UV LED disinfecting floor mat

Disinfecting floor mats may be achieved by a variety of systems, processes, and techniques. In one general implementation, a disinfecting floor mat may include a UV LED array, a base, and a transparent cover. The UV LED array may have a top surface, a bottom surface, a perimeter and include multiple UV-emitting LEDs. The base may be configured to receive the UV LED array. The transparent protective cover may include a top surface of an encapsulating sheet for encapsulating the array or a top surface of a non-encapsulated protective sheet, the cover comprised of polyurethane and having substantial strength to withstand a person standing directly thereon with shoes on. The LED array is adapted to irradiate at least a portion of a bottom surface of a shoe positioned on the protective cover.

FIELD OF THE INVENTION

BACKGROUND OF THE INVENTION

Floors, ground, or other support surfaces that are intended to be walked upon or stood on typically are covered with germs and other pathogens. One of the most common places superbugs, such as MRSA, can attach themselves to us and enter our bodies is through being picked up on our feet. A simple, easy method of disinfecting the shoes of the wearer would help reduce the pathogens carried on the shoes, especially if a floor mat capable of performing that function was provided outside a clean area. With a floor mat upon which one is standing, a shoe-wearing person could achieve disinfection or reduction of pathogens on the surface of the shoe sole before they entered a clean area.

SUMMARY OF THE INVENTION

A floor mat for disinfecting a shoe bottom including, in some embodiments, a rigid or flexible UV LED array having a top surface, a bottom surface, a perimeter and further including multiple UV emitting LED bulbs; a base for receiving the UV LED array, in some embodiments; a transparent protective cover including a top surface of an encapsulating sheet for encapsulating the array or a top surface of a non-encapsulated protective sheet; and a power source engaging the UV LED array. In certain embodiments, the encapsulating sheet of the protective cover is an elastomer (e.g., a cured, two-part polyurethane or an equivalent).

The floor mat may further include a pressure switch for activating the UV LED array, the pressure switch responsive to a weight on the protective cover.

DETAILED DESCRIPTION

FIGS. 1, 2A, 2B, 2C, and 3illustrate an example UV disinfecting floor mat10(“floor mat”). Floor mat10may include an LED array14, which may be flexible or rigid and may have a top surface14a, multiple UV emitting LEDs14b, and multiple leads14cextending therefrom, the leads intended to engage a power source, and, optimally, a controller (e.g., a microcontroller or a microprocessor) as set forth herein below.

Floor mat10may also include a base16, which may be made from durable, rigid plastic or other suitable material or a semi-flexible material. In particular implementations, base16may be rolled into a cylinder shape. Base16includes a cutout16adimensioned to receive UV LED array14, which may, as shown, be rectangular or any other appropriate configuration.

UV LED array14may be bare (non-encapsulated) and have a protective sheet12typically on or above top surface14aof the bare UV LED array. Protective sheet12may be a separate sheet such as a durable, transparent, scuff-proof plastic, or protective sheet12may include the top surface18aof an encapsulating body18bof an encapsulating sheet18. That is to say, bare UV LED array14may further comprise a transparent encapsulating sheet18with a protective top surface18athat may simply be the top surface of encapsulating body18b, body18bencapsulating the multiple bulbs14bof the LED array. Thus, LED array14may be a bare LED array with a protective sheet or one with a transparent encapsulating sheet18. Moreover, a separate protective sheet12may be laid atop LED array, with or without the encapsulation sheet18. While top surface18amay include protective sheet12, a separate protective sheet12is typically provided that is a scuff-proof, transparent—like body12bof the encapsulating sheet is transparent—protective sheet12(or top surface18a), being intended to receive the shoes thereon.

To be transparent, protective sheet12may be totally or partially clear with respect to visible light. Additionally, although it may block certain wavelengths of light, sheet12should allow at least certain UV light (e.g., UVC) to pass without significant degradation (e.g., greater than 90% transmission).

In some embodiments, protective sheet12may be tacky. Tack is a property whereby light contact with the surface of another body brings about a condition requiring force to restore the original separated state. It is a property that will inhibit but not wholly prevent the removal of a contacting surface or surfaces, such as opposing surfaces contacting each other under compression. Inherent tack means the surface possesses this property (tack) without requiring the addition of any further adhesion promoting component, or a tackifier. By being tacky, protective sheet12may trap dirt and contaminants, which may help to clean shoes better.

Because a tacky surface is likely to become dirty fairly quickly, which would likely inhibit the penetration of UV light therethrough, protective sheet12may be replaceable (e.g., on a weekly or as needed basis). Due to the inherent tackiness of the sheet, the sheet may be readily removed from and applied to body18b.

Base16is configured to receive in recess16athe encapsulated or unencapsulated (with protective sheet) UV LED array14as seen inFIG. 3. It is further seen inFIG. 3that base16, in one embodiment, may have a cutout to contain batteries20, and also may include an electrical circuit21, a controller25, a door22for accessing batteries, a switch23, optionally, a timer24with a timer circuit, and a speaker26.

Batteries20are intended to engage leads14cthrough use of electrical circuit21. Switch23, which may, for example, be a pressure sensitive switch, may be placed in a cutout16bin base16so as to extend partly thereabove. Switch23is typically placed below an outline of the shoe bottoms (“SB”), seeFIG. 1, and may be set to a minimum close pressure, so that placement of a hand on the mat will not close it. Thus, a user may be around, over, or partially on the mat without it activating.

SB outline inFIG. 1may simply be an indicia forming a first line in the shape of one foot and an indicia forming a second line in the shape of a second foot, the lines embossed or otherwise applied to transparent sheet12or top surface18a. SB outline allows a user to stand in the designated spot, and with switch23located under one of the two feet (or both), circuit21may be energized with batteries20for energizing bulbs providing UV light (and, optionally, some visible light). The protective cover should be at least partially transparent. In a preferred embodiment, only the shoe outlined portion is transparent, the rest is opaque. The bulbs of the LEDs are at least under the shoe outline portion of the protective cover.

Optionally, electrical circuit21may include timer24or timer and a speaker26. Timer24may initiate a timed circuit to maintain the closed circuit condition providing illumination to the UV LED bulbs14b, such as for a period of 10 to 300 seconds. Timer24may include speaker26that emits an audible signal when the time circuit is completed and the LED lights are de-energized (open circuit condition) even if the user is still on mat10, or even if the user has left mat10, time circuit24allows the energized period to be responsive to an initial closed circuit condition initiated by pressure on pressure switch23. Controller25can check switch condition for pressure or for timer complete and either timer complete or no pressure will dictate an open circuit. In some implementations, two pressure switches, one underneath each shoe outline, may be used, insuring a closed circuit when both feet are on the protective cover.

LED array14may be flexible or rigid. As shown, LED array is an 8×32 LED panel. Other sizes may be used in other implementations. In certain implementations, for example, LED array14is a flexible LED array and, in some embodiments, is a 16×16 RGB panel requiring low voltage DC, with, however, light emitting in the UV spectrum or at least partially in the UV spectrum. Controller25and electrical circuit21may selectively power individual bulbs as set forth in more detail below.

Body18(or protective sheet12) may made of flexible material. For example, body18may be a cured polyurethane, which is commonly made by mixing a polyol with an isocyanate. Even in its general form, polyurethane typically allows some transmission of UV light. One composition that may be used is the two-part polyurethane found in U.S. Pat. No. 7,229,516 (Busby et al. Dec. 25, 2003), which is herein incorporated by reference.

In certain implementations, compositions may be added to the mixture to improve the transmission of UV light through the polyurethane. For example, an acrylic polyurethane blend could be used. The acrylic could, for instance, be blended with the polyol before it is combined with the isocyanate.

Body18(or protective sheet12) may be relatively soft yet tough enough to withstand being walked on by humans wearing shoes. In certain implementations, body18may have a hardness between about 20-80 on the Shore OO scale.

A method of making the encapsulated body for the light emitting array may be found in the '516 patent, namely,FIGS. 8-13, wherein the “skeleton” of the gasket illustrated in the patent is the bare UV LED array14of this disclosure. Additionally, particular implementations may not use heat.

This '617 patent discloses a method of disinfecting and lighting by using LEDs, using both lighting visible light LEDs and UV LEDs on a circuit board that mixes the two. The disinfecting properties of UV LED lights may be appreciated with respect to this reference.

The '705 patent discloses a flexible ultraviolet LED sanitizing apparatus that may be folded or rolled for storage and transport, and may be used as a sanitizing apparatus to sanitize a variety of objects beneath enclosure panels. This reference discloses the use of UVC light, which is ultraviolet electromagnetic radiation having a wavelength of about 100 nm to about 300 nm, and can provide 99.9% destruction of various organisms, including bacteria and influenza virus, in 60 seconds or less. In one embodiment, the UV LEDs emit at least some radiation in this range and some in the visible light range.

Similarly, the '576 patent discloses a UV LED light projection method and apparatus including UVC light band “germicidal UV”. The '710 publication shows an illuminable auto floor mat that includes a visible light source that illuminates in the illuminable region, the visible light source being powered by a receiver that is wirelessly supplied by a transmitter.

Capacitive sensing technology exists for sensing human interface applications when a person initiates contact with the sensor electrodes—for example by finger touch. High performance contact sensing applications exist which may measure sensor contact against a baseline reference level of environmental conditions. Capacitive sensing has advantages over other detection approaches, such as optical detection methods, in its ability to sense different kind of materials (e.g., skin, plastic, leather, rubber, metal, liquid) and it may be contactless and wear free. See Texas Instruments application report SN0A927—December 2014 incorporated herein by reference. Thus, controller25may receive input from a membrane including such technology to sense a skin/no-skin condition. This will avoid UV illumination when skin is sensed (seeFIG. 5).

Touch screen technology, such as capacitive or resistive touchscreen technology, can be used in conjunction with controller25to locate points of contact with the footwear (e.g., shoe). The controller then can selectively illuminate the UV LED lights at the same grid location that matches the pressure area. This will help minimize UV light leakage around areas outside the footwear.

FIG. 4illustrates selected components of an example control system400for a disinfecting floor mat. System400may, for example, be used for floor mat10. Among other things, system400includes a controller410, a user sensor420, a skin sensor430, a shoe sensor, and an LED array450.

Controller410is responsible for the logical operation of system400. Controller410may, for example, include a microprocessor, a microcontroller, a field-programmable gate array, or any other device for manipulating data in a logical manner. Controller400may also include instructions, whether in RAM, ROM, or otherwise, that dictate the logical operations.

Coupled to controller410is user sensor420. User sensor420is adapted to sense when someone is present on the disinfecting floor mat. User sensor420may, for example, be a load cell or a pressure switch. In some implementations, user sensor420may be set so that it does not report to controller410unless the weight is above a certain level (e.g., 80 pounds). In other implementations, user sensor420may report the sensed weight to controller410, and controller410may determine what operations to take based on the weight (e.g., to activate LED array450or not).

Also coupled to controller410is skin sensor430. Skin sensor430is adapted to sense when someone's skin (e.g., foot or hand) is contacting the disinfecting floor mat. Skin sensor430may, for example, be a capacitive sensor. Using this information, controller410may determine whether to illuminate LEDs in LED array450.

Also coupled to controller410is shoe sensor440. Shoe sensor440is adapted to sense where someone's shoe is contacting the disinfecting floor mat. Shoe sensor440may, for example, be a number of pressure sensors (e.g., one associated with each LED). Using this information, controller410may determine which of LEDs in LED array450to illuminate.

Control system400also includes an alarm460, which is coupled to controller410. Controller410may activate alarm460for any of a variety of reasons (e.g., user is not wearing shoes). Alarm460may generate a visual and/or audible notification.

Other implementations may include fewer, greater, and/or a different arrangement of components. For example, a control system may not include a shoe sensor. For instance, if light is only allowed to pass through an outline of shoes on the protective cover, detecting the shoe bottoms may not be necessary, especially since UVC rays do not travel well in air. Similarly, some implementations may not include the skin sensor. In certain implementations, the floor mat may be powered by batteries or power from an electric grid. Particular implementations, may include a display (e.g., an LCD or LED screen) for communication information to a user or a user interface (e.g., touchscreen or a screen and a touchpad) for communicating information to and receiving information from a user.

FIG. 5illustrates example operations of a process500for operating a disinfecting floor mat. The operations may, for example, be controlled by controller25and include no skin condition and user presence detections (e.g., pressure above a preset50# minimum), so casual contact with (e.g., with a bare hand) will not set off UV source, to create an “on” condition for the UV source (e.g., LED array). The “on” condition may be timed, for example, every 0.250 sec, for a pressure switch open condition or time out (about 30 sec-300 sec UV exposure). The pressure switch open condition on UV source cycle is provided so if a person steps off early, before time out, UV light shuts off.

Process500calls for determining whether a user is present (operation504). Determining whether a user is present may, for example, be accomplished with a pressure-activated sensor. The pressure-activated sensor may be set to a minimum level (e.g., 50 pounds), which may help to ensure that the system does not active for accidental touches. Thus, a user may actually be on, around, or over the floor mat without being considered present by operation504. If a user is not present, process500calls for continuing to wait for a user to be present.

Once a user is present, process500calls for determining whether the user's skin is covered (operation508). Determining whether a user's skin is protected may, for example, be accomplished by capacitive-touch sensors, which may sense to bottom of the foot. If a user's skin is not protected, process500calls for activating an alarm (operation512) and determining whether the user has exited (operation516). The alarm may be a visual indicator (e.g., a warning light or a warning message) and/or an audible indicator (e.g., a bell, buzzer, siren, etc.). Determining whether the user has exited may be accomplished be sensing deactivation of a pressure switch. Once the user has exited, process500calls for deactivating the alarm (operation520) and again detecting whether a user is present.

If the user's skin is protected, process500calls for detecting the user's shoe pattern (operation524). Detecting a user's shoe pattern may, for example, be accomplished by using pressure activated sensors in the mat or capacitive sensing. Process500also calls for activating the illumination source based on the shoe pattern (operation528). For example, only LEDs underneath the positions of the shoe pattern could be activated. For some shoes, the entire sole does not touch the ground (e.g., for heeled shoes). However, the UV light associated with the portions that do touch the ground may bleed over to these portions too, providing some disinfecting.

Process500calls for determining whether there is a change in shoe pattern (operation532). This could, for example, occur by a user lifting their feet or rocking back and forth. If there is a change in shoe pattern, process500calls for deactivating the illumination sources (operation536). As UV light is potentially harmful to humans, the system is designed to try to contain the light to the bottoms of the shoes as much as possible.

If there is no change in shoe pattern, process500calls for determining whether the user is present (operation540). Again, as UV light is potentially harmful to humans, the system is designed to try to contain the light to the soles of the shoes as much as possible. Thus, if no user is present, the illumination sources are deactivated (operation536).

If the user is present, process500calls for determining whether sufficient cleansing has occurred (operation544). This may, for example, be accomplished based on time (e.g., 30 seconds). If sufficient cleansing has not occurred, process500calls for continuing to make sure that the user shoe pattern is remaining constant and that the user is present.

Once sufficient cleansing has occurred, process500calls for deactivating the illumination sources (operation536). Process500also calls for waiting for the user to exit (operation548). Process500then returns to determining whether a user is present (operation504).

AlthoughFIG. 5illustrates one implementation of a process for operating a UV cleansing mat, other processes may include fewer, additional, and/or a different arrangement of operations. For example, a process may not call for detecting a user's shoe pattern. UVC light is known to degrade quickly in air. Thus, illuminating the entire mat may be possible. Additionally, if a change in user shoe pattern is detected, the illumination sources could be adjusted rather than deactivating all the illumination sources and requiring the user to reenter.

The floor mat may be used in locker rooms, surgery centers, medical supplies/equipment or food preparation or processing areas, nursing homes or anywhere where a clean room is required.

Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. On the contrary, various modifications of the disclosed embodiments will become apparent to those skilled in the art upon reference to the description of the invention. It is therefore contemplated that the appended claims will cover such modifications, alternatives, and equivalents that fall within the true spirit and scope of the invention.