Slip resistant mat and method and system for making same

Abstract

A system and method for making a slip resistant mat can include assembling parts with predetermined geometries to form a mold that can be used for making slip resistant mats that have channels to account for moisture between the mat and the floor. The unique geometries of the parts which form the mold can be manufactured efficiently and with reduced costs. The mold of this invention can be used to make slip resistant mats with channels that can both dissipate water and offer a high degree of mat to floor surface contact.

We claim: 
     
         1 . A slip resistant mat comprising:
 an upper surface to support traffic thereon;   a backing integrally molded on an opposite face of the mat from the upper surface and adapted to be juxtaposed to a floor surface on which the mat is positioned; and   a slip resistant pattern formed on the backing to inhibit slipping of the mat relative to the floor surface when positioned thereon, wherein the slip resistant pattern further comprises a repeating pattern of projections and channels extending over a substantial portion of the backing of the mat such that the projections in combination form a lower surface of the mat which contacts the floor when the mat is positioned thereon;   wherein moisture trapped between the mat and the floor is dispersed away from the projections and into the channels when the mat is positioned on the floor surface to thereby inhibit movement of the mat relative to the floor surface.   
     
     
         2 . The slip resistant mat of  claim 1  wherein the lower surface formed by the combination of the projections is at least about 90% of the surface area of the backing of the mat. 
     
     
         3 . The slip resistant mat of  claim 1  wherein the upper surface further comprises:
 a fabric layer. 
 
     
     
         4 . The slip resistant mat of  claim 1  wherein the projections further comprise:
 a plurality of spaced hexagonal-shaped protuberances; and 
 a plurality of bridges each of which joins together two adjacent hexagonal-shaped protuberances. 
 
     
     
         5 . The slip resistant mat of  claim 1  wherein the channels are in a zig-zag arrangement. 
     
     
         6 . The slip resistant mat of  claim 1  wherein the projections and the channels extend generally diagonally across the backing of the slip resistant mat. 
     
     
         7 . A method of making a slip resistant mat having a slip resistant pattern on a backing of the mat, the method comprising the steps of:
 forming a model platen with a replica of the slip resistant pattern;   forming a screen mold with the model platen in which the screen mold has a negative of the slip resistant pattern formed by the replica of the slip resistant pattern; and   forming the slip resistant mat with the screen mold in which the negative of the slip resistant pattern forms the slip resistant pattern on the backing of the mat.   
     
     
         8 . The method of  claim 7  wherein the forming of the model platen step is accomplished with a CNC router. 
     
     
         9 . The method of  claim 7  wherein the model platen is formed from a metal plate. 
     
     
         10 . The method of  claim 7  further comprising:
 forming a pocket in the model platen with the replica of the slip resistant pattern therein. 
 
     
     
         11 . The method of  claim 7  further comprising:
 applying mold material to the model platen; and 
 curing the mold material on the model platen to form the screen mold. 
 
     
     
         12 . The method of  claim 11  wherein the mold material is a two-part curable silicone mold material in which one part is silicone and another part is Nomex® or Kevlar®. 
     
     
         13 . The method of  claim 7  further comprising:
 minimizing entrapped air in the screen mold in conjunction with the forming of the screen mold step. 
 
     
     
         14 . The method of  claim 11  wherein the forming of the screen mold step further comprises:
 spreading the mold material onto the model platen with a tool. 
 
     
     
         15 . The method of  claim 7  wherein the screen mold has a substantially solid backing opposite from the negative of the slip resistant pattern formed thereon. 
     
     
         16 . The method of  claim 7  wherein the model platen has a substantially solid backing opposite from the replica of the slip resistant pattern formed thereon. 
     
     
         17 . A slip resistant mat comprising:
 an upper surface including a fabric layer to support traffic thereon;   a backing integrally molded on an opposite face of the mat from the upper surface and adapted to be juxtaposed to a floor surface on which the mat is positioned; and   a slip resistant pattern formed on the backing to inhibit slipping of the mat relative to the floor surface when positioned thereon, wherein the slip resistant pattern further comprises a repeating pattern of projections and channels extending over a substantial portion of the backing of the mat such that the projections in combination form a lower surface of the mat which contacts the floor when the mat is positioned thereon;   wherein the lower surface formed by the combination of the projections is at least about 90% of the surface area of the backing of the mat;   wherein moisture trapped between the mat and the floor is dispersed away from the projections and into the channels when the mat is positioned on the floor surface to thereby inhibit movement of the mat relative to the floor surface.   
     
     
         18 . The slip resistant mat of  claim 17  wherein the projections further comprise:
 a plurality of spaced hexagonal-shaped protuberances; and 
 a plurality of bridges each of which joins together two adjacent hexagonal-shaped protuberances. 
 
     
     
         19 . The slip resistant mat of  claim 18  wherein the channels are in a zig-zag arrangement. 
     
     
         20 . The slip resistant mat of  claim 19  wherein the projections and the channels extend generally diagonally across the backing of the slip resistant mat. 
     
     
         21 . The method of  claim 7  wherein the forming of the slip resistant mat step is accomplished in a batch process.