Abstract:
A polymeric matting article includes a web of extruded polymer monofilaments, the polymer monofilaments being heat welded at junctions to form a matrix of tangled monofilament; and at least one pair of interlocking formations; wherein the web is configured to be foldable onto itself and secured in a folded position by engaging the interlocking formations.

Description:
This application is a national phase of International Application No. PCT/US2014/035843 filed Apr. 29, 2014 and published in the English language, which claims priority to U.S. Provisional Application No. 61/816,975 filed Apr. 29, 2013. 
    
    
     TECHNICAL FIELD 
     The present invention relates to a polymeric matting article, and in particular, to a polymeric matting article configured to be foldable onto itself and secured in a folded position by engaging interlocking formations. 
     SUMMARY 
     In one aspect of the invention there is provided a polymeric matting article that includes a web of extruded polymer monofilaments, the polymer monofilaments being heat welded at junctions to form a matrix of tangled monofilament; and at least one pair of interlocking formations; wherein the web is configured to be foldable onto itself and secured in a folded position by engaging the interlocking formations. 
     The extruded polymer monofilaments of the matting article may be composed of a polyolefin, polyamide, polyester, polyvinylhalide, polystyrene, polyvinylester, or a mixture of two or more thereof. 
     In one embodiment, the interlocking formations include an elongated rib and a complementary elongated channel into which the elongated rib fits in a folded position. 
     In one embodiment, the web of extruded polymer monofilaments includes top and bottom shell halves and a hinge integrally formed with and interconnecting the top and bottom shell halves, the top and bottom shell halves cooperatively defining a filament free cavity. 
     In one embodiment, the polymeric matting article is a packaging material. 
     In another embodiment, the polymeric matting article is a building construction material. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top view of a portion of the polymeric matting article formed from tangled polymer filaments. 
         FIGS. 2A and 2B  are perspective views of an embodiment of the polymeric matting article having an elongated rib and a complementary elongated channel in an unfolded position and in a folded position, respectively, in accordance with the present invention. 
         FIGS. 3A and 3B  are cross-sectional views of an embodiment of the polymeric matting article having a clam shell configuration with complementary interlocking domes in an unfolded and folded position, respectively. 
     
    
    
     DETAILED DESCRIPTION 
     The polymeric matting article of the present invention is formed from a web of extruded polymer monofilaments. The fibrous web is extruded onto a substrate having a surface profile corresponding to that of the desired matting article, the matting article configured to be foldable onto itself and secured in a folded position by engaging interlocking formations 
     Referring to  FIG. 1 , a portion of the matting article is shown. The matting article is constructed of a web  10  formed from a plurality of extruded polymer monofilaments  12 . The plurality of filaments  12  that are heat fused to one another at randomly spaced points to form a three-dimensional, convoluted and mutually interconnected filamentatious body having an open structure. Filament free voids  13  are formed within the resilient structure, which allows air flow within the structure while allowing the structure to absorb impacts. The polymer filament material is preferably constructed in accordance with techniques such as disclosed by, for example, U.S. Pat. Nos. 3,687,759; 3,691,004; and 4,212,692, the contents of all of which are hereby incorporated by reference in their entireties. 
     The monofilaments  12  of web  10  may be made from any thermoplastic polymer that provides the desired properties of strength and resilience for the application in which it is used. For example, the monofilaments  41  may be made of a polyolefin (e.g., polyethylene, polypropylene, etc.), polyamide (e.g., Nylon), polyester, polyvinylhalide (e.g., polyvinylchloride (PVC), polyvinylidene chloride, polyvinyltetrafluoride, polyvinyl chlorotrifluoride), polystyrene, polyvinylester (e.g., polyvinyl acetate, etc.) or a mixture of two or more thereof. The monofilaments  12  are extruded onto a substrate having the desired structural profile to form the web  10 . 
     Referring to  FIGS. 2A and 2B , in one embodiment the matting article  20  includes an elongated channel  22  positioned between a first raised region  32  and a second raised region  34 , the raised regions  32  and  34  including a thickness of entangled filaments extending from the a first surface  36  of the matting article. The second raised region  34  is closest to the fold line  26  and is adjacent a flat planar region  30  on the opposite side of the fold line  26 . Adjacent the flat planar region  30  is an elongated rib  24  having a width that is the same or less than the width of the elongated channel  22 . The matting article  20  is illustrated in  FIG. 2A  in its unfolded position. Arrow  28  indicates the fold direction of the matting article  20 . The matting article  20  is illustrated in  FIG. 2B  in its folded position. Upon folding the matting article  20  along fold line  26  in the folding direction, the elongated rib  24  fits into and engages the elongated channel  22  to form a device having a uniform thickness. The device may be, for example, a lightweight, resilient building construction device. The building construction device being useful for providing, for example, cushioning, drainage, air circulation and/or sound damping when included as part of a building structure. 
     Referring to  FIGS. 3A and 3B , in one embodiment the matting article  40  has a clam shell configuration, including a bottom shell half  42  and a top shell half  44  that are connected by connecting section  46 . Matting article  40  is illustrated in  FIG. 3A  in the unfolded, or open position. The bottom shell half  42  has an outer lip  56  that includes a downwardly facing locking dome  54 B. The top shell half  44  has an outer lip  58  that includes an upwardly facing locking dome  54 A, which is complementary to locking dome  54 B. The connecting section  46 , which acts as a flexible hinge for the matting article  40 , includes a pair of complementary interlocking domes  52 A and  52 B positioned on opposing sides of fold line  48 . Arrow  50  indicates the fold direction of the matting article  40 .  FIG. 3B  illustrates the matting article  40  in the folded, or closed position. Upon folding the matting article  40  along fold line  48  in the folding direction, dome  52 A engages dome  52 B and dome  54 A on the outer lip  58  of the top shell half engages dome  54 B on the outer lip  56  of the bottom shell half to secure the matting article in a closed position. Matting article  40  may be useful, for example, as a packaging material or as a building construction component for drainage and/or air circulation. 
     While the invention has been explained in relation to various embodiments, it is to be understood that various modifications thereof will become apparent to those skilled in the art upon reading this specification. Therefore, it is to be understood that the invention provided herein is intended to cover such modifications as may fall within the scope of the appended claims.