Rib Cored Rubber/Latex Backing For Memory Foam Bathmat
Field of invention
The present invention relates to a Memory Foam Mat, comprising a first
layer of Surface Fabric, a second layer of Polyurethane Foam and a third
layer of Rubber/Latex Backing. More particularly, the present invention
relates to the third layer of Rubber/Latex backing of the Memory Foam
Mat which is Rib Cored Rubber/Latex Backing. This invention further
relates to a process for making a Memory Foam Mat by direct latex
application on foam material in the rubber/latex coating machine. The
rib cored impressions are created on rubber/latex in semi dry state,
which is then completely dried out through the machine.
Background of the invention
Mat is a piece of protective material placed on a floor or a flat piece of coarse
fabric or other material used for wiping one's shoes or feet, or used in various
other forms such as floor covering. It can be a small flat piece densely woven
or thickly tangled mass used as a decorative material placed under a lamp, dish
of food, or other object.
Conventionally, the mats have been used as a floor covering for a portion of a
floor surface or to allow more comfortable seating or kneeling to be achieved
by a user who sits or kneels on the mat rather than directly on the floor surface.
Mats can also be used in areas which may get wet from time to time, for
example, on the floor surface adjacent to a bath or sink. Furthermore, in a tiled
bathroom, it is common to provide a bath mat that can both offer a slipresistant
surface to stand and absorbent properties to handle inevitable water
from sinks, baths or showers.
Mats also used to provide safe surfaces on which a person can walk, preventing
slips and falls that cause injury and liability damages. Anti-slip mats are now
required in many areas of houses, hospitals and offices to ensure maximum
protection during the movements. However, conventionally, mats tend to be
relatively thin and slippery and therefore provide little comfort to a person
sitting or kneeling on the same on a hard floor surface.
Prior to this invention the mats were not so good in slip resistance and there
was danger of someone falling accidently causing injury and fatal accident.
Hence, conventional mats are not fully reliable and were not considered safe to
use. The present invention has better slip resistance, better customer appeal and
better appearance.
Objects of the Invention
The present invention is intended to solve such problems associated with the
prior art as mentioned above and it is an object of the invention to provide a
Memory Foam Mat and process thereof, comprising a first layer of Surface
Fabric, a second layer of Polyurethane Foam and a third layer of
RubberILatex Backing.
It is further object of the invention to provide increased and better slip
resistance for the mat on the base through the RubberILatex Backing.
Other objects of the invention are as follows:
1. To provide Memory Foam Mats in various constructions and
thicknesses.
2. To provide Memory Foam Mats in numerous colours from light to
dark and/or dull to bright.
3. To provide Memory Foam Mats in solid, multi and any decorative
patterns.
4. To provide Memory Foam Mats in various thicknesses and density.
Summary of the Invention
The present invention provides a Memory Foam Mat, comprising a first layer
of Surface Fabric, a second layer of Polyurethane Foam and a third layer of
RubberLatex Backing. More particularly, the present invention relates to the
third layer of rubbedlatex backing of the Memory Foam Mats having rib
cored impressions. This present invention further relates to a process .for
making a Memory Foam Mat by direct latex application on foam material in
the latex coating machine. The rib cored impression is created on the latex in a
semi dry state. Thereafter, it is completely dried out through the machine.
The foregoing and other features of the invention are hereinafter fully
described and particularly pointed out in the claims, the following description
setting forth in detail certain illustrative embodiments of the invention, these
being indicative, however, of but a few of the various ways in which the
principles of the present invention may be employed.
Features and characteristics of the present invention will become more
apparent upon consideration of the following description and the appended
claims with reference to the accompanying drawings, all of which form a part
of this specification.
Description of the Invention
The present invention relates to a Memory Foam Mat and a process thereof
comprising layers as follows-
First layer: Surface Fabric
It can be available in various constructions and thickness
There are numerous colors available from light to dark, dull to bright
Solid, multi and any decorative patterns are possible;
Second layer: Polyurethane Foam
It can be available in various thickness and density;
Third Layer: RubberILatex Backing.
A method for manufacturing a Memory Foam Mat according to a preferred
embodiment of the invention comprises gluing of first and second layers of the
Mat to each other. The surface fabric layer can be of numerous colours from
light to dark and/or dull to bright or may carry solid, multi and decorative
patterns thereon. The third layer of 'Rib Cored Rubber/L,atex Backing' is
prepared by application of latedrubber directly on foam material in the
rubberllatex coating machine.
More particularly, the present invention relates to the RubberILatex Backing of
the Memory Foam Mat which is rib cored rubberllatex backing. The
rubberllatex backing used in the invention is made of Natural Latex and
Synthetic Latex blend before latexing. The rib cored impression on the
rubberllatex backing of the Memory Foam Mat is created through roller when
it comes out as semi dry material from the rubberllatex coating machine.
Thereafter, it is completely dried out through the steam chamber.
Figure 1 illustrates a series of rib cored impressions or indents at spaced
intervals on the rubberllatex backing of the Memory Foam Mat. These rib
cored impressions or indents increases the slip resistance of the present
invention. It is to be expressly understood, however that this drawing is for the
purpose of illustration and description only and is not intended as a definition
of the limits of the invention.
In accordance with the invention, the rubberllatex backing is directly applied
on foam material using special high temperature heating chamber machine.
During the rubbedlatex application the temperature is preferably 120 degree
Celsius in chamber for curing. A special high temperature heating chamber
machine is used to apply the rib cored rubberllatex backing on the mat.
Preferred embodiments of the present invention provide a Memory Foam
Mat having a structure which is such that it is comfortable in use and has
increased slip resistance. Characteristically, when a person applying pressure
on the foam material, such as by sitting, kneeling or standing on the mat, gets
up from the mat the material returns to at least partially to its original state.
In one embodiment, the thickness of the cushioning layer is selected with
respect to the particular use to which the mat is to be used. For example, a mat
which is provided most typically to be stood on may not have as thick a layer
of foam as a mat which is provided to be sat or kneeled upon.
In the preferred embodiment of the invention, the Memory Foam Mat has a
final thickness of about 10 mm, 15 mm, 20 mm and density 50 kglm3. More
particularly, the second layer of the Memory Foam Mat is of 10 mm, 15 min
and 20 mm and the third layer of the Memory Foam Mat is of 2 mm.
The application of the memory foam in the production of mats provides a
comfortable feel to a person when standing, kneeling or sitting on such mat.
Furthermore, the third layer of rib cored rubberllatex backing provides good
slip resistance.
The present invention is used on textile products and hence has got various
applications in textiles industry. Although the invention has advantageous
application to bathroom mats, mats embodying the invention can be useable for
a variety of applications; for example, a mat embodying the invention might be
used as a changing mat, play mat, pet mat, seat cushion mat, stadium seat
cushion mat, picnic seat cushion mat, yoga mat, sports mat, bedroom mat,
kitchen mat, computer arm rest mat, tug mat, crib mat, mattress topper, garden
mat, car mat or car seat mat.

We Claim,
1. A Memory Foam Mat comprising: a first layer of Surface Fabric which is
available in various constructions and thickness; second layer of
Polyurethane Foam, available in various thickness and density; third layer
of RubberLatex Backing having increased slip resistance.
2. The Memory Foam Mat according to claim 1, wherein the said a first
layer can be of numerous colors from light to dark, dull to bright having
solid, multi and any decorative patterns.
3. The Memory Foam Mat according to claim 1, wherein the second layer
of Polyurethane Foam cab be of various thicknesses preferably of 10 mm,
15 mm and 20 mm.
4. The Memory Foam Mat according to claim 1, wherein the said third
layer is made of Natural Latex and Synthetic Latex which is blend before
latexing.
5. The Memory Foam Mat according to claim 1, wherein the third layer of
rib cored rubberllatex backing is of 2 mm.
6. The Memory Foam Mat according to claim 1, wherein the said memory
foam mat is produced in various thickness preferably 10 mm, 15 mm,
20 mm and density 50 kg/m3.
7. A method for manufacturing a Memory Foam Mat, comprising steps of
gluing the first layer of surface fabric and second layer of polyurethane
foam; creating rib cored impressions on the third layer of rubberllatex
backing when the rubberllatex comes out as semi dry and then completely
drying it out through a machine; and attaching the third layer of rib cored
rubberllatex backing directly on foam material in the rubberllatex coating
machine.
8. The method for manufacturing the Memory Foam Mat according to
claim 7, wherein a series of rib cored impressions or indents at spaced
intervals are created on the rubberllatex backing of the Memory Foam
Mat.
9. The method for manufacturing the Memory Foam Mat according to
claim 7, wherein the rib cored impressions are created through roller.
10. The method for manufacturing the Memory Foam Mat according to
claim 7, wherein drying process takes place in steam chamber.
11. The method for manufacturing the Memory Foam Mat according to
claim 7, further comprising a step of blending the Natural Latex and
Synthetic Latex before latexing.
12. The method for manufacturing the Memory Foam Mat according to
claim 7, wherein the rubberllatex backing is applied using special high
temperature heating chamber machine.
13.The method for manufacturing the Memory Foam Mat according to
claim 7, wherein during latexing the temperature is preferably 120 degree
Celsius in chamber for curing.