Note: Descriptions are shown in the official language in which they were submitted.
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ANTI-SLIP DROPCLOTH
FIELD OF THE INVENTION
[0001] The present invention is related to a dropcloth. More specifically, the
present invention relates to a dropcloth with anti-slip or anti-skid
properties and protective safety features and further to a dropcloth which
is impermeable to paint.
BACKGROUND OF THE INVENTION
[0002] There has been a long-standing need for dropcloths. Painters use
dropcloths to cover floors or other objects in rooms that are being
painted. Dropcloths may also be used when tilers, plumbers or other
workers are working in an area where floors, objects or other surfaces
need protection from paint overspray, construction debris, materials and
tools, or worker activities. Other uses of a dropcloth may also include
covering railings, countertops or furniture during painting, or when
furniture is being stored, to prevent dust accumulation, or by movers to
cover a floor surface when moving furniture.
[0003] Traditionally, dropcloths may be made of a heavyweight canvas fabric,
heavier canvas being an indication of quality and durability. While these
heavy canvas dropcloths serve a purpose, they have drawbacks. The
heavy canvas dropcloths may be fatiguing and awkward to use, place
properly without bunching and move repeatedly, when used in
applications such as painting, where the dropcloths may be moved many
times a day. Canvas dropcloths also have drawbacks for use in painting
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applications, as the dropcloths may tend to slip or slide during use,
particularly when covering relatively smooth surfaces, such as tile, or
wood floors. This can also cause them to bunch, causing uneven and
problematic work surfaces for paint trays and other tools like ladders,
also creating trip hazards for workers. A bunching or slipping dropcloth
used by painters or workers can move out of place exposing objects and
surfaces needing protection from paint, tools, workers and debris. A
slipping dropcloth may also be dangerous, possibly causing workers to
fall, resulting in injury, paint spills and other damages, especially when
standing on ladders or scaffolds placed on the dropcloth. Traditional
canvas dropcloths are also disadvantageous in that the canvas dropcloths
allow paint to seep through the relatively coarse weave of the canvas
fabric, allowing the paint which has seeped through the canvas to stain
the floor being covered, unless a non-permeable sheet is attached to a
bottom surface of the canvas fabric of the dropcloth. This non-
permeable sheet, if present, adds weight and cost to the dropcloth and is
most often plastic, resulting in an extremely slippery and dangerous
contact surface for the drop cloth. This plastic non-permeable sheet is
also not very durable and has a relatively short life before it rips or tears,
defeating its purpose. If paint is spilled and trapped between the canvas
and this non-permeable sheet, it makes cleanup of the spilled paint
difficult to remove. This spilled paint becomes heavy and rigid as it
dries, limiting the dropcloth's utility and increasing the likelihood of
disposal. Paint spilled on heavy canvas without the non-permeable sheet
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can also have similar results, because the heavy canvas fibers make it
difficult and time consuming to wash and remove the spilled paint.
[0004] Additional deficiencies in the prior art dropcloths may include a lack
of a
clear visual indicators to clearly distinguish between the top, bottom and
edges of the dropcloth. If a portion of a prior art dropcloth is "folded-
over", such as a corner or edge, the folded-over portion of the dropcloth
may not be clearly recognizable and users may have difficulty visually
locating and distinguishing between the edges, top and or bottom
surfaces of the dropcloth. This lack of clear visual distinction between
different areas of the dropcloth can result in the dropcloth not covering
the intended surface, and further creating an uneven work surface or trip
hazard. If a prior art dropcloth is equipped with anti-skid protrusions
and those protrusions are inadvertently facing upward at an edge, or
corner of the dropcloth, as opposed to being in contact with the floor
surface, a slippery or uneven work surface and trip hazard can result. A
further deficiency in the prior art dropcloths may also be a lack of a clear
visual indication that a user is not within a central portion of the
dropcloth and may instead be proximal an edge of the dropcloth. A
location of a worker proximal an edge of a dropcloth, or items being
used by a painter, such as a container of paint proximal an edge of a
dropcloth, may be disadvantageous in that the worker may trip on the
edge of the dropcloth, or paint may be spilled proximal or beyond the
edge of the dropcloth staining the work surface or other object needing
coverage.
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[0005] Additional deficiencies in prior art dropcloths may include edges or
seams which are folded and sewn creating an elevated edge or uneven
work surface which may result in a trip hazard. If a prior art dropcloth is
equipped with anti-skid protrusions, seamed or folded or sewn edges
would prevent the anti-slip protrusions from having contact with the
intended surface potentially causing slipping or skidding.
[0006] To attempt to solve the slipping, or skidding problem of the prior art
dropcloths, anti-slip, or anti-skid dropcloths have been developed
utilizing anti-slip protrusions on a bottom surface. Examples of such an
anti-slip dropcloths are patent publications US 2007/0275209, US
8142851 and US 7833619. One weakness of prior art anti-slip
dropcloths utilizing anti-slip protrusions is that the anti-slip protrusions
are arranged in a non-equidistant fashion. Anti-slip dropcloths with
anti¨slip protrusions arranged in a non-equidistant fashion will not result
in consistent and maximum gripping properties of the anti-slip
dropcloths across a surface. While these dropcloths with anti-skid
protrusions on a bottom surface may be an improvement over the
previous prior art dropcloths, further improvements in anti-slip
properties of dropcloths are needed.
[0007] From the above, a need exists in the art for further improvements in
dropcloths, particularly anti-slip dropcloths. This need for
improvements in dropcloths may include a dropcloth with improved anti-
slip properties, including anti-slip protrusions arranged in an equidistant
fashion. This need for improvements in dropcloths may also include a
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dropcloth which is light in weight. This need for improvements in
dropcloths may further include a dropcloth which is impermeable to
paint, without the need for utilizing a non-permeable sheet which is
attached to a bottom of the dropcloth. This need for improvements in
dropcloths may additionally include a dropcloth which has a clear visual
indication if a portion of a dropcloth is "folded-over", such as at a
corner, such that the folded-over portion of the dropcloth is not covering
a floor surface and the anti-skid protrusions are facing upward, as
opposed to being in contact with the floor surface. This need for
improvements in dropcloths may also further include a dropcloth with a
clear visual indication that a worker is within a central portion of the
dropcloth and not proximal an edge of the dropcloth. This need for
improvements in dropcloths may also include a dropcloth which is
composed of an anti-skid protrusion material which will not mark or
"rub-off" on surfaces such as lacquered or vinyl floors. This need for
improvements in dropcloths may further include a dropcloth which is
composed of anti-skid protrusions which are applied to the edges, so as
to avoid folded over, seamed or sewn edges which would create edges
without anti-skid protrusions.
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SUMMARY OF THE INVENTION
[0008] The above needs in the art are satisfied by the disclosed invention
including in an embodiment a fabric dropcloth with a relatively fine
weave. In an embodiment, the fabric dropcloth may be manufactured of
cotton. In other embodiments, other fabrics may be utilized. The type
and size of the fiber and fabric material which may be used combined
with the weave results in a fabric which may be relatively light in weight
compared to a canvas fabric and is impermeable to paint.
[0009] The above needs in the art are additionally satisfied by the disclosed
invention by utilizing anti-slip protrusions. The material of the anti-slip
protrusions may be such that improved anti-slip properties are present
over the prior art dropcloths, and that small amounts of the surface of the
material of the anti-skid protrusions will not "rub-off" on floor surfaces,
particularly certain floor surfaces, such as lacquered floors. The color or
properties of the anti-skid protrusions may be such to provide the worker
with clear visual indications when a portion of the dropcloth is "folded-
over" and the anti-skid protrusions are facing upward, therefore not
covering a floor surface, as opposed to being in contact with the floor
surface, which aids to avoid bunching and creating trip hazzards. To
further aid in preventing the dropcloth from bunching and creating trip
hazards, the dropcloth includes anti-skid protrusions which are present to
the edges of the dropcloth. This may be accomplished by cutting the
drop cloth to size without folded, sewn or seamed edges, thereby
ensuring that the pattern and application of anti-skid protrusions run to
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and through the cut-edges of the dropcloth. The top surface of the
dropcloth may include a clear visual indication that a user is within a
central portion of the dropcloth and not proximal an edge of the
dropcloth.
[0010] An embodiment of the invention may include a dropcloth composed of a
fabric material where gripping protrusions project from the bottom
surface of the fabric. The dropcloth includes a plurality of anti-skid
gripping protrusions arranged on a bottom surface of the fabric of the
dropcloth in a uniformally spaced diagonally orientated grid pattern.
[0011] An embodiment of the invention further includes printed indicia located
on a center portion of the top surface of the fabric of the dropcloth, the
printed indicia forming a visual "safety track". The dropcloth further
includes a boundary zone extending inward from the outer edges of the
dropcloth. The boundary zone extends between the outer edges of the
dropcloth and outer edges of the safety track, with the boundary zone
having no printed indicia within the boundary zone. In an embodiment,
the safety track is provided on two side edges of the dropcloth. In
another embodiment, the visual safety track is provided on all four sides
of the dropcloth.
[0012] An embodiment of the invention further includes the plurality of anti-
slip
gripping protrusions arranged in uniformally spaced diagonally
orientated grid pattern on the bottom surface of the dropcloth extending
to outer edges of a periphery of the dropcloth. The gripping protrusions
may form a partial gripping protrusion at the outer edges of the
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periphery, in order to extend to each outer edge of the periphery of the
dropcloth while maintaining uniform spacing of the diagonally oriented
grid pattern. The partial gripping protrusion is formed by a gripping
protrusion being cut "flush" with the edge of the dropcloth and a cut-off
portion of the gripping protrusion being removed so that the gripping
protrusion does not extend beyond an edge of the dropcloth, while
maintaining a non-cut-off portion of the partial gripping protrusion
attached to the dropcloth and also maintaining the proper location of the
partial gripping protrusion within the uniformally spaced diagonally
orientated grid pattern.
[0013] In some applications the desired area to be covered by the dropcloth is
greater than the area of the dropcloth. In order to cover the desired area
to be covered by the dropcloth, the use of a plurality dropcloths will be
required. In order to prevent paint spills, trip hazards, and other
problems which may be related to the use of a pluralilty of dropcloths, a
"joiner" is installed between the boundaries of the plurality of
dropcloths. The joiner is configured as a strip. The "joiner strip" is wide
enough to cover a top portion of the top surface of adjoining dropcloths,
where the top portion of the adjoining dropcloths is proximal the mating
edges of each of the adjoining dropcloths. The joiner strip is further
configured to include the hook portion of a hook-and-loop fastener
fabric. The hook portion of the hook-and-loop fastener fabric is sewn
onto the bottom surface of the joiner strip. The loop portion of the hook-
and-loop fastener fabric is sewn on some, or all sides, or edges of the top
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portion of the top surface of the dropcloth. The hooks in the bottom
surface of the hook portion of the joiner strip will then allow adjacent
dropcloths to be "joined" by placing the bottom surface with the hook
portion of the hook-and-loop fastener fabric over the loop portions of the
hook-and-loop fastener fabric on the top portions of the mating edges of
the two or more cloths, so as to allow the hooks of the hook portion to
engage the loops of the loop portion, altogether referred to as the "joiner
stip". The joiner strip may be fluorescent or phosphorescent in color,
and may differ in color to distinguish from the gripping protrusions on
the bottom of the dropcloths or from the safety track or boundary zone,
to provide visual indications of the dropcloth edges where adjacent
dropcloths are joined.
[0014] An embodiment of the invention includes a method of manufacturing
the dropcloth configured as a roll to be cut into individually sized
dropcloths.
[0015] An embodiment of the present invention may include these and other
features, aspects, and advantages of the present invention and will
become better understood with regard to the following description,
appended claims, and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0016] FIG. 1 is a top perspective view of the dropcloth manufactured in a
roll
form abutted against a wall and utilized to protect a floor surface,
according to an embodiment of the invention.
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[0017] FIG. 2 is a top perspective view of the dropcloth manufactured in a
roll
form utilized to protect a floor surface, according to an embodiment of
the invention.
[0018] FIG. 3 is a schematic top perspective view of the dropcloth
manufactured in a roll form and illustrating the safety track on all 4-
sides, according to an embodiment of the invention.
[0019] FIG. 4A shows a close-up top perspective view of the safety track
region
of the dropcloth, according to an embodiment of the invention.
[0020] FIG. 4B shows a close-up top perspective view of the boundary zone on
one side of the dropcloth, according to an embodiment of the invention.
[0021] FIG. 5 is a top view of the dropcloth fabric without printed indicia
and
compared to a canvas fabric which may be utilized for a conventional
canvas fabric dropcloth, showing how the fabric material of the
dropcloth of this invention does not fray when cut, while a canvas fabric
which may be utilized for a conventional dropcloth does fray when cut,
according to an embodiment of the invention.
[0022] FIG. 6A is a top view of paint spilled within the safety track of the
dropcloth, showing that the dropcloth is impermeable to paint, according
to an embodiment of the invention.
[0023] FIG. 6B is a bottom view of spilled paint on the topside of dropcloth,
showing that the dropcloth does not allow spilled paint to permeate
through the cloth and onto a floor surface underneath.
[0024] FIG. 6C is a bottom view of spilled paint 29 on the topside of the
prior
art dropcloth 11 with canvas fabric 26, showing that the prior art
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dropcloth 11 allows permeated paint 31 to seep through the cloth and
onto the floor surface underneath.
[0025] FIG. 7 is a bottom view of the dropcloth showing the gripping
protrusions arranged in a uniformally spaced diagonally orientated grid
pattern, according to an embodiment of the invention.
[0026] FIG. 8 is a bottom view of the dropcloth illustrating schematically the
gripping protrusions extending to the edges of the dropcloth, according
to an embodiment of the invention.
[0027] FIG. 9 is a close-up illustrating schematically a section view of a
gripping protrusion mechanically attached to the dropcloth fabric by
being interlocked within fibers of the fabric of the dropcloth, according
to an embodiment of the invention.
[0028] FIG. 10 is a perspective view of the dropcloth with a corner folded-
over,
showing a visual indication that the corner is folded-over, according to
an embodiment of the invention.
[0029] FIG. 11 is a perspective view of a ladder leaning against a wall with a
worker climbing the ladder and the ladder and the worker being
supported by the dropcloth, showing the gripping properties of the
dropcloth, according to an embodiment of the invention.
[0030] FIG. 12 is a section view schematically illustrating a joiner strip
used to
join two adjacent dropcloths, where a plurality of dropcloths are utilized
in a large room, according to an embodiment of the invention.
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[0031] FIG. 13 is a top view schematically illustrating the use of a plurality
of
joiner strips to join a plurality of adjacent dropcloths, according to an
embodiment of the invention.
[0032] FIG. 14 illustrates a method of using the joiner strips to join a
plurality
of adjacent dropcloths, according to an embodiment of the invention.
[0033] FIG. 15 is a flow chart illustrating a method of manufacturing the
dropcloths in roll form.
[0034] FIG. 16 illustrates a perspective view of a dropcloth in a rolled
configuration, according to an embodiment of the invention.
[0035] FIG. 17 schematically illustrates the manufacture of dropcloths in a
roll
form with the 4-sided safety track, according to an embodiment of the
invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
SINGLE DROPCLOTH WITH THE 2-SIDED OR 4-SIDED SAFETY TRACK
FEATURE MANUFACTURED IN A ROLL FORM
[0036] FIG. 1 shows a top perspective view of the dropcloth 10 manufactured in
a roll form abutted against a wall and utilized to protect a floor surface,
according to an embodiment of the invention. A dropcloth with a 2-
sided safety track manufactured in roll form may be more advantageous
where the dropcloth is used to prevent scuff marks, dirt, etc., as may
occur when movers, plumbers, etc. are moving large objects, such as
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furniture, or a dishwasher, for example, over long hallways, or large
rooms. As shown on FIG. 1, the center portion 12 of the dropcloth 10,
between left 14 and right 15 sides of the dropcloth 10 forms a safety
track 17. The safety track 17 is located inboard of left 14 and right 15
outer edges 18 which may form up to a 12-inch boundary zone 19
adjacent outer side edges 18 of the dropcloth 10. The safety track 17 is
defined by printed indicia 22 on a top surface of the dropcloth 10. The
boundary zone 19 has no printed indicia on a top surface of the boundary
zone 19. The safety track 17, as identified by the printed indicia 22,
provides a visual indication that a user or worker of the dropcloth is
within the center portion 12 of the dropcloth 10 when working. A
worker working in the center portion 12 of the dropcloth 10 is important,
as when painting, for example, as paint which is spilled in the center
portion 12 of the dropcloth 10, does not seep through the dropcloth 10,
or additionally is less likely to run-off the dropcloth 10 and beyond the
edges onto a floor or other surface needing protection. As discussed
below, paint does not seep through the dropcloth 10, due to the weave of
the dropcloth 10. If a worker were not working within the safety track
17, and instead was painting in the boundary zone 19, spilled paint
would be more likely to stain a floor or other surface. Additionally, dirty
shoes staining a floor surface and tripping are more likely to occur when
working in the boundary zone 19. Further, use of equipment, such as
ladders, should be used within the safety track 17 in order to maximize
coverage of the dropcloth 10 under the active working area and to reduce
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the chances of the worker falling or equipment overturning when located
proximal a side edge 18 of the dropcloth 10 which may cause an accident
or an uneven working surface or trip hazzard. FIG. 11 illustrates proper
use of a ladder on a dropcloth 10. Please note that when the 2-sided
version of the dropcloth 10 is manufactured in a roll form, that the
boundary zone 19 is only located on the left 14 and right 15 outer side
edges 18 of the dropcloth 10.
[0037] FIG. 2 shows a top perspective view of the dropcloth 10 with a 2-sided
safety track manufactured in a roll form utilized to protect a floor
surface, according to an embodiment of the invention. The dropcloth 10
of FIG. 2 may be utilized by workers other than painters, such as
movers, plumbers, etc., to prevent tracking of dirt or debris from their
activities onto a floor surface. The anti-slip dropcloth 10 may be
particularly advantageous for use by movers to protect a floor surface
from dirt and damage while minimizing the chance of slipping while
moving heavy furniture, or by workers moving equipment and materials
during construction or painting. FIG. 2 also illustrates the safety track
17 and boundary zone 19 of the dropcloth 10. The dropcloth 10
manufactured in the a roll form may be more useful to workers, such a
movers and plumbers when floor surfaces of hallways and other long
floor surfaces are desired to be covered in order to prevent tracking of
dirt, or other debris onto the floor surface.
[0038] FIG. 3 illustrates a schematic perspective view of the drop cloth which
may be manufactured in a roll form where the boundary zone 19 may be
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present on all four sides of the dropcloth 10. Having a dropcloth 10
manufactured with a 4-sided safety track, as illustrated on FIG. 3 may be
advantageous when it is desired to abut the dropcloth against two or
more wall surfaces in a room, such as might be desirable by painters
painting walls and a ceiling of an interior room of a building. Having a
boundary zone 19 present on all four sides of a dropcloth 10, as
illustrated on FIG. 3 may be advantageous when being used by workers,
such as painters, who may be working proximal multiple edges of the
dropcloth 10 to alert the workers that they are on, or proximal an outer
edge 18 of the dropcloth 10.
[0039] FIG. 4A shows a close-up top perspective view of the safety track 17 of
the dropcloth 10, including an example of printed indicia 22. FIG. 4B
illustrates a close-up top perspective view of the boundary zone 19 on
one side of the dropcloth 10, illustrating the weave of the fabric 24,
according to an embodiment of the invention.
[0040] FIG. 5 is a top view of the dropcloth 10 without printed indicia 22 and
compared to a canvas fabric 26 which may be utilized for a conventional
canvas fabric dropcloth, showing how the fabric material 24 of the
dropcloth 10 of this invention does not fray when cut, while a canvas
fabric 26 which may be utilized for a conventional dropcloth 11 does
fray when cut, according to an embodiment of the invention. As shown
on the upper-portion of FIG. 5, when the fabric 24 utilized for the
dropcloth 10 of this invention is cut to form a cut edge 25, fraying of the
fabric 24 does not occur. In contrast, the canvas fabric 26 which may be
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utilized for conventional dropcloths 11 fray when being cut to form a cut
edge 27, as shown on the lower portion of FIG. 5. The fabric utilized for
the dropcloth 10 of this invention in an embodiment is cotton fabric 24
with a warp density of about 100 to 106, a weft density of about 54 to
58, a yarn count of about 16 to 24 and a fabric thickness of about 0.29 to
0.45 millimeters (mm). The fabric of the dropcloth 10 of this invention
in an embodiment has a lightness in color defined by an L* dimension
value of about 80 to 98. The L* dimension value is defined for this
application as a lightness on the lab color space also termed CIE 1976
(L*, a*, b*) or color space or CIELAB, as specified by the International
Commission on Illumination (French Commission Iinternationale de
Ll'eclairage, hence the CIE abbreviation). In an embodiment of the
invention, the dropcloth 10 may also be prewashed to remove any loose
fibers on the fabric surface and to prevent shrinkage.
[0041] FIG. 6A is a top view of paint spilled within the safety track 17 of
the
dropcloth 10, showing that the dropcloth 10 is impermeable to paint 29
spilled on the the dropcloth 10. FIG. 6B is a bottom view of spilled paint
29 on the topside of dropcloth 10, showing that the dropcloth 10 does not
allow spilled paint 29 to permeate through the cloth and onto a floor
surface underneath 30. The weave and type of yarn or fiber used for the
fabric 24 of the dropcloth 10, as described above, allows the dropcloth
to be impermeable to spilled paint 29 on the dropcloth 10. This is
advantageous, in that prior art dropcloths, which may utilize canvas
fabric 26 may not be impermeable to paint. Accordingly, a prior art
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canvas fabric 26 dropcloth may allow spilled paint 29 to seep through
the canvas fabric 26 dropcloth, potentially damaging a floor surface
underneath 30. FIG. 6C is a bottom view of spilled paint 29 on the
topside of the prior art dropcloth 11 with canvas fabric 26, showing that
the prior art dropcloth 11 allows permeated paint 31 to seep through the
cloth and onto the floor surface underneath 30. A prior art canvas fabric
26 dropcloth may require a plastic sheet to be attached to a bottom
surface of the dropcloth in order to be impermeable to paint potentially
making this bottom surface slippery and dangerous. This plastic sheet, if
present on a prior art dropcloth 11 may also increase the cost, volume
and weight of the prior art dropcloth 1 land may also complicate the
manufacturing process of the prior art dropcloth 11. The use of the
plastic sheet may also result in bulky edges and seams that may create
trip hazards. Even though the weave and type of yarn used for the fabric
24 of the dropcloth 10, as described above is impermeable to paint, the
dropcloth 10 of this invention may weigh less per unit area than a
conventional canvas fabric dropcloth, particularly if a plastic sheet is
attached below the conventional canvas fabric dropcloth 11 to prevent
spilled paint 29 seeping onto a floor or other surface.
[0042] FIG. 7 is a bottom view of the dropcloth 10 illustrating the gripping
protrusions 32 arranged in a uniformally spaced diagonally orientated
grid pattern 34 on a bottom surface of the dropcloth 10.
[0043] FIG. 8 is a bottom close-up view of the dropcloth 10 illustrating the
schematically gripping protrusions 32 extending to each edge 18 of the
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dropcloth 10. The "anti-fraying" and "interlocking" properties of the
fabric 24 used for the dropcloth 10 of this application is advantageous, in
that it allows gripping protrusions 32, as noted above, to extend to each
edge 18 forming the periphery 65 of the dropcloth 10, wherein the
gripping protrusions may be cut to form a partial gripping protrusion 66
at each edge 64 of the periphery 65 in order to extend to each outer edge
18 of the periphery 65 of the dropcloth 10 while maintaining uniform
spacing of a diagonally oriented grid pattern 34. Gripping protrusions 32
extending to the very edge 18 of the periphery 65 of the dropcloth 10 is
advantageous in that the outer edges 18 of the dropcloth 10 remain
secure to a floor surface, thus eliminating, or minimizing tripping and
other potential hazards which may be present if the outer edges 18 were
not secure to a floor surface. Gripping protrusions 32 extending to the
very outer edges 18 of the dropcloth 10 would not be possible if the
canvas fabric 26 as illustrated on the lower portion of FIG. 5, which
frays when being cut, is used for the fabric of a prior art dropcloth 11, as
the frayed canvas fabric 26 would not allow gripping protrusions 32 to
be secured to a bottom surface of a prior art dropcloth 11.
[0044] FIG. 9 is a close-up section view of a gripping protrusion 32
mechanically attached to the dropcloth fabric 24 by being interlocked
within the fibers 42 of the fabric 24 of the dropcloth 10. FIG. 9 also
illustrates an average height H and average base diameter D of the
truncated spherical shape of the gripping protrusions 32. In an
embodiment, the height H from the bottom surface of the dropcloth 10 to
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a bottom surface of the gripping protrusions 32 is about 0.74 to 0.99
millimeters (mm) (0.029 to 0.038 inches). In an embodiment, the base
diameter D of the truncated spherical shape of the gripping protrusions
32 is about 2.00 to 3.02 mm (0.079 to 0.119 inches). In an embodiment,
the gripping protrusions are made of a polymer material. In an
embodiment, a material composition for the gripping protrusions may
include the following ingredients: for every 100 parts of a polymer, 100
parts of a soft polyvinyl chloride (PVC) with a viscosity at a temperature
of 30 Celcius ranging from 500 to 5000 megapoise (MPas) per American
Society for Testing and Materials (ASTM) specification D2857, a first
mineral filler, which in an embodiment may be 50 to 70 parts of calcium
carbonate (CaCO3), a second mineral filler, which in an embodiment
may be 5 to 15 parts silica, a plasticizer, which in an embodiment may
be 80 to 120 parts, and a hydrogenated C5 or C9 resin which in an
embodiment may be 5 to 8 parts, an antioxidant, which in an
embodiment may be 1 to 2 parts and a pigment, as described further
below, which in an embodiment may be 1 to 3 parts. The term "parts"
used above refers to a weight, such that parts of different chemicals, such
as 100 parts of the soft PCV represents 100 units of weight and 50 to 70
parts of CaCO3 represents 50 to 70 units of weight of CaCO3. However,
the invention may not be limited to the above as the material
composition of the gripping protrusions 32. Regarding the terms C5 and
C9 above, C5 is a polymerized 5 carbon monomer and C9 is a
polymerized 9 carbon monomer, used as "tackifiers" to increase the
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compression and traction force of the gripping protrusions 32 and may
be replaced by other materials that have a similar effect. The soft PVC
may be replaced by a thermal plastic elastomer (TPE) and/or a thermoset
elastomer (Rubber). In an embodiment, the density of the gripping
protrusions 32 may be within a range of between 1.0 to 1.3g/cm3 (grams
per cubic centimeter) (0.58 to 0.75 oz/in3)(ounces per cubic inch).
However, the invention may not be limited to these heights, base
diameters, materials and densities. In an embodiment, the tensile
strength of the gripping protrusions 32 as measured by ASTM D412 may
be in the range of 3 to 7 MPa (0.44 to 1.02 lbs/in2). The attachment of
the gripping protrusions 32 to the fabric 24 of the dropcloth 10 in an
embodiment may be made by heating of the dropcloth 10 and the
gripping protrusions 32. In an embodiment, heating of the dropcloth 10
and the gripping protrusions 32 during manufacture causes the gripping
protrusions 32 to become soft and flow into and between the fibers 42 of
the fabric 24 creating areas of mechanical interlock 44 on a portion of
the gripping protrusions 32 proximal the fibers 42 of the dropcloth 10,
such that the areas of mechanical interflock 44 reside within an upper
portion 45 of the gripping protrusions and the fibers 42 of the fabric 24
of the dropcloth 10. The areas of mechanical interlock 44 cause the
gripping protrusions to be mechanically attached to and captivated
within the fibers of the fabric 24 of the dropcloth 10. However, the
attachment of the gripping protrusions 32 to the dropcloth 10 is not
limited to the above described method. Other means, or methods of
CA 02840878 2014-01-28
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attaching the gripping protrusions 32 to the dropcloth 10 may include the
use of adhesives, for example. Comparison tests were conducted to
quantify the traction force improvements and lightness of weight of the
dropcloth 10, relative to the prior art dropcloth 11. In comparison tests
conducted, the traction force measured as units of pressure required to
move a specimen of the dropcloth samples on a glass surface per unit
area, is for dropcloth 10 a minimum of 455 Pascals (Pa) (0.066 pounds
per square inch) (lbs/in2) and can range from 455 to 565 Pa (0.066 to
0.095 lbs/in2). However, even with the comparatively high traction
force, the dropcloth 10 is relatively light in weight at 634 Pa (0.092
lbs/in2) when compared to the prior art dropcloth 11 which weighs 52%
more than dropcloth 10 at 965 Pa (0.14 lbs/in2) and has a traction force
of only 393 Pa (0.06 1bs/in2). Further the traction force of the dropcloth
occurs uniformly across the product whereas the traction force is
negated at the outer sewn and folded edges of the prior art dropcloth 11.
These traction force and weight improvements of the dropcloth 10
relative to the prior art dropcloth 11, can be attributed to the formulation
and height H and diameter D of the gripping protrusions 32, the design
and uniform spacing of a diagonally oriented grid pattern 34, and the
design of the fabric 24 and fibers 42 which allows for the "interlocking"
of the gripping protrusions 32. The fabric of the dropcloth 10 and
material composition of the gripping protrusions 32 allows for the
creation of certain characteristics of the gripping protrusions 32 which
are necessary to create traction force. The material composition and
CA 02840878 2014-01-28
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height H of the gripping protrusions 32 are significant in creating the
"compression" needed for superior traction force. The material
composition provides the ability to manufacture the gripping protrusions
32 with increased height H which remain durable and do not degrade or
"rub-off'", and which mechanically interlock 44 between the fabric fibers
42. In comparison, the gripping protrusions of the prior art dropcloth 11
have an average height of 0.68mm (.0268 inches).
[0045] FIG. 10 is a perspective view of the dropcloth 10 showing that the
corner
52 is "folded-over". This visual indication of the corners 52 being
folded-over indicates that the gripping protrusions 32 in an embodiment
may have an orange or blue or yellow color produced by a pigment
added to the above described material composition mixture. The use of
these colors further provide the user with a visual reference as to the size
of the dropcloth (orange for "runners" or hallway sizes, blue for medium
sizes and yellow for large sizes). The gripping protrusions 32 in an
embodiment may further have fluorescent or phosphorescent pigment,
which is added to the above described material composition, in which
the pigment causes the gripping protrusions 32 to glow in low light or to
absorb light thereby illuminating, to provide a further visual indication if
areas of the bottom surface or comers of the dropcloth 10 are folded
over. The visual indication of one, or more comers 52, or one, or more
outer edges 18 being folded over is advantageous in that it is readily
apparent that of one, or more corners 52, or one, or more outer edges 18
being folded over, thus potentially alerting workers of a potential trip
CA 02840878 2014-01-28
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hazard and increasing the likelihood of eliminating a potential tripping
hazard, and eliminating a possibility that portions of a floor surface are
left uncovered and thus unprotected from dirt, or paint, and alerting
workers that folded-over portions of one, or more corners 52, or one or
more outer edges 18 being folded over, which may reduce the gripping
properties and safe use of the dropcloth 10.
[0046] FIG. 11 is a perspective view of a ladder 62 leaning against a wall at
an
extreme angle with a worker 64 climbing the ladder 62 and the worker
64 being supported by the dropcloth 10, illustrating the gripping
properties of the dropcloth 10, according to an embodiment of the
invention.
USE OF MULTIPLE-SIZED DROPCLOTHS
[0047] A dropcloth, such as may be available in sizes four feet wide by 8 or
12
feet long, for example, may be too small to cover a significant area or a
large room or surface to be painted or protected. While a single
dropcloth may be utilized for the painting of a large room, in order to
prevent staining of floor areas beyond the edge of the single dropcloth,
and for greater efficiency, a plurality, or multiple-sized dropcloths may
be utilized. In order to prevent the creation of uneven work surfaces
which could be problematic and unsafe for workers, from "bunching" or
"overlapping" of multiple dropcloths abutted against, or adjacent to each
other, and to cover gaps which may be present between adjacent
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dropcloths, which could allow paint to stain the floor surface under the
gaps, one or more joiner strips 110 may be utilized.
[0048] FIG. 12 is a section view of a joiner strip 110 used to join two
adjacent
dropcloths 114, where a plurality of dropcloths 114 which may be of
varying sizes, are utilized to cover larger or irregular areas and to join
dropcloths without having to overlap. As illustrated on FIG. 12, the
joiner strip 110 is wide enough to cover a top surface 116 of an edge
portion 118 of adjoining dropcloths 114, where the mating edge 119 of
the edge portion 118 of each adjoining dropcloth 114 meets. The joiner
strip 110 includes a body portion 111 which may be colored and may be
distinct in color from other safety features of the dropcloth 10 like the
safety track 17 and gripping protrusions 32 in order to alert the user of
proximity to a joined section of dropcloths 110 for ease of visual
reference and to exercise caution. The joiner strip 110 is further
configured to include the hook portion 122 of hook-and-loop fastener
fabric 120. The hook portion 122 of the hook-and-loop fastener fabric
120 is sewn onto a bottom surface 112 of the body portion 111 of the
joiner strip 110. The loop portion 124 of the hook-and-loop fastener
fabric 120 is sewn on some, or all sides, of the top surface 116 of the
edge portion 118 of the dropcloth 114. The hook portion 122 on the
bottom surface 112 of the joiner strip 110 will then allow adjacent
dropcloths 114 of the same or varying sizes to be "joined" by placing the
bottom surface 112 of the joiner strip 110 with the hook portion 122 of
the hook-and-loop fastener fabric 120 over the loop portion 124 sewn on
CA 02840878 2014-01-28
the edge portions 118 of the two or more adjacent dropcloths 114 to
allow the hooks of the hook portion 122 to engage the loops of the loop
portion124, so that the joiner strip 114 joins the adjacent dropcloths 114
together.
[0049] FIG. 13 is a top view of the use of a plurality of joiners 110 to join
a
plurality of adjacent dropcloths 114. It should be noted that the
dropcloths 114 may be of varying sizes. The hook-and-loop fastener
fabric 120 may be sewn intermittently, or continuously along each edge
of the dropcloth 114. FIG. 13 illustrates the loop portion 124 of the
hook-and-loop fastener fabric 120 sewn continuously onto all four sides
of the dropcloth 114. The joiner strip 110 may be applied intermittently,
or continuously along each edge of adjacent dropcloths 114. Due to the
dropcloths 114 gripping the floor surface due to the presence of the
gripping protrusions 32, it is anticipated that in many applications, only
intermittent application of the joiner strips 110 will be needed. In some
applications, such as where tripping, or paint seeping through small gaps
between mating edges 119 of two adjoining dropcloths 114 is of
paramount concern, the joiner strips 110 may be applied continuously
along each edge of adjoining dropcloths 114. These joiner strips 110
may also be impermeable to paint. FIG. 13 illustrates intermittent
application of joiner strips 110 on a plurality of adjoining dropcloths
114. In an embodiment, the loop portion 124 may cover the entire width
of the boundary zone 19. In an embodiment, the loop portion 124 may
cover only a portion of the width of the boundary zone 19. FIG. 13
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illustrates the loop portion 124 extending along an entire width of the
boundary zone 19.
[0050] FIG. 14 illustrates a method 200 of using the joiner strips 110 to join
a
plurality of adjacent dropcloths 10, 114. In use, a decision is made to
determine the type of dropcloths 10, 114 to be used in step 210 of the
method 200 depending on the size and shape of the room or surface area
to be covered. In step 220 of the method 200, a decision made as to the
exact number and/or length, as applicable, of the plurality of dropcloths
or 114 to be arranged adjacent each other, as necessary to cover a
desired floor area. A decision is then made in step 230 whether to
completely cover, or partially cover mating edges of the dropcloths 10 or
114 with joiner strips 110. In step 235, the dropcloths 10 or 114 are
joined by the joiner strips 110. In step 240 of the method 200, a chosen
task is then performed with a floor surface protected from damage or
staining by the dropcloths 10 or 114. Step 250 is the end of the method
200.
METHOD OF MANUFACTURING DROPCLOTHS IN A ROLL
CONFIGURATION
[0051] FIG.15 is a flow chart illustrating a method of manufacturing
dropcloths
in roll form.
[0052] The method of manufacturing dropcloths in a roll configuration is
explained in the following steps (Figs. 15-17) :
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1) Fabric to be used for the manufacture of a dropcloth 10, 114 is
mounted on a unwinding station 305 and may be pulled through
various washing tanks (307 ¨ FIG. 15) containing water and
detergents to clean the fabric. The fabric may be put through a wash
drying oven or dryers (310 ¨ FIG. 15) set at 150-200 Celsius (C) to
dry the fabric.
2) The fabric may be pulled through a printer head (312 ¨ FIG. 15) to
print the indicia 22 for the safety track 17. The fabric used to form
the dropcloth 10, 114 may be then fed into a dry oven 310 set at 150-
170C (315 ¨ FIG. 15) to dry and cure the printed indicia 22. The
printed fabric may then be again re-rolled (319 ¨ FIG. 15) into a
rolled configuration 320, as shown on FIG. 16.
3) The printed fabric roll is then mounted to an unwinding station (330 ¨
FIG. 15) to be un-rolled for the manufacture and installation of the
gripping protrusions 32. The end of each roll of printed fabric may
be sewn at a sewing station (333 ¨ FIG. 15) to the beginning of the
next roll of printed fabric to form a continuous roll, or rolled
configuration 320.
4) The gripping protrusions 32 are manufactured by mixing the polymer
resin with all other ingredients, as detailed in the description above,
including fillers, antioxidants and colourants, to form a completed
resin mix 335. The completed mixture 335 is then fed to a pressure
container (340 ¨ FIG. 15) to be transferred through a hose (350 ¨
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FIG.15), to the inside of a screen drum (360 ¨ FIG. 15) fabricated
with the desired size and pattern 34 of the gripping protrusions 32.
5) Each roll of printed fabric may then be fed to rollers 361 underneath
the screen drum (360 ¨ FIG. 15).
6) As illustrated by FIG. 15, the screen drum 360 is driven by a motor
362 with a scraper knife 370 and roller 380 installed inside the screen
drum 360. The completed resin mixture 335 from Step 4 is fed to the
inside of the screen drum 360. The continuous roll of printed fabric
320 is pulled by a roller 361 underneath the screen drum 360. The
resin mix 335 is "scraped" by the scraper knife 370 or other means to
push the completed resin mix 335 through a screen 390 formed on the
drum 360 to the continuous printed fabric to form the gripping
protrusions 32 on the dropcloth 10, 114. The continuous roll of
printed fabric with gripping protrusions 389, or dropcloth 10, 114
may be then pulled by nail chains or other means through an oven
394 which has a temperature range between 155C and 170C which
cures and hardens the gripping protrusions 32 for 45-90 seconds. The
printed fabric with gripping protrusions 389, or dropcloth 10, 114
exits from the oven 394, as illustrated on FIG. 15 and is then re-
rolled on a rewinder 396 into large round bales 320.
[0053] The method of manufacturing dropcloths with 4-sided safety tracks 114
is the same as above Steps 1) to 6) for the method of manufacturing
dropcloths in a roll configuration 320 with the following additional steps
as illustrated in FIG. 17:
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a) The fabric manufactured to dropcloth 114, is required to have
four boundary zones 19, one on each side of the dropcloth
114. This is accomplished by having the printer head 312
alternatively temporarily printing the indicia 22 for a distance
D1 of the continuous cloth 410, used for manufacture of the
dropcloth 114. This distance D1 corresponds to the length of
the safety track 17 for each dropcloth 114. The printer head
then temporarily stops printing the indicia 22 for a distance
D2 corresponding to twice the width of the boundary zone for
each dropcloth 114.
b)This printing process is continued as long as the continuous
length of cloth 410 is fed under the printer head 312. This
alternative temporary starting and stopping of printing the
printing indicia 22 may be accomplished by programming the
printer head 312 to temporarily start and stop printing the
indicia 22 on the continouous length of cloth 410 for distances
D1 and D2, respectively. This may alternatively be
accomplished by manual taping-off or otherwise covering the
continuous length 410 of cloth for a distance of D2, the taped-
off, or covered portion of the continuous length of cloth D2
being spaced along the continuous length of cloth 410 by a
distance of Dl.
c) After printing, the dropcloth 114 is created by cutting the
continuous length of cloth at a distance of D3.
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Changes may be made in the above description without departing from
the scope hereof. It should thus be noted that the matter contained in the
above description or shown in the accompanying drawings should be
interpreted as illustrative and not in a limiting sense. The following
claims are intended to cover all generic and specific features described
herein, as well as all statements of the scope of the present method and
system, which, as a matter of language, might be said to fall
therebetween.
