ramp. The ramp also has opposing end portions.
The connecting flange is positioned between an underside portion of the top layer and an upper surface portion of the sponge layer, each portion being in the peripheral portion of the center section, wherein the connecting flange, underside portion and upper surface portion are attached together to form an integral connection between the ramp and mat center section. The end portions of adjacent ramps are also configured to be attached together.
In one embodiment, the end portions of adjacent ramps are connected together using a plurality of corner connectors. Each corner connector has opposing side faces with each opposing side face configured to attach to an adjacent end portion of one of the plurality of ramps. In another embodiment for adjacent ramp connections, at least one end portion of at least two of the ramps is angled with respect to a longitudinal axis of the ramp. The angled end portions attach together by a bonding of the end portions or by use of fasteners, or a combination thereof.
The bottom portion of each ramp can be inclined when the ramp is attached to the center section such that only the free end of the ramp is in contact with a floor surface. The connecting flange can have at least a portion that is tapered in thickness and/or be angled downwardly as compared to an upper surface of the top plate. The downward angling of the connecting flange assists in keeping the edge of the ramp on a floor or ground as the flange angling is changed when the ramp and center section are assembled into the mat assembly.
For the corner connectors, each corner connector can include a plurality of tree connectors or other kinds of connectors, each tree connector configured to engage one of the channels in the ramp.
The top plate of the mat assembly can have any known configuration, including one with protrusions extending from an upper surface of the top plate for slip resistance or a smooth surfaced top plate. The ramp and corner connectors could also have configurations matching the top plate in terms of means for slip resistance or different surface combinations, e.g., the ramps and top plate would have protrusions, ribs, or the like and the corner connectors would be smooth surfaced.
The invention also includes the use of the inventive mat assembly to cover a desired floor surface to provide cushioned support for a user that would use the desired floor surface.
The inventive mat assembly offers a number of advantages over the mat assembly designs of the prior art, including the one depicted in
Moreover, the use of a specially configured flange on the ramp to interface with both the top plate and sponge layer of the center section provides a more robust attachment between the ramps and center section and provides a more durable mat assembly.
The flange is also specially configured so that the part of the connection between the flange and top plate is either not seen or less visible as an irregularity in the surface of the top plate, e.g., a line following the edge of the flange, that would take away from the overall look of the mat assembly.
The ramp is also preferably formed as an extrusion that allows the ramp to have internal strengthening members, which also facilitate connections between adjacent ramps when a connector at each corner of the mat assembly is used.
One ramp is designated by the reference numeral 23 and the other ramp is designated by the reference numeral 25. Depending on a given mat assembly construction, a mat could have four of the ramps 23 or four of the ramps 25. If so desired, the mat assembly could be configured as shown in
If ramps 23 are used in a given mat assembly, a connector 27 is included to facilitate the connection between adjacent ends of the ramps 13. Details of the connector are provided below.
Referring now to
The top plate 29 and sponge layer 31 are sized to match, with center portions of the top plate 29 and the sponge layer 31 joined together to form a laminate construction. The joining of the top plate 29 and sponge layer 31 can be any known type, adhesive, heat welding, or the like.
The sponge layer 31 can be made of any known resilient material that would provide sufficient cushion when the mat assembly is used. An example of such a material for the sponge insert would be a PVC/NBR foam.
An example of the material for the top plate 29 would be a flexible PCV. However, other known mat top plate materials could be employed as well in the inventive mat assembly.
Referring now to
The ramp end portion 53 also includes a step 58, see
As noted above, the flange 51 itself has a tapered shape so that the free end 58 of the flange has a thickness that is less than a thickness of the flange where it extends from the top portion 45 of the ramp 23. The flange 51 is also angled downwardly with respect to the floor surface or an upper surface of the top plate. The thin or tapered free end 58 is advantageous in that an outline of the free end 58 of the flange is either not seen or is less visible from the top of the mat assembly.
Referring to
From
By having the ramp bottom portion 47 spaced from floor surface 15 as shown in
In construction of the mat assembly, the top plate 29 and sponge layer 31 could be joined together but for the area where the flange 51 would be positioned. Once the flange 51 would be positioned between the top plate 29 and sponge layer 51, the joining of these components could be completed. In the alternative, the top plate 29 and sponge layer 31 could be joined together as part of the joining of the flange 51, top plate 29, and sponge layer 31.
The ramp is preferably made as an extrusion so that the rib, 39, channels 49, and flange 51 can be easily created. Any known extrudable polymer would be a candidate for the ramps, e.g., polyethylenes, polyurethanes, polypropylenes, polyvinyl chlorides and the like. Preferred material to facilitate making the ramp as an extrusion include flexible polyvinyl chloride.
Another advantage of the mat assembly is the ability to reduce the wear and tear on the ramp sections of the prior art mats. Typically, the thickness of the top plate for a prior art mat would range between 0.075-0.09 inches. Thus, when this top plate would overhang the sponge layer, it would be susceptible to tearing and curling. By providing the ramps as a component part of the mat assembly, the ramp edge thickness can be made to be twice or more in thickness as compared to the prior art thicknesses, e.g., 0.18 inches. Thus, the thicker free edges of the ramp are more resistant to wear and tear and this objective is achieved without having to increase the overall thickness of the mat plate and increase the overall cost of the mat assembly due to the use of more material.
Use of the members 43 to create channels provides strength for the ramp, while at the same time reducing the overall material needed to make the ramp and facilitate connection with the connector 27.
While it is preferred to make the ramp as an extruded structure as this saves material and cost while still allowing the ramp to have the desired strength and allows the use of connectors for the channels in the ramp to facilitate connection between ramp end portions, the ramps could be made with a solid construction. In this embodiment, channels could be formed just in the end portions of the ramps to accommodate the tree connectors of the connector 27 or the solid ends of the ramps could be bonded together.
The connector 27 is shown in more detail in
As shown in
The connector 27 also includes a set of ramp connectors 71, 73, 75, 77, and 79 on each of the faces 67 and 69. Each ramp connector is uniquely sized as the channels 49, 50, 52, 54, and 56 in the ramp 23 that are designed to receive the ramp connectors are all differently sized due to the taper or incline of the ramp 23. In
The connectors are preferably made of the same material as the ramps to that the feel to a user of the mat assembly is generally same whether the connector or the ramp is stepped on. The connectors can be made in any way, including molding to be able to produce the intricate tree connectors.
Referring back to
As noted above, the mat assembly 10 could have a combination of mitered connections and connectors 27 as shown in
The mat assembly 10 can be used in virtually any area where a cushioned area with ramp access is needed for worker use. While the mat assembly 10 is shown in a square shape, the mat assembly could also be made rectangular with two sides being longer than the other. In fact, the mat assembly could be any polygonal shape. For example, the mat assembly could be configured with six sides, and the mitered connections would be adjusted for the proper angle to join adjacent ramps or the connectors 27 could be designed such that the faces 67 and 69 would form a 60 degree angle rather than the 90 degree angle shown in
Moreover, the ramp sections 23 and 25 and/or connectors 27 could be colored, e.g., yellow, to provide notice to a user as to the end of the flat part or center section of the mat assembly.
As such, an invention has been disclosed in terms of preferred embodiments thereof which fulfills each and every one of the objects of the present invention as set forth above and provides a new and improved unitary mat assembly and method of use.
Of course, various changes, modifications and alterations from the teachings of the present invention may be contemplated by those skilled in the art without departing from the intended spirit and scope thereof. It is intended that the present invention only be limited by the terms of the appended claims.
Claims
1. A mat assembly comprising:
- a center section having a peripheral portion, the center section comprising a sponge layer and a top layer, a center portion of each of the top layer and the sponger layer secured together,
- a plurality of ramps, each ramp having an inclined top portion, a bottom portion, and a connecting flange, one end of the inclined top portion terminating at a free end of the ramp, the free end extending longitudinally along the ramp, the ramp having a plurality of channels extending longitudinally along the ramp, adjacent channels of the plurality of channels separated by a member extending between the inclined top portion and bottom portion of the ramp, the ramp also having opposing end portions,
- the connecting flange positioned between an underside portion of the top layer and an upper surface portion of the sponge layer, each of which being in the peripheral portion of the center section, the connecting flange, underside portion and upper surface portion bonded together to form a bonded and laminated connection between each ramp and the center section, and
- the end portions of adjacent ramps configured to be attached together.
2. The mat assembly of claim 1, further comprising a plurality of corner connectors, each corner connector having opposing side faces, each opposing side face configured to attach to an adjacent end portion of one of the plurality of ramps.
3. The mat assembly of claim 1, wherein at least one end portion of at least two of the ramps is angled with respect to a longitudinal axis of the ramp, the angled end portions attached together by a bonding of the end portions or by use fasteners, or a combination thereof.
4. A mat assembly comprising:
- a center section having a peripheral portion, the center section comprising a sponge layer and a too layer, a center portion of each of the top layer and the sponger layer secured together,
- a plurality of ramps, each ramp having an inclined too portion, a bottom portion, and a connecting flange, one end of the inclined top portion terminating at a free end of the ramp, the free end extending longitudinally along the ramp, the ramp having a plurality of channels extending longitudinally along the ramp, adjacent channels separated by a member extending between the inclined top portion and bottom portion of the ramp, the ramp also having opposing end portions,
- the connecting flange positioned between an underside portion of the too layer and an upper surface portion of the sponge layer, each of which being in the peripheral portion of the center section, the connecting flange, underside portion and upper surface portion attached together to form an integral connection between each ramp and the center section, and
- the end portions of adjacent ramps configured to be attached together
- wherein the bottom portion of each ramp is inclined when the ramp is attached to the center section such that only the free end of the ramp is in contact with a floor surface.
5. The mat assembly of claim 1, wherein the connecting flange has at least a portion that is tapered in thickness, the taper extending along a longitudinal direction of the portion of the connecting flange to an end portion of the flange.
6. A mat assembly comprising:
- a center section having a peripheral portion, the center section comprising a sponge layer and a top layer, a center portion of each of the top layer and the sponger layer secured together,
- a plurality of ramps, each ramp having an inclined top portion, a bottom portion, and a connecting flange, one end of the inclined top portion terminating at a free end of the ramp, the free end extending longitudinally along the ramp, the ramp having a plurality of channels extending longitudinally along the ramp, adjacent channels separated by a member extending between the inclined top portion and bottom portion of the ramp, the ramp also having opposing end portions,
- the connecting flange positioned between an underside portion of the top layer and an upper surface portion of the sponge layer, each of which being in the peripheral portion of the center section, the connecting flange, underside portion and upper surface portion attached together to form an integral connection between each ramp and the center section, and
- the end portions of adjacent ramps configured to be attached together
- wherein the connecting flange is angled downwardly when unassembled and prior to bonding to form the bonded and laminated connection as compared to an upper surface of the top layer, such that when the connecting flange is positioned between the underside portion of the top layer and the upper surface portion of the sponge layer as the laminated connection, the free end of the ramp is further forced downward to maintain contact with a floor surface receiving the mat assembly.
7. A mat assembly comprising:
- a center section having a peripheral portion, the center section comprising a sponge layer and a too layer, a center portion of each of the top layer and the sponger layer secured together,
- a plurality of ramps, each ramp having an inclined top portion, a bottom portion, and a connecting flange, one end of the inclined top portion terminating at a free end of the ramp, the free end extending longitudinally along the ramp, the ramp having a plurality of channels extending longitudinally along the ramp, adjacent channels separated by a member extending between the inclined top portion and bottom portion of the ramp, the ramp also having opposing end portions,
- the connecting flange positioned between an underside portion of the top layer and an upper surface portion of the sponge layer, each of which being in the peripheral portion of the center section, the connecting flange, underside portion and upper surface portion attached together to form an integral connection between each ramp and the center section, and
- the end portions of adjacent ramps configured to be attached together
- wherein the connecting flange is angled downwardly when unassembled and prior to bonding to form the bonded and lamina connection as compared to an upper surface of the top layer, such that when the connecting flange is positioned between the underside portion of the top layer and the upper surface portion of the sponge layer as the laminated connection, the free end of the ramp is further forced downward to maintain contact with a floor surface receiving the mat assembly.
8. The mat assembly of claim 2, wherein each opposing side face of each corner connector includes a plurality of tree connectors, each tree connector configured to engage one of the channels in the ramp.
9. The mat assembly of claim 1, wherein the top layer has protrusions extending from an upper surface thereof for slip resistance.
10. The mat assembly of claim 1, wherein each ramp has protrusions extending from an upper surface thereof for slip resistance.
11. The mat assembly of claim 1, wherein each ramp is an extruded polymer.
12. In a method of covering a floor surface with a cushioned mat, the improvement comprising covering the floor surface with the mat assembly of claim 1.
13. In a method of covering a floor surface with a cushioned mat, the improvement comprising covering the floor surface with the mat assembly of claim 4.
14. In a method of covering a floor surface with a cushioned mat, the improvement comprising covering the floor surface with the mat assembly of claim 6.
15. In a method of covering a floor surface with a cushioned mat, the improvement comprising covering the floor surface with the mat assembly of claim 7.
Type: Application
Filed: Aug 26, 2020
Publication Date: Mar 3, 2022
Inventor: Philip C. HUSS (Smyrna, TN)
Application Number: 17/002,974