Patent Publication Number: US-2013227855-A1

Title: Drying Mat

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
     This application is a continuation of U.S. Nonprovisional patent application Ser. No. 12/707,386 filed Feb. 17, 2010, currently pending, which is a continuation-in-part of U.S. Nonprovisional patent application Ser. No. 12/569,450 filed Sep. 29, 2009, the disclosures of which are hereby incorporated by reference in their entireties. 
    
    
     FIELD OF INVENTION  
     The present invention relates to a drying mat for receiving wet dishes or that may be stood upon by an individual after bathing. 
     SUMMARY OF INVENTION  
     A drying mat is described. The drying mat includes at least one layer of a microfiber material attached or joined to at least one layer of a foam material. The drying mat may be used as dish mat to absorb water from dishes. The drying mat may be used as a shower mat or a bath mat to absorb water from a bather standing upon the drying mat. The drying mat may also be used for drying wet or freshly washed produce and vegetables. The drying mat may also be used as a protective mat or a seat cover in a vehicle to protect a seat from damage from a child&#39;s car seat placed thereon or to absorb moisture from a passenger&#39;s swimming suit. 
     The drying mat may be placed under a dish drying rack to catch, hold, and/or absorb moisture and water from the dishes placed in the drying rack. Dishes may also be placed directly on the drying mat. The drying mat is machine washable. The drying mat provides a highly absorbent and fast drying alternative to a conventional dish towel, plastic drain board, or rubberized mat. 
     In one embodiment, a drying mat includes a first microfiber layer, a second microfiber layer, and a foam layer. An adhesive joins the first microfiber layer and the second microfiber layer to the foam layer. A binding material is applied around the perimeter of the drying mat. The drying mat includes the first microfiber layer, the second microfiber layer, and the foam layer in a layered or laminated construction. 
     In another embodiment, a laminated drying mat includes a first microfiber layer with a honeycomb pattern having a first surface and a second surface, a foam layer having a first and a second surface, a first adhesive layer of a non-water based adhesive that joins the second surface of the first microfiber layer to the first surface of the foam layer after heated compression, a second microfiber layer with a honeycomb pattern having a first and a second surface, and a second adhesive layer of a non-water based adhesive that joins the first surface of the second microfiber layer to the second surface of the foam layer after heated compression. 
     In a further embodiment, a method of forming a laminated drying mat is described. The method includes providing a first microfiber layer, a second microfiber layer, and a foam layer. Next, adhesive is applied between the first microfiber layer and the foam layer and between the second microfiber layer and the foam layer. Finally, heat and compression are applied to join the first microfiber layer, the second microfiber, and the foam layer. 
     In a further embodiment, absorbent and protective mats are described. Such mats may be used as seat covers for a vehicle. The mats are sized and shaped to fit on a vehicle&#39;s seat. The absorbent and protective mats include at least one layer of a microfiber material, at least one layer of a foam material, and adhesive to join the layers. The mats may be placed on the vehicle seat, with the children&#39;s car seat resting thereon. The soft and cushiony nature of the microfiber materials, along with the foam, protect the upholstery and the seat surfaces from abrasion and damage caused by the children&#39;s car seats. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS  
         FIG. 1  is a perspective view of the drying mat. 
         FIG. 2  is a top view of the drying mat. 
         FIG. 3  is a side view of the drying mat. 
         FIG. 4  is another side view of the drying mat. 
         FIG. 5  is a close-up view of the drying mat. 
         FIG. 6  is a cross-sectional view of the drying mat. 
         FIG. 7  is a cross-sectional view of the drying mat formed through flame lamination. 
         FIG. 8  is a flow chart for processes for forming drying mats through flame lamination. 
         FIG. 9  is another flow chart for processes for forming drying mats through flame lamination. 
         FIG. 10  is a cross-sectional view of the drying mat formed through binding. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
     The drying mat will now be described with reference to the FIGURES. A drying mat  10  is shown in  FIG. 1 . The drying mat  10  may be used as a dish mat, a counter mat, a shower/bath mat, or for other applications in which an absorbent or cushioning medium is needed. The drying mat  10  absorbs significantly more water than other similarly sized mats of conventional construction. 
     The drying mat  10  includes a top surface  20  and a bottom surface  30 . When the drying mat  10  is used as a dish mat, the wet dishes and/or the dish drying rack is placed on the top surface  20 . The bottom surface  30  is placed in contact with countertop, table, etc. 
     The drying mat  10  includes a first microfiber layer  100 , a second microfiber layer  130 , and a foam layer  160  in a laminate or layered configuration. Adhesives or glues are used to join and hold the first microfiber layer  100 , the second microfiber layer  130 , and the foam layer  160  together. 
     With reference to  FIG. 6 , a first surface  105  of the first microfiber layer  100  forms the top surface  20  of the drying mat  10 . A second surface  108  of the first microfiber layer  100  is glued via a first adhesive layer  120  to a first surface  165  of the foam layer  160 . A first surface  135  of the second microfiber layer  130  forms the bottom surface  30  of the drying mat  10 . A second surface  138  of the second microfiber layer  130  is glued via a second adhesive layer  140  to a second surface  168  of the foam layer  160 . As such, the foam layer  160  is in between the first and second microfiber layers  100  and  130 . 
     A suitable adhesive, for the first and second adhesive layers  120  and  140 , is a composite material glue, such as a polyurethane adhesive. Preferably, the adhesive is a non-water based adhesive. The amount of adhesive applied between the first microfiber layer  100  and the foam layer  160  (forming the first adhesive layer  120 ) and between the second microfiber layer  130  and the foam layer  160  (forming the second adhesive layer  140 ) is important. Too much adhesive in the first and second adhesive layers  120  and  140 , and the drying mat  10  becomes stiff. Too little adhesive in the first and second adhesive layers  120  and  140 , and the microfiber layers  100  and  130  and the foam layer  160  will tend to delaminate. Typically, approximately 30 g/m 2  to approximately 50 g/m 2  of adhesive is applied to the first and second microfiber layers  100  and  130 . The embodiment shown in the FIGURES utilizes approximately 40 g/m 2  for the first and second adhesive layers  120  and  140 . 
     Although the term “adhesive layer” is used, the term adhesive layer encompasses the intermittent spraying or partial coating of the adhesive to the microfiber layers or foam layer, as well as the spot application of the adhesive to the microfiber layers or to the foam layer. In other embodiments, the adhesive layer may fully or nearly fully coat the microfiber layers or the foam layer. 
     A binding  200  affixes or connects together the perimeter portions or edges of the first microfiber layer  100 , the second microfiber layer  130 , and the foam layer  160 . The binding  200  may be applied using an over-edging machine at a rate of approximately 5 stitches/inch. The binding  200  may be a polyester, microfiber, polyamide, satin, cotton, synthetic, nylon, or other durable material. The binding  200  is attached to the microfiber layers  100  and  160  via stitching  210 . 
     When used as a shower mat, the fibers in the microfiber of the drying mat  10  are in frictional contact with the bathroom floor. The porous nature of the microfiber layers  100  and  130  essentially forms a vacuum/suction grip on the substrate, e.g., the bathroom floor, to hold the drying mat  10  securely to the substrate. Also, the drying mat  10  absorbs water, which adds to the weight of the drying mat  10 . The extra weight of the drying mat  10  assists in holding the position of the drying mat  10  on the floor so that the drying mat  10  does not slip. 
     The size of the drying mat  10  may vary depending upon its intended purpose. Typically, the first microfiber layer  100 , the second microfiber layer  130 , and the foam layer  160  will all generally have approximately the same overall length and width. A dish mat may have a size of approximately 12 inches to approximately 22 inches in width by approximately 14 inches to approximately 36 inches in length. Typical embodiments of the dish mat have a size of approximately 16 inches by approximately 18 inches or approximately 18 inches by approximately 24 inches. Typical embodiments of the counter-top mat have a size of approximately 18 inches by approximately 32 inches. Typical embodiments of the shower mat have a size of approximately 18 inches by approximately 24 inches. 
     The first microfiber layer  100  and the second microfiber layer  130  have a thickness of approximately 3 mm to approximately 7 mm. In the embodiment shown in the FIGURES, the first microfiber layer  100  and the second microfiber layer  130  have a thickness of approximately 5 mm. The soft and cushiony nature of the microfiber layers  100  and  130  cushions delicate stemware and glasses. The soft and cushiony nature of the microfiber layers  100  and  130  protects the counter-top from contact with the drying dishes and cooking utensils. Certain pots and pans may scratch or ding some counter-top materials. The drying mat  10  may also be used as a protective support on the counter-top for appliances, like a mixer, blender, food processor, etc. to protect the counter-top from scratches and scuffs. 
     The foam layer  160  has a thickness of approximately 0.4 centimeters to approximately 0.8 centimeters. If the foam layer  160  is too thin, then the drying mat  10  will loose some of its absorbency. If the foam layer  160  is too thick, then the dishes, such as drinking glasses, may tip over when placed on the drying mat  10 . The foam layer  160  absorbs water, as well as cushioning the dishes placed thereon. 
     The drying mat  10  may be placed under a dish drying rack to catch, hold, and/or absorb moisture and water from the dishes placed in the drying rack. Dishes may also be placed directly on the drying mat  10 . The drying mat  10  is machine washable. The drying mat  10  provides a highly absorbent and fast drying alternative to a conventional dish towel, plastic drain board, rubberized mat. 
     The drying mat  10  provides a water absorbent structure that will absorb up to approximately 4 to 5 times its own weight in water. For example, a 16 inch by 18 inch drying mat  10  weighs approximately 150 to 155 grams. As such, this particular drying mat  10  will absorb up to approximately 26 ounces of water. Of course, one of ordinary skill in the art will recognize that the amount of absorption will depend on the size of the drying mat  10 . 
     The first microfiber layer  100  and the second microfiber layer  130  may include a honeycomb pattern. The honeycomb pattern increases the surface area of the layer of microfiber  100  and  130  as compared to a flat sheet of microfiber. The increased surface area promotes water absorption into the microfiber layers  100  and  130 , as well as the drying of the microfiber layers  100  and  130 . 
     With reference to  FIGS. 5 and 6 , the honeycomb pattern forms a grid or matrix of squares  300  in the top and bottom surface  20  and  30  of the first microfiber layer  100  and the second microfiber layer  130 . A central region of each square  300  includes a depression  250 , which provides a hollow void interior to the square  300 . All or essentially all of the squares  300  include the depression  250 . The squares  300  adjacent to the binding  200  may have their depressions  250  fully or partially covered or blocked by the binding  200 . 
     The depressions  250  generally extend into the top and bottom surface  20  and  30 . The depressions  250 , through gravity and wicking action of the microfiber material, receive and direct beads of water and moisture into the interior of the drying mat  10  and toward the foam layer  160 . Each depression  250  includes sidewalls  310  leading to an interior surface  320  of the depression  250 . The sidewalls  310  connect either the top surface  20  or the bottom surface  30 , respectively, with the interior surface  320  of the depression  250 . 
     The honeycomb pattern comprises approximately 50,000 to approximately 150,000 depressions  250  per square meter of the first and second microfiber layers  100  and  130 . In the embodiment shown in the FIGURES, the honeycomb pattern comprises approximately 100,000 depressions  250  per square meter of the first and second microfiber layers  100  and  130 . Each depression  250  is approximately 0.3 mm to approximately 2 mm in depth. In the embodiment shown in the FIGURES, the each depression  250  is approximately 1 mm in depth, i.e., there is a distance of approximately 1 mm between the interior surface  320  and either the top surface  20  or the bottom surface  30 , respectively. Each depression  250  is approximately 3 mm by approximately 3 mm in width. In other embodiments, the width of the depressions  250  may range from approximately 2 mm to approximately 25 mm. 
     Although a honeycomb pattern is shown in  FIGS. 1-6 , other patterns or plain surface types of microfiber material may be used for the first and second microfiber layers  100  and  130 . For example, a waffle pattern, a terry pattern, a circular knit pattern, a flat loop pattern, a suede pattern or a herringbone pattern may be used in forming the drying mat  10 . Also, a non-woven microfiber material may be used in forming the microfiber layers  100  and  130 . The honeycomb pattern may also form a matrix of rectangles instead of the squares  300 . Patterns of microfiber containing circular, ovular, geometric, or non-geometric shapes and designs of depressions may also be utilized. Microfiber materials having patterns, which increase surface area for the drying mat  10 , such as the honeycomb pattern, are well suited for use in the drying mat  10 . The increased surface area promotes absorption of water into the drying mat  10  and the drying of the drying mat  10 . 
     The foam layer  160  may include a variety of different foam materials, such as polyester, polyether, polyvinyl alcohol, cellulose, natural foam, and synthetic foam materials. The foam layer  160  forms a porous structure to absorb water. One type of suitable foam material are foams from the demospongea class of foams. Such foams may have a density of approximately 18 to approximately 20 kg/m 3 . Such foams have a hydrophilic action that helps absorb water into the drying mat  10 . 
     The first microfiber layer  100  and the second microfiber layer  130  comprise polyester and polyamide in a range of approximately 65% to approximately 95% polyester to approximately 35% to approximately 5% polyamide. One embodiment includes approximately 80% polyester and 20% polyamide. An increased amount in the polyamide content provides for a softer and more absorbent microfiber. The individual fibers of the microfiber used in the first and second microfiber layers  100  and  130  generally have a thickness of 0.1 denier or less. The high number of individual fibers in the microfiber material forming the first microfiber layer  100  and the second microfiber layer  130  promote the absorption of water into the drying mat  10 , as well as the ability of the drying mat  10  to dry quickly. 
     The drying mat  10  typically has a rectangular shape. The drying mat  10  may include rounded corners. The drying mat  10  may be provided in different colors depending upon consumer preference. 
     A process used to manufacture the drying mat  10  will now be described. The first microfiber layer  100  and the second microfiber layer  130  are bonded to the foam layer  160  using heated compression. Other embodiments may utilize a flame type compression. In detail, the first microfiber layer  100  is provided. The second microfiber layer  130  is provided. The foam layer  160  is provided. An adhesive is applied to join the first microfiber layer  100  and the second microfiber layer  130  to the foam layer  160 . Specifically, the adhesive is applied between the first microfiber layer  100  and the foam layer  160  to form the first adhesive layer  120 , and the adhesive is applied between the second microfiber layer  130  and the foam layer  160  to form the second adhesive layer  140 . Heat and compression are applied to join the first microfiber layer  100 , the second microfiber layer  130 , and the foam layer  160 . The binding material  200  is applied around the perimeter via a sewing machine. 
     The drying mat  10  may also be used as a protective mat or seat cover in a vehicle to protect the seat from damage from a child&#39;s car seat placed thereon or to absorb moisture from a passenger&#39;s swimming suit. The protective mat or seat cover includes at least one layer of a microfiber material, at least one layer of a foam material, and adhesive to join the layers. The drying mat  10  may be used as the protective mat without further alteration. However, the drying mat  10  may be dimensioned to fit on top of the seats of the vehicle. 
     A drying mat  11 , produced using flame lamination, is shown in  FIG. 7 . The flame lamination process creates a bond between the foam layer and the microfiber layer or layers. The foam layer is passed over an open flame, which produces a thin layer of molten polymer at a surface of the foam. The thin layer of molten polymer acts as an adhesive for bonding or attaching the foam layer to the microfiber layer or layers. When urged against the microfiber layer, the molten polymer may flow into or between the pattern, weave, and/or fibers of the microfiber. After the molten polymer cools, the foam layer is bonded to the microfiber. 
     In this embodiment, the first surface  105  of the first microfiber layer  100  forms the top surface  20  of the drying mat  11 . The second surface  108  of the first microfiber layer  100  is attached or bonded to the first surface  165  of the foam layer  160  by flame lamination. The first surface  135  of the second microfiber layer  130  forms the bottom surface  30  of the drying mat  11 . The second surface  138  of the second microfiber layer  130  is attached or bonded to the second surface  168  of the foam layer  160  by flame lamination. As such, the foam layer  160  is in between the first and second microfiber layers  100  and  130 . Other embodiments, may only utilize a single layer of microfiber attached via flame lamination to a foam layer. For example, the second microfiber layer  130  may be omitted from the drying mat  11 , and the foam layer  160  would form a bottom surface of such a drying mat. 
     During flame lamination, the foam layer  160  is passed over a flame in several steps, which melts the first surface  165  of the foam layer  160  and the second surface  168  of the foam layer  160 . The melted first surface  165  and the melted second surface  168  are then applied to the second microfiber surfaces  108  and  138 . The melted first surface  165  and the melted second surface  168  adhere and bond to the second microfiber surfaces  108  and  138 . The melted first surface  165  and the melted second surface  168  should be immediately applied to the second microfiber surfaces  108  and  138 . If the melted first surface  165  and the melted second surface  168  are allowed to cool, then the foam layer  160  will not bond to the second microfiber surfaces  108  and  138 . 
     The flame used for the flame lamination may be approximately 350 degrees F. to approximately 450 degrees F. The foam layer  160  may be passed over the flame at a rate of approximately 20 meters per minute to approximately 30 meters per minute. The temperature and/or rate of the passing of the foam layer  160  over the flame may be increased or decreased depending upon the specific composition of the foam layer  160  and/or the microfiber layers  100  and  130 . The temperature and/or rate of passing of the foam layer  160  over the flame will vary depending on the density, weight, and specific material of the foam layer  160 . A temperature of approximately 350 degrees F. at a rate of approximately 25 meters per minute forms a molten polymer surface for the foam layer  160  suitable for bonding to the microfiber layers  100  and  130 . Other temperatures and rates will provide suitable results. 
     The flame lamination only melts the exterior surface, i.e., the first and second surfaces  165  and  168  of the of the foam layer  160 . A middle section of the foam layer  160  should not be melted during the flame lamination. Otherwise, the structural integrity of the foam layer  160  may be compromised, and the cushioning and adsorptive properties of the foam layer  160  could be diminished. 
     With reference to  FIGS. 8 and 9 , methods of flame lamination of the drying mat  11  are shown.  FIG. 8  describes a method for forming a drying mat with a single microfiber layer, while  FIG. 9  describes a method for forming a drying mat with two microfiber layers. The foam layer  160  is passed over an open flame to melt the first surface  165  of the foam layer  160 . The first microfiber layer  100  is applied to the foam layer  160 , such that the second surface  108  of the first microfiber layer  100  is in direct contact with the melted first surface  165  of the foam layer  160 . The foam layer  160  and the first microfiber layer  100  are layered together. Next, pressure is applied to the combination of the foam layer  160  and the first microfiber layer  100 . The pressure may be applied through the use of pressure rollers. 
     After the foam layer  160  has cooled and the foam layer  160  is bonded to the first microfiber layer  100 , the second surface  168  of the foam layer  160  is melted. The second surface  168  is passed over the flame to melt the second surface  168 . The second microfiber layer  130  is applied to the foam layer  160 , such that the second surface  138  of the second microfiber layer  130  is in direct contact with the melted second surface  168  of the foam layer  160 . The foam layer  160 , the first microfiber layer  100 , and the second microfiber layer  130  are now layered together. Next, pressure is applied to the combination of the foam layer  160 , the first microfiber layer  100 , and the second microfiber layer  130 . After cooling, the binding material  200  may be applied around the perimeter of the drying mat  11 . 
     In commercial production of the drying mat  11 , large sheets of bulk foam material and microfiber materials are utilized. For example, the large sheet of foam material may be unwound from a roll of the foam material. The long sheet of foam material, having a width of approximately 8 feet, may be passed by a flame in order to melt its outer surface. Meanwhile, a long sheet of a first microfiber material is urged against the melted foam material under pressure to bind the microfiber material to the foam material. After cooling, the opposite side of the foam material is melted by the flame, and a second long sheet of a second microfiber material is urged against the melted foam material under pressure to bind the second microfiber material to the combination of the foam material and the first microfiber material. After cooling, small sections of the flame laminated, foam and microfiber composite material may be cut to form the drying mats  11 , as well as other mats for other purposes described herein. 
     In forming the drying mats  11 , the flame may be applied to the foam layer  160  in any number of manners. For example, the foam material may pass over or under a stationary flame. The flame may also move relative to foam material, which could remain stationary. The flame may be provide by a flame applicator that extends the width of the bulk foam material. The entire or nearly the entire surface of the foam material may be melted. The foam may also be melted by the flame at intervals on the surface of the foam, thus leaving unmelted portions of the foam material. 
     The foam layer may also be melted by other types of heating devices. For example, heating devices with a hot element may be passed near the foam material to melt the surface of the foam. 
     A drying mat  12  is shown in  FIG. 10 . The first microfiber layer  100  and the second microfiber layer  130  are attached to the foam layer  160  by binding or sewing. In this embodiment, the first surface  105  of the first microfiber layer  100  forms the top surface  20  of the drying mat, while the first surface  135  of the second microfiber layer  130  forms the bottom surface  30  of the drying mat  11 . The foam layer  160 , the first microfiber layer  100 , and the second microfiber layer  130  are layered together and held together by stitching  215 . 
     The first and second microfiber layers  130  are attached to the foam layer  160  by the stitching  215 . The foam layer  160  is in between the first and second microfiber layers  100  and  130 . Other embodiments may only have a single layer of microfiber attached to the foam layer. For example, the second microfiber layer  130  may be omitted from the drying mat  12 , and the foam layer  160  would form a bottom surface of the drying mat. 
     The stitching  215  may pass through all of the foam layer  160 , the first microfiber layer  100 , and the second microfiber layer  130 . In other embodiments, portions of the stitching  215  may also pass through the foam layer  160  and the first microfiber layer  100 , while other portions of the stitching  215  pass through the foam layer  160  and the second microfiber layer  130 . As such, in certain embodiments, the foam layer  160  is bound to the first microfiber layer  100 , and the foam layer  160  is bound to the second microfiber layer  130 . 
     The sewing or binding of the various layers may be in different patterns and styles. The stitching  215  may be at the perimeter of the drying mat  12 . The stitching  215  may occur in patterns across the width and length of the drying mat  12 . The stitching  215  may occur at specific points, locations, or regions of the drying mat  12 . The sewing of the stitching  215  may occur at points at specific intervals, such as, for example, the stitching of the thread  215  may occur at points at every several inches of the drying mat  12 . 
     In still further embodiments, the various microfiber layer(s) and the foam layer(s) may be held together by combinations of binding, sewing, adhesives, and flame lamination. 
     The drying mats  10 ,  11 , and  12  and may use combination of one or more different types or patterns of microfiber, such as, for example, a waffle pattern, a terry pattern, a circular knit pattern, a flat loop pattern, a suede pattern or a herringbone pattern. As such, the first microfiber layer  100  and the second microfiber layer  130  may use the same or different types of microfiber. For example, the first microfiber layer  100  and the second microfiber layer  130  may both use a waffle pattern. Or, for example, the first microfiber layer  100  may use a waffle pattern, while the second microfiber layer  130  may use a terry pattern. 
     It should be understood from the foregoing that, while particular embodiments of the invention have been illustrated and described, various modifications can be made thereto without departing from the spirit and scope of the present invention. Therefore, it is not intended that the invention be limited by the specification; instead, the scope of the present invention is intended to be limited only by the appended claims.