TABLE OR COUNTER MAT

Abstract: A table or counter mat having a composite sheet structure comprising a non-slip backing layer (3); a top liquid absorbent textile surface (1) for resting cups, mugs or glasses; and an intermediate stabilisation layer (2) joining the backing layer (3) to the textile surface (1) wherein the resultant mat is absorbent and readily able to be laundered. The invention also provides a method of forming the table or counter mat by curing and bonding of the nitrile rubber backing layer (3) to the intermediate layer (2) and upper polyester textile layer (1) at greater than 100 DEG C and preferably greater than 170 DEG C and a sublimation printing (4) for printing on the textile layer (1) occurs at greater than 100 DEG C and preferably greater than 170 DEG C such that the mat is able to be laundered in hot water.

Description: TABLE OR COUNTER MAT Technical Field This invention relates to a table or counter mat that lies flat and is readily laundered. The invention is particularly related to a device to protect and provide a functional non-slip absorbent and message communication covering for hospitality bar tops although the invention is not limited to such use. background Art The product used by the hospitality industry, including hotels, clubs and restaurants for absorbing spilt liquids on bar tops is generally in the orm of strips of cotton towelling. Problems experienced by hotel operators with the towelling product is that it slips on the work surface. It also wrinkles, bunches up in an unsightly appearance and it presents an unstable suiface where glasses may topple over, spilling the contents. Towelling tends to lose colour and shrink in the washing process, further detracting from its appearance and presentation of the bar. In addition, when the towelling product carries a printed brand message, there is a loss of colour, shrinkage and creasing which greatly detracts from the brand image and diminishes the investment value for the brand owner. It is also known to have Hour mats which may have a rubber backing and a top tufted pile of some 2 or ore centimetres or alternatively a plurality of upwardly extending rubber fingers. However, such articles are used as floor mats with the upper layer having a physical mode of operation of brushing diit or mud or the like from soles of shoes and allowing the residue dirt to fall within the spaces between the fingers or tufts of carpet. In essence such a structure is like a form of an upturned brush and is not liquid absorbent or providing a stable sui face. Such an article is therefore not practical or useable as table or counter mats. DISCL URE OF INVEN ION It is an object of the invention to provide a table or counter mat that overcomes one or more of the disadvantages of the prior art. In accordance with the invention there is provided a table or counter mat having a composite sheet structure comprising a non-slip backing layer; a lop liquid absorbent textile surface for resting cups mugs or glasses; and an intermediate stabilisation layer joining the backing layer to the textile surface wherein the resultant mat is absorbent and readily able to be laundered. The non-slip backing layer can be formed from rubber such as a nitrile rubber of less than 2 mm thick with a density of about 1000 grams per square metre. The intermediate stabilisation layer can compi ise a heat curable material non-woven polyester curable al temperatures greater than I O0°C and preferably al about I 70°C and wherein the mat is able to be laundered in hot water. The textile surface of the (able or counter mat can include a textile marking providing a print or advertising message viewable from above. This can be formed by a sublimation textile printing process as will be further detailed hereinafter. Preferably the sublimation printing occurs at greater than I ( ) ( ) "(. ' .' and preferably greater than I 70°C such that the mat is able to be laundered in hot water. T e lop liquid absorbent textile .surface can be formed from a polyester surface with a pile height substantially in the range of 3 to 7 millimetres. Another embodiment has the top liquid absorbent textile surface formed from a tufted nylon cut pile sui face with a pile height substantially in the range of 5 to 10 millimetres. However this textile surface receives its colour marking by an acid dye proces The invention also provides a method of forming a table or counter mat including the steps of forming a nitrile rubber sheel material as a backing layer; forming an intermediate layer of non-woven polyester fabi ic, oi ming a textile sui face layer to form an upper layer; aligning all three layers and compressing the layed up materials by a heated platen for a selected time duration, pressure and temperature settings to cure and bond the nitrile rubber backing to the intermediate layer and upper textile layer; wherein the resultant table or counter mat lays flat and is able to stably support a glass or other similar liquid vessel with the table or counter mat liquid absorbent to absorb any spilled liquid. The step of the curing and bonding of the nitrile rubber backing to the intermediate layer and upper textile layer occurs preferably at greater than 100°C and preferably greater than 170°C such that the mat is able It) be laundered in hot water. The step of providing a sublimation piinting process can be by using a screen printed or digital image print paper which carries the lequired design and placing on the upper textile layer surface of the bar runner blank with print face down and activating a heat platen to press the screen print or digital image print paper to the textile surface under a selected heat, pressure and time duration. Pieferably both the curing and bonding of the niliile rubber backing to the intermediate layei and uppei textile layei occurs at greater than I 00"C and preferably greater than I 70"C and the sublimation printing occurs at greater than K)0°C and preferably greater than I 70°C such that the mat is able to be laundered in hot water. BRIEF DESCRIPTION OF THE DRAWINGS In order that the invention is more readily understood, a particular embodiment thereof will now be described by way of example only with reference to the accompanying drawings wherein: figure I is a perspective view oi " a table or counter mat according to a first embodiment of lhe invention. figure 2 is a diagrammatic exploded constiuclional view of the table or counter mat of Eiguie I BEST MODE FOR ( ARRYING OUT HIE INVENTION Refeπing to Figuie I, it can be seen that the table oi counter mat of the invention can be a non-slip, loose lay bai lunnci eompiising a rectangular strip of nitiile lubbei backing, heat cuietl and moulded to a tufted cut pile textile fabric dyed to a plain colour oi a printed design Refenϊng to Figuie 2, it can be seen that the invention comprises thice construction layers which are heat piessed and moulded together to oim a homogeneous product foi dimensional stability and to withstand a liequenl laundiy pi cess The top layei I is a textile suiface which in one embodiment is a tufted synthetic yarn cut pile suiface with a pile height of 6 mm, and pile weight of 620 grams pei square meter, cut to a size blank lequiied, geneially 250 x 0 nun, but not limited to this size i he intei mediate layer 2 is a spun bonded polyester non-woven piimaiy abiic layer 110 giams pei squaie meter, pioviding added stability and pile caiiier The backing layei 3 is a nitiile uibbei compound backing material 1 mm thickness, 1 00 gia s pei squaie meter The textile sui ace I can be mai ed such as by sublimation piinting so as to pi vide a message oi logo viewable fiom the lop suiface 4 of the textile suiface 1 Cut pile suiface dyed to plain colouis as lequircd, oi printed designs by heat tiansfei textile piimaiy process Raw Material Contents Looking at the composition in moie detail the backing layer compiises F2224 - nitrile uibbei compound applied as the pi duct back suppoil with a I m thickness of density 1000 giams pei squaie inelie It is composed of niineial lillei with caibon black leinlbieing Zinc oxide and stearic acid activation together with ester plaslicisalion are used as understood in the field. Phenolic derived antidegradanls ai e used. Also organic accelerators in combination with sulphur allow for conventional curing. Miscellaneous additives including resins and activators can be included. fhe nitrile rubber backing provides a non slip sui face The thickness of the backing aids the stability while still allowing l eady laundering. 'fhe primary supporting intermediate layer comprises 100% Polyester thermally bonded non-woven fabric with a weight density of 1 10 gram per nr and tensile strength of 190 Newtons per 5 cm providing maximum elongation of L10% and tear strength of 140N. Particular advantageous characteristics are dimensionally stable, high thermal stability, reduced ilammability and ensures the product always lays Hal With the top textile suiiace there is a choice of: a) Polyester fibre needlefell, polyester scrim supported, high density heavy duly needled 500 grams per metre " , heat set, and laser cul to required size. This product is the preferred textile sui face for bi and message printing, offering print clarity and colour fastness to I S O., British and Australian standards. b) Tufted polyester cul pile surface with a pile height of 5-6 mm, pile weight of 600-620 grams per metre 2 , knife cut to required size. This suiiace is suitable for brand messcTge printing, colour fast to I S O., British and Australian standards. c) ' fulled nylon cut pile sui face, with a pile height of 5-6 mm, pile weight of 600 grams per metre 2 , which can be knife cul to required size. This sui face is suitable for acid dye for solid plain coloui s, which are colour fast to I S , British and Australian slandauls. Manufacturing Process Selected textile suiiace is laser cut in the case of needlefelt material, or knife cut in case of tufted polyester or nylon sui face material to the required blank shape and size, generally 250 x 900 mm, but not limited lo this size. The blanks are stored on a holding table behind the rubber process line for the operator to lay up. Uncuied nitrile rubber is cut into required length strips from a continuous roll as leceived from the rubber supplier fhe niti ile rubber sn ips aie laid in parallel across the width of a Teflon I M continuous cai iier bell on the rubber process line. The selected textile blank and the primary support layer are laid in position onto the uncui ed nitrile rubber to allow for a minimum of a 2 cm border of llie rubber lo be visible on either side of the textile blank. Product identification labels are positioned beneath the rubber on the Teflon l lNI belt to be cured to the back of each product The layed up batch of uncui ed nitrile rubber and textile blanks are advanced on the belt into the heat zone of the press over a heated platen. A press head is activated to compress the layed up materials lo ihe heatetl platen for a selected time duialion, pressui e and temperature settings to cin e and bond ihe nili ile uibber backing lo the primary carrier and textile top. Sellings applied lo cin e and bond a I mm thick nitrile rubber compound to the textile material are 170° for three minutes at 75 pounds per square inch. Following the selected time duration the press head raises, and releases Ihe cured materials, for the belt drive lo advance clear of Ihe heated platen area, drawing in the following uncui ed layed up matet ials for the cure process lo recur. This process is repeated continuously for each layed up batch of materials. Once the materials are clear of the heat press they are cooled, taken from the carrier bell anil stacked to be edge d immed by a guillotine opeialor. Following the trim process the bar runner product in its finished blank form is passed to a textile sublimation printer where the end finish requires a printed design on the product. In the case of a plain dyed colour finish, the product is passed to Ihe dye house lo be vat dyed. Sublimation Print Process A computer generated design is output with film colour separations, to be exposed on screens, which in turn are used to screen print sublimation dyes of the design onto transfer print papers for volume repeat prints Shoi t run and strike of rint designs are output from the design computer to a digital image printer employing sublimation dyes for exact image transfer. The finished nitrile uibbei blank table or counter mat are placed on the bed of the sublimation print machine, a screen printed or digital image print paper which carries the required design, is placed on the textile surface of the table or counter mat blank, dye face down. A heal platen is activated pressing the print paper to the textile surface under a selected heat, pressure and time duration T his process sublimates the dye turning it into a gas which is transferred into the textile fibre, resulling in a mirror image of Ihe screen-print design on to the textile surface of the table or counter mat. On release from the press, Ihe spent pi inl paper is removed, leaving the finished design to be cooled and stored for packing and dispatch. The above descriptions are of preferred embodiments of the invenliion and are priovided as illustration and not limitation of the invention. Clearly persons skilled in the art would understand variations of ihe descibed invention without any inventive step and these are included within the scope of the invention as defined in ihe claims.

Claims: CLAIMS 1. A table or counter mat having a composite sheet structure comprising a non-slip backing layer; a top liquid absorbent textile surface for resting cups, mugs or glasses; and an intermediate stabilisation layer joining the backing layer to the textile suiface wherein the resultant mat is absorbent and readily able lo be laundered. 2. A table or counter mat according to claim 1 wherein the non-slip backing layer is formed from rubber 3 A table or counter mat according lo claim 2 wherein the non-slip backing layer is formed from a nitrile rubber. 4. A table or counter mat according to claim 3 wherein the nitrile rubber is in the range of less than 2 mm thick with a density of about 1000 grams per square metre. 5. A table or counter mat according to any one of claim 3 wherein the intermediate stabilisation layer comprises a heat curable material curable at temperatures greater than 100°C and preferably at about 170°C such that the mat is able to be laundered in hot water. 6 A table or counter mat according to claim 5 wherein the intermediate layer is formed from a non-woven polyester. 7. A table or counter mat according to claim 6 wherein the non-woven polyester has a density of about 450 to 650 grams per square metre. 8 A table or counter mat according to claim 5 wherein the textile surface includes a textile marking providing a colouring or a print or advertising message viewable from above. 9 A table or counter mat according to claim 8 wherein the textile marking is formed by a sublimation textile printing process. 10 A table oi counter mat accoiding to claim 9 wheiein the sublimation piinting occuis at greater than I00"C and piefeiably greatei than 170°C siitii that the mat is able lo be laundered in hot walei 11 A table oi counler mat accoiding lo claim 10 wheiein the lop liquid absoibenl textile suiface is foimed liom a polyester suiface with a pile height substantially in ihe range of 3 to 7 millimetres . 12 A lable oi counlei mat accoiding lo claim 8 wheiein the top liquid absoibenl textile sui ace is foimed liom a tufted nylon cut pile suiface with a pile height substantially in the lange of 5 to 10 milli eties 13 A table oi counter mat accoiding lo claim 12 wheiein the textile suiface has a density of about 600 giams per squaie etie 14 A table oi counlei mat accoiding lo claim 13 wheiein the textile maiking is formed by an acid dye piocess. 15 A table or counter mat accoiding to claim 14 wheiein the dye process occurs such that the mat is able It) be laundeied in hot walei 16 A method of foiming a table oi counlei mat including the steps of. a) forming a nitiile lubber sheet maleiial as a backing layei, b) foiming an intei mediate layei of non-woven polyestei fabiic, c) foiming a textile sui ace layei It) Ibim an uppei layei, tl) aligning all thiee layei s and compiessing the layed up mateiials by a heatetl platen foi a selected lime duialion, piessuie ami tempeialuie settings to cine and bond the nitiile uibbei backing lo the intermediate layei anil uppei textile layer, whei ein the l esultant table 01 counlei mat lays flat and is able to suppoit stably a glass oi othei similai liquid vessel with the table oi counter mat liquid absorbent to absorb any spilled liquid 17 A method of foiming a table oi counler mat accoiding to claim 16 wheiein the curing and bonding of the nitrile uibbei backing to the intei mediate layer and uppei textile layer occuis at gieatei than I 00°C and piefeiably gieatei than I 70 such that the mat is able to be laundeied in hot watei 18 A method of foiming a table oi counlei mat accoiding lo claim 16 including the step of pioviding a sublimation printing piocess by using a sci een punted oi digital image punt papei which cai i ies the l equnetl design and placing tin the uppei textile layei sui face of the bai l iinnei blank with punt face down and activating a heat platen to pi ess the scieen punt oi digital image print papei to the textile sui face under a selected heat, piessui e and time duiation 19 A method of foi ming a table oi counlei mat accoi ding to claim 18 wherein the curing and bonding of the niti ile uibbei backing to the mtei mediate layei and uppei textile layei occui s al gieatei than 100°C and pi efeiably gi eatei than 170°C and the sublimation punting occui s at gieatei than I 00 and pi efei bly gieatei than 170T such that the mat is able to be laundeied in hot watei

Inventors: CARKEEK STEPHEN ROBERT, CARKEEK, STEPHEN, ROBERT
Applicants: CARKEEK STEPHEN ROBERT, JAYFIELD PTY LTD, CARKEEK, STEPHEN, ROBERT, JAYFIELD PTY. LTD.
Application year: 1999
Main classification: A47G23
IPC codes: A47G23, B32B25, D06P5