FLOOR MAT

Abstract: The floor mat is formed from an array of interlocking tiles (2). Each tile is based on an open matrix structure which defines in its upper surface rows a recesses (8) for receiving carpet strips (10) interleaved with rows of scraper elements (32). The carpet strips are anchored in the recesses with the aid of nipples (18) which engage apertures (20) in the carpet strip backing (14) and by peripheral retaining projections(12). The scraper elements (21) protrude above the surface of the matrix structure and scrape and agitate the scrapings down the cavity in which they are located. An array of probes (46) agitate the underside of the carpet strips (10) and double action male and female connectors (4, 6) enable adjacent tiles (92) to be securely locked together irrespective of which way up the tiles are placed next to each other.

Description: FLOOR MAT The present mvention relates to floor mats. It is known to have a scraper mat at the entrance of a building which enables those entering the building to remove moisture, soil or other detritus from the underside of their footwear as they enter the building. Such scraper mats may comprise bristles be of natural or synthetic plastics or fibres, or of ferrous or non-ferrous metals. PCT Patent Specification No PCT/GB 98/02737 discloses a reversible scraper mat formed by a series of interlocking tiles. Each tile comprises on one side an array of carpet strips interleaved with an array of flexible flaps or posts. The reversible side comprises an array of flaps and posts. Engagement of the footwear with the flaps and posts dislodges some of the detritus from the footwear, and engagement of the footwear with the carpet strip brushes the underside of the footwear to dislodge residual detritus. It is an object of the invention to provide an improved floor mat. According to the present invention there is provided an interlocking floor tile for a floor mat, the tile comprising a matrix structure defining in its upper surface a plurality of recesses, a plurality of scraper elements arranged in interleaving relationship with the recesses, each recess containing an array of carpet engaging nipples upstanding from the base of the recess, and arranged to engage corresponding apertures in a carpet strip destined for the recess, and a plurality of inwardly projecting carpet strip retaining projections extending around the perimeter of the recess to engage and retain the perimeter portion of the carpet strip when placed on the recess. According to the present invention there is further provided an interlocking floor tiLe for a floor mat comprising an open matrix structure defining a plurality of spaced scraper elements, each scraper element comprising a generally laminar member extending laterally from the side of a respective generally vertically extending open cavity within said matrix structure to lie in a generally vertically extending plane each scraper element projecting above the upper surface of the matrix structure and being flexibly resilient whereby to simultaneously scrape any contacting traffic across the upper surface of the matrix structure and agitate any material dislodged down its corresponding cavity. According to the present invention there is still further provided an interlocking floor tile comprising an open matrix structure defining on its upper surface a plurality of carpet element strip receiving recesses, the matrix structure supporting an array of probes extending towards the base of the recess, said probes responding to varying pressure placed on said tile to agitate the underside of any carpet element placed in said recess. According to the present invention there is yet further provided an interlocking floor tile for a floor mat comprising a plurality of laterally extending male and female connectors for engagement with female and male connectors of similar adjoining tiles, each male connector comprising a generally planar support member having a respective stud projecting generally at right angles thereto from opposite sides thereof, each female connector comprising a pair of parallel support plates spaced apart by a distance substantially equal to the thickness of the support plate of the male connector, each support plate having an aperture positioned to receive a corresponding stud of the male connector of another tile when the stud support plate of that tile is inserted into the space between the two support plates of the female connector. According to the present invention there is yet further provided an interlocking floor tile for a floor mat, the tile having front and rear faces and a predetermined depth, the tile comprising an array of alternate male and female connectors arranged along each of the four sides of the mat, means connecting the connectors extending along two adjacent sides of the mat, to the mat, at a location nearer the rear face than the front face, with the male and female connectors being oriented to receive and couple with mating connectors approaching from the direction of the front face, means connecting the connectors extending along the other two adjacent sides of the mat to the mat at a location nearer the front face than the rear face of the tile with the male and female connectors being oriented to receive and couple with mating connectors approaching from the direction of the rear face. Floor mats embodying the present invention will now be described, by way of example, with reference to the accompanying diagrammatic drawings, in which: Figure 1 is a fragmentary plan view of two floor mat elements interlocked together; Figure 2 is an underplan view of the mats of Figure 1; Figure 3 is a fragmentary perspective view from above, of two floor mats locked together; Figure 4 is a section taken on line IN-IN of Figure 1; Figure 5 is a section taken on line N-N of Figure 1; Figure 6 is a fragmentary perspective view of a female connecting portion of the mat; Figure 7 is a fragmentary perspective view of a male connecting portion of the mat; Figure 8 is an underplan view of a carpet strip for the mat; Figure 9 is an end elevation of the carpet strip of Figure 8; Figure 10 is a fragmentary perspective detail of the underside of the mat; and Figure 11 is a perspective view of another floor mat element with a different array of connectors along the sides. The floor mats to be described are intended to be located in a matwell or other recess (not shown) at the entrance to a building but may also be laid on the floor free of constraint in any appropriate area. The floor mat is made up of individual floor mat elements or tiles 2 which are interlocked together so that the floor mat can be inserted into or removed from the mat well in one piece. Individual elements which are damaged or worn can be replaced as required and the mat can be initially assembled using an appropriate number and configuration of mat elements as required. Each mat element 2 may be of square or rectangular profile having four sides or any other tessellating shape having more than four sides or just three sides. In order for the mats to be interconnected to each other, each mat element 2 has a row of male connectors 4 along two adjacent sides and a row of corresponding female connectors 6 along the other two adjacent sides (see Figures 6 and 7 for more detail). Instead, the male and female connectors 4 and 6 may be arranged in any other manner which allows two similar adjacent tiles to be interconnected with each other, irrespective of which way up the tiles are placed next to each other. Each mat element 2 which is generally of an open matrix structure of resilient plastics material, has in its upper face a plurality of parallel rectangular recesses 8 separated by intervening rows 9 of scraper elements. In a modification, the element may be of a closed matrix structure and be of other material than plastics, for example of a ferrous or non-ferrous metal. Each rectangular recess 8 accommodates a respective caφet strip 10 (shown shaded in Figure 1). Around the upper perimeter of each rectangular recess 8 are a plurality of inwardly directed retaining projections or nibs 12 under which the edges of the carpet strip 10 can be tucked whereafter the carpet strip 10 is retained by the nibs 12 even when the floor mat is rolled up for removal from the floor well. The caφet strip 10 has a rigid or semi-rigid backing 14 (see Figures 8 and 9). The backing is either of water permeable material or made water permeable by an array of perforations 16 (see Figure 8). Upstanding from the base of each rectangular recess 8 are a plurality of caφet retaining nipples 18 arranged equally spaced apart in a row extending longitudinally along the centre of each recess 8. The nipples 18 are arranged to engage a corresponding one of a row of apertures 20 provided in the caφet strip (see Figure 8). Each nipple comprises an upstanding cylindrical rod 24 supported at its base by a pair of intersecting cross-members 22 (see Figure 2) forming part of the matrix structure of the mat element 2. At its upper end, the rod extends through a circular cavity 24 in the matrix structure, into the rectangular recess 8. The upper end portion of the nipple 18 has a neck 26 and a bulbous head 28 which projects just beyond the recess 8. In operation, when the caφet strip 10 is inserted into the recess 8, a corresponding aperture 20 is forced over the bulbous head 28 until the backing layer 14 settles around the neck 26. Advantageously, the aperture 20 should be slightly smaller than the head 28 so that it has to be stretched against its own resilience to pass over the head and so be securely anchored to the nipple 18. With the backing 14 of the caφet strip anchored to the nipples, the tufts of the caφet will project out of the recess 8. The perimeter of the backing layer 14 is then tucked under the retaining nibs 12. In a modification, the material of the nipples 18 may be resiliently compressible to allow passage through a corresponding aperture in the caφet strip whereafter it expands to resume its original shape and so hold the caφet captive. Each row 9 of scraper elements is bounded on opposite longitudinal sides by a pair of walls 30 which also flank the rectangular recess 8 of the row 9. The scraper elements 32, which are generally laminar, are arranged in pairs and he in a common vertical plane. With the elements 32 of each pair extending from opposite sides of a corresponding strut 34 also extending in a vertical plane, and bridging the two walls 30. The walls 30 and the struts 34 thus define a row of vertically extending cavities or chambers 36 accommodating two scraper elements 32 extending towards one another and lying in a common vertical plane. Each scraper element 32 can flex against its own resilience about a vertical axis and extends upwardly to stand proud of the upper limit of the walls 30. The scraper elements 32 thus act when contacted by the underside of footwear to scrape off detritus and to flex under the scraping action to agitate any debris which has accumulated in the chamber and discharge it from the bottom of the chamber. Each third chamber 36a in the row 9 is an enlarged chamber accommodating a central upstanding guide pin 38. The guide pin 38 is supported by a pair of intersecting struts 40 extending at right angles to each other between the walls 30. The struts 40 radiate at angles of 45° from the centre of the guide post 38. Each strut 40 carries a curved ramp 42 leading to an upper portion of the guide post 38 so as to guide any debris falling on to the chamber 36a laterally away from the guide post to prevent the chamber 36a from clogging. A slot 44 is provided in the lower portion of each scraper element 32 immediately adjacent the strut 34 to which it is attached, to provide for a less stiff hinging action when displaced and to allow component of deflection in the direction of the horizontal plane. Below each recess 8 is an array of probes 46 which extend upwardly up to the base of the recess to engage and act on, when deflected, the underside of the caφet strips 10 when in place. Each probe 46 is mounted atop of a vertically extending paddle 48 (see Figure 5) which extends from a respective strut forming the matrix structure of the tile 2. The paddle 48 will flex against its own resilience to provide the probe 46 with components of motion in both the horizontal and vertical directions. The lower portion of each paddle 48 extends below the lower limit of the matrix structure so as to directly engage the floor on which the tile is placed. Thus, when pressure is placed on the tile, as by someone walking on the tile, the paddle 48 is displaced and the probe 46 is caused to act on the underside of the caφet 10. This action squeezes the caφet between the foot landing on the caφet 10 and the probe 46 to cause any liquid retained by the caφet to be expressed through the perforations 16. The underside of the support structure is provided with an array of castellations 50 (see Figure 10) to act as ground engaging stops when the pressure on the tile becomes too great to be supported by the paddles 48 alone. The male and female connectors 4 and 6 are more clearly shown in Figures 6 and 7. The male connector comprises a generally planar circular cantilevered plate 60, which projects laterally from the side of a tile and is located generally equidistant from the upper and lower surfaces of the tile. A respective stud 62 located centrally of the plate 60 extends from opposite sides of the plate. Each stud 62 has a bulbous head and a narrow neck. The female connector 6 comprises two spaced apart generally planar cantilevered plates 64 extending from the side of the tile. The spacing between the plates 64 is generally equal to the thickness of the plate 60 of the male connector 4. Each plate 64 has an opening 66 to receive a respective head62 when the plate 60 of one male connector is inserted between the two plates 64 of the female connector. The leading edges of the plates 64 of the female connector 6 are provided with sloping recesses 68 to provide an initial location for the two heads 62 when they are brought into engagement with the female connector so that by cam action the heads 62 can force the two plates 64 of the female connector 6 apart as the two components are brought into progressive engagement until the heads 62 become aligned with the openings 66 at which point the two plates 64 return near to their original position under their own resilience, and the heads 62 become fully engaged with their respective openings under slight pressure. At this point, the two tiles become locked together. The plate 60 is flanked by a pair of arcuate walls 70 which matingly engage corresponding recesses 72 on the plates 64 to shield the mating components from the ingress of dirt and accidental damage. It will be appreciated that the provision of caφet strip retaining nipples and the caφet strip retaining projections allow the caφet strips to be installed and removed without the need for special tools. It allows ready replacement of the strips if damaged or a new colour scheme is required without the need to completely replace the floor matting. The caφet retaining projections ensure that the perimeter of the caφet strips is securely tucked into the recess without the danger of any portion protruding and providing a hazard to floor traffic. The matrix structure is kept dense preventing footwear such as stiletto heels becoming lodged in a gap in the matrix structure. The modified mat shown in Figure 11 allows two mat elements to be joined with their face sides uppermost with their reverse sides uppermost or with one mat face side up and the other mat with its face side down. As shown, the mat has four sides 80, 82, 84 and 86. The male and female connectors 88 and 90 along the two adjacent sides 86 and 80 are upwardly facing with the male and female connectors arranged alternately along each side. The male and female connectors 88 and 90 along the other two adjacent sides 82 and 84 are downwardly facing with the female and male connectors being arranged alternately along each side. Each connector 88 and 90 is partially housed in a respective one of an array of circular recesses 92 along each of the four sides 80 to 86. Each connector comprises a cylindrical portion 94 connected by a radially extending flange 96 to the wall of the circular recess 92. In the case of the recesses 92 along the two sides 80 and 86, the flange 92 engages the wall of the recess 92 in the lower half portion, ie at a location nearer the lower face than the upper face of the mat, while in the case of the recesses 92 along the other two sides 82 and 84, the flange 92 engages the wall of the recess 92 in the upper half portion, ie at a location nearer the upper face than the lower face of the mat. The cylindrical portions 94 of each female connector 90 define a recess 98 for engagement by a stud of the male connector 88 of another mat while the cylindrical portion 94 of the male connector 88 rigidly supports a stud 100 for engaging a female member of the other mat. In the case of the two adjacent sides 80 and 86, the studs 100 are upwardly directed to receive the mating male and female connectors of another mat approaching from the direction of the upper face of the mat, while in the case of the adjacent sides 82 and 84, the studs are downwardly directed to receive the mating male and female connectors of another mat approaching from the direction of the lower face of the mat. It will thus be seen that adjacent mats can be oriented so that they can be interconnected which ever way up they are.

Claims: CLA S 1. An interlocking floor tile for a floor mat, the tile comprising a matrix structure defining in its upper surface a plurality of recesses, a plurality of scraper elements arranged in interleaving relationship with the recesses, each recess containing an array of caφet engaging nipples upstanding from the base of the recess, and arranged to engage corresponding apertures in a caφet strip destined for the recess, and a plurality of inwardly projecting caφet strip retaining projections extending around the perimeter of the recess to engage and retain the perimeter portion of the caφet strip when placed on the recess. 2. A floor tile according to Claim 1, wherein said matrix is an open matrix. 3. A floor tile according to Claim 1, wherein said matrix is a closed matrix. 4. A floor tile according to any one of Claims 1 to 3, wherein said recesses comprise spaced elongate recesses extending parallel to one another, and wherein said scraper elements are arranged in rows with said rows being in interleaved relationship with said elongate recesses. 5. A floor tile according to any one of Claims 1 to 4, which is reversible and has on a side opposite said side defining said recesses, a plurality of scraper elements, interleaved with a plurality of guide posts and agitator flaps which when agitated promote the flow of detritus through the floor tile. 6. A floor tile according to Claim 4, wherein said array of caφet engaging nipples are arranged to extend in a row extending generally along the central axis of the elongate recess. 7. A floor tile according to any preceding claim, wherein each said nipple comprises a rod having a bulbous head and a necked region below said head. 8. A floor tile according to Claim 7, wherein said rod extends upwardly to the base of said recess through a chamber in said matrix structure which communicates with the base of the recess. 9. A floor tile according to Claim 8, wherein said rod is resiliently flexible in a direction normal to its longitudinal axis. 10. A floor tile according to any one of Claims 7 to 9, wherein said rod is supported at the intersection of two struts of said matrix structure. 11. A floor tile according to any preceding claim, including a caφet strip located in each recess and anchored thereto by said nipples and said retaining projections, each said caφet strip having a rigid or semi-rigid backing and a series of nipple engaging openings for receiving said nipples. 12. A floor tile according to Claim 11, wherein the backing of each said strip is permeable. 13. A floor tile according to Claim 11, wherein the backing of each said strip is made permeable by being provided with an array of perforations. 14. A floor tile according to any one of Claims 11 to 13, wherein said backing is resiliently stretchable and each said nipple receiving opening is sized to be greater than the neck of a said nipple but smaller than the head of said nipple. 15. A floor tile according to any one of Claims 11 to 13, wherein each said nipple is resiliently compressible to allow passage through said nipple receiving opening which is sized smaller than the size of the head of the nipple when compressed. 16. An interlocking floor tile for a floor mat comprising an open matrix structure defining a plurality of spaced of scraper elements, each scraper element comprising a generally laminar member extending laterally from the side of a respective generally vertically extending open cavity within said matrix structure to lie in a generally vertically extending plane each scraper element projecting above the upper surface of the matrix structure and being flexibly resilient whereby to simultaneously scrape any contacting traffic across the upper surface of the matrix structure and agitate any material dislodged down its corresponding cavity. 17. A floor tile according to Claim 16, wherein each said cavity accommodates two scraper elements extending towards each other from opposite sides of the cavity. 18. A floor tile according to Claim 16 or to Claim 17, wherein all the scraper elements in one row are aligned to extend generally in the same vertical plane. 19. A floor tile according to Claim 17, wherein selected chambers are provided with a vertically extending guide member upstanding from the base of the cavity, the guide member being resiliently flexible and located between the two scraper elements. 20. A floor tile according to Claim 19, wherein each such guide member has a ramped lower section to guide all debris falling onto the cavity progressively in a direction away from the vertical axis of the guide member. 21. A floor tile according to Claim 20, wherein said guide member comprises a vertically extending rod upstanding from the intersection of two horizontally extending struts of the matrix structure, extending across the lower part of the cavity and wherein said ramped lower section comprises a ramp on each of the four arms of the struts leading up to the rod. 22. A floor tile according to any one of Claims 16 to 21 , wherein each scraper element is provided with a generally vertically extending slot to allow the scraper element a component of flexure towards the horizontal. 23. An interlocking floor tile comprising an open matrix structure defining on its upper surface a plurality of caφet element strip receiving recesses, the matrix structure supporting an array of probes extending towards the base of the recess, said probes responding to varying pressure placed on said tile to agitate the underside of any caφet element placed in said recess. 24. A floor tile according to Claim 23, wherein each said probe is supported by a laminar member extending from the side of a generally vertically extending cavity within said matrix structure. 25. A floor tile according to Claim 24, wherein each said laminar member projects from the cavity below the underside of the matrix structure to engage the floor there below whereby pressure applied to said tile will cause said laminar member to flex against its own resilience so as to impart to the probe components of motion in both the vertical and horizontal directions. 26. A floor tile according to Claim 20, wherein said matrix structure is provided with ground engaging stops on its underside to limit the extent to which the laminar members can be deflected. 27. An interlocking floor tile for a floor mat comprising a plurality of laterally extending male and female connectors for engagement with female and male connectors of similar adjoining tiles, each male connector comprising a generally planar support member having a respective stud projecting generally at right angles thereto from opposite sides thereof, each female connector comprising a pair of parallel support plates spaced apart by a distance substantially equal to the thickness of the support plate of the male connector, each support plate having an aperture positioned to receive a corresponding stud of the male connector of another tile when the stud support plate of that tile is inserted into the space between the two support plates of the female connector. 28. A floor tile according to Claim 27, wherein each said stud comprises a bulbous head and a narrow neck. 29. A floor tile according to Claim 28, wherein the two support plates of the female connector are provided with ramped grooves in their facing surfaces leading from their distal ends towards the apertures therein the grooves being positioned so as to be engaged by the studs of a male connector when the male connector is being coupled to the female connector whereby the two support plates are progressively forced apart against their own resilience as the male connector is progressively forced home into the female connector until the studs engage respective apertures in the female connector whereupon the two support plates of the female connector return into abutment with the support plate of the male connector. 30. A floor tile according to any one of Claims 27 to 29, wherein the two studs of the male connector are axially aligned, and the two apertures of the female connector are axially aligned. 31. A floor tile according to any one of Claims 27 to 30, wherein all the male connectors extend from one pair, of two adjoining sides, and all the female connectors extend from the other pair of adjoining sides. 32. A floor tile according to any one of Claims 27 to 31 , wherein the male connector has a pair of walls which extend partially around the support plate and which are arranged to matingly engage corresponding recesses in the support plates of a female connector of an adjoining tile whereby to provide a shielding wall around a coupled male and female connector. 33. A floor tile according to any one of Claims 27 to 32, wherein the male and female connectors of each tile are so configured as to engage the corresponding female and male connectors of a similar tile which ever way up the tile is placed adjacent the similar tile. 34. A floor tile according to any one of Claims 27 to 33, wherein the tile is a four sided tile. 35. A floor tile according to any one of Claims 27 to 33, wherein the tile has more than four sides. 36. An interlocking floor tile for a floor mat, the tile having front and rear faces and a predetermined depth, the tile comprising an array of alternate male and female connectors arranged along each of the four sides of the mat, means connecting the connectors extending along two adjacent sides of the mat, to the mat, at a location nearer the rear face than the front face, with the male and female connectors being oriented to receive and couple with mating connectors approaching from the direction of the front face, means connecting the connectors extending along the other two adjacent sides of the mat to the mat at a location nearer the front face than the rear face of the tile with the male and female connectors being oriented to receive and couple with mating connectors approaching from the direction of the rear face. 37. A floor tile according to Claim 36, wherein each male and female connector comprises a cylindrical portion with the cylindrical portion defining a recess when forming a female connector and supporting an axially extending stud when forming a male connector. 38. A floor tile according to Claim 37, wherein each cylindrical portion is at least partially housed in a respective arcuate recess in the side of the mat and wherein each cylindrical portion includes a radially extending flange which is rigid with the wall of said recess.

Inventors: MOUL ANDREW DOUGLAS, MOUL, ANDREW, DOUGLAS
Applicants: MOUL ANDREW DOUGLAS, SPECIALTIES UK LTD CONST, CONSTRUCTION SPECIALTIES (UK) LTD., MOUL, ANDREW, DOUGLAS
Application year: 2001
Main classification: A47L23
IPC codes: A47L23