Note: Descriptions are shown in the official language in which they were submitted.
NON-SKID SAFETY MAT FOR PROVIDING ADHERING SUPPORT WHEN
PLACED UPON A SLOPING ROOF
FIELD OF THE INVENTION
The present invention discloses a mat, such as constructed of a neoprene or
other rubberized or suitable nonskid surface material. Versions of the mat
include
both magnetic attracting and conformal contacting/draping adhesion configured
undersides for placement upon any of a magnetic attracting or other roof
material, and in order to provide nonskid support to a user standing on the
roof,
such having any slope or angle and during both wet and dry conditions. The mat
can further integrate any type of hinged or flex capability which enables the
mat
to conform to any irregular surface associated with the roof. The mats are
further
typically provided in plural fashion and end-to-end or side-to-side arrayed
fashion in order to provide any of a walkway or working surface upon the metal
roof.
BACKGROUND OF THE INVENTION
In the field of construction, ascending or descending from sloped roofs,
including
both the metal and non-metal varieties, can be hazardous. Many injuries and
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some deaths occur each year. Safety and efficiency are key in construction
productivity. Construction and weather conditions, may challenge the ability
of
workers to maintain a safe footing.
In the field of building construction, problems incurred with metal roofs
notably
include safety while standing or walking. A layer of dew, dust, or pollen can
create conditions of great hazard for walking metal roofs.
Safety harnesses are required in many areas, yet a worker maintaining a
comfortable foothold can still be a concern and, in the course of a work day,
can
cause leg, ankle, knee, back stress. Many workers on metal roofs have
encountered slippery dangerous conditions and fallen. In cases of sudden foul
weather, such as rain or snow, loss of footing may cause workers to slip and
fall
from roofs or be trapped there.
As such, ascending and descending and standing, kneeling or crawling on any
metal roof, can be hazardous and cause many injuries and deaths each year.
Safety and efficiency are key in worker productivity in dealing with
construction
and weather conditions in order to maintain a safer foothold such as during
installation of material and equipment and in presence of such hazards as
including any of water/oil/silicones on the surface.
Damage to finished/painted metal surfaces is often incurred due to falls of
workers and hand tools, and equipment due to loss of footing. In the field of
metal roof construction and maintenance, workers incur conditions of rain or
dust, a hazard which may cause insecure footing and falls. Standing on pitched
roofs for hours is fatiguing on leg and back muscles, Lanyards, harnesses, and
rib clamps are used in ferritic metal roof construction, yet do little to
relieve
workers' footing and muscle stress. Also in weather conditions of mist, fog,
or
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rain, safely ascending and descending a pitched metal roof is extremely
difficult.
Each year many workers are injured and sometimes die in falls from ferritic
metal roofs.
It is also known that steel roofing today mimics most known roofing styles
such
as asphalt shingles, cedar shakes, slate, and terra cotta. Whereas asphalt
roofing
today is a landfill problem, steel roofing is recyclable. Steel roofing has a
long
term service capability of up to 60 years or more with good maintenance.
Steel roofing is 100% recyclable with high durability and long-term roofing
effectiveness. It offers the option of changing color simply by painting and
upgrading an old roof's appearance, thereby, holding a higher value to
business
and home owner's investment. Yet to workers, roofers, painters, and
maintenance people, slipping and falling from steel roofs is very hazardous
resulting in may injuries and deaths each year. There is a clear need for
providing workers safer ways to walk/traverse steel roofs. Structures such as
water towers, tractors, and ship decks also present a footing problem.
In the field of steel roofing, many of the current safety systems do not
address
footing, sitting in place, or kneeling down positions. Lanyards or harnesses
to
protect against falls do little to steady or provide secure footing. In
conditions of
a steep pitch steel roof 6/12 or more, leg and back fatigue from insecure
footing
can be extreme on workers, Similar problems with slippage of workers atop a
non-metallic or magnetically attracting roof surface also exist and which are
not
adequately addressed by the existing prior art.
Accordingly, in view of the many hazardous and safety concerns associated with
steel roofing and steel decking work, there is a clear need for an affordable,
easy
to use and safer footing system to be available to workers.
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SUMMARY OF THE INVENTION
The present invention addresses better safety for workers and reduced damage
to finished surface of a variety of roofs including both the metallic and non-
metallic variety. It is further the object of the invention to provide a
nonskid mat
for surer footing for workers, reducing the number of injuries and providing
better protection of finished surfaces associated with magnetic attracting and
non-attracting roofs, such for instance from dropped tools or equipment
falling
.. from tool belts. With the mat design of the present invention, a safer and
more
assured foothold is achieved, the mats being easily moved in all environmental
conditions to provide the user with a safer way of ascending and descending a
roof with reduced risk of injury.
One type of mat includes magnetic adhering undersides which conform to any
surface configuration of steel roof, such as which produces a wide variety of
styles not limited to cedar shake, Spanish terra cotta, slate tile, and many
others. The mats are further applicable to provide repositionable and antiskid
support to any other ferritic metal surface, not limited to metallic decks on
marine craft or the like. These and other objects and advantages of present
invention are more readily apparent with reference to the detailed description
and accompanying drawings.
In another variant, a non-magnetic version of the mat operates under the
principles of draping or conformal adhesion (such as illustrated by the
adhering
underside toe pad configuration of the gecko). A reconfiguration and
reapplication of this concept includes the provision of multiple and surface
contact area increasing microfibers, such as setae (hairs or bristles)
projecting
from the underside of the mat. Additional spatulae (nanometer scale
projections
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covering the setae as is also known with gecko toe pads), can likewise be
reconfigured into a conformal adhesion mat configuration such that the
pluralities
of setae/spatula bristles are adapted to adhere to the surface of the roof in
order
to dramatically increase surface area conformance and thereby maximize the
generation of skid-resistant electronegativity forces (also termed Van der
Waal
forces).
As will be further described, the integration of the phenomena of draping
adhesion to an anti-skid mat for use with a sloping roof permits the creation
of
conformal and skid resistant contact, and while maintaining high, elastic
stiffness
in downward sloping directions resisting to skidding. The directional skid-
resistant aspect of the Van der Waal forces is further such that removal of
the
mat is accomplished by simply and effortlessly lifting the same in a direction
opposite to the conformally adhering and skid resistant forces.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference will now be made to the attached drawings, when read in combination
with the following detailed descriptions, wherein like reference numerals
refer to
like parts throughout the several views, and in which:
FIG. 1 is a side perspective of a sheet metal roof construction according to
one
known configuration and exhibiting an uneven surface profile;
FIG. 2 is an illustration of the safety mat in a pre-applied position;
FIGS. 3-4 are successive illustrations of the safety mat in an intermediate
applied and adhering position upon the metal roof;
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FIG. 5 is a fully applied illustration of the safety mat magnetically adhered
to the
metal roof exterior;
FIG. 6 is a upper perspective of another variant of alternating peak and
valley
sheet metal roofing construction, further to that depicted in FIGS. 1-5;
FIG. 7 is a further assembly protocol utilizing the safety mats of FIGS. 11-12
and
illustrating the manner in which the mats can be applied to the sheet metal
roofing in order to provide a more secure walkway surface;
FIGS. 8-10 illustrate a succession of views of an installation protocol for
applying
a plurality of nonskid mats upon a metal peaked roof construction;
FIGS. 11A-11B are perspective and side views of a safety mat according a
further embodiment and which includes an upper-most nonskid (e.g. neoprene or
other rubberized) material layer, (tear-resistant or ripstop fabric layer), an
intermediate adhesive layer, and a plurality of subset spaced and underside
attached magnetic strips;
FIG. 12 is an exploded view of the safety mat of FIGS. 11A-11B;
FIG. 13 is an illustration of a full layer of magnetic backing material in a
generally grid profile nonskid strips according to one non-limiting
configuration of
the present invention;
FIGS. 14A-14B are bottom and side view illustrations of a further variant of
magnetic adhering safety mats such as which can exhibit any type of flex
pattern
for conforming when placed upon the metallic roof;
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FIGS. 15A-15B are bottom and side view illustrations of a yet further and
related
variant of safety mats similar to FIGS. 14A-14B;
FIG. 16 is a sectional illustration taken from FIG. 15A and showing a
quartered
diamond style pattern associated with each of the flexible magnetic bottom
layers in order to provide (greater) enhanced surface area contact when placed
upon existing steel roofing, such as which can further exhibit a known
imitation
pattern not limited to cedar shake, terra cotta, slate tile or the like; and
FIG. 17 is an illustration of a single layer chemical, self-assembled or
extruded
programmable particle material which can be constructed as a nonskid mat
according to a further possible variant of the present invention;
FIG. 18 is an illustration of another single layer mat design incorporating a
first
plurality of skid-resistant strips/portions in combination with an alternating
second plurality of flex-hinged connecting and magnetic strips/portions;
FIG. 19 is an illustration of a plurality of microscopic sized synthetic
polymer
fibers, such as which project from an underside surface of an anti-skid mat
according to a further variant and which replicate the conformal/draping
adhesion properties of setae/spatulae incorporated into a gecko toe pad;
FIG. 20 is an illustration of a textured and anti-slip exterior surface of a
mat
according to a further variant;
FIGS. 21-22 are sectional partial plan views of additional mat designs and
illustrating pluralities of magnetic portions having either of
hexagonal/polygonal
or circular edge profiles and which are embedded within a flexible planar and
rubberized mat;
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FIG. 23 illustrates a variant of FIG. 21 in which sub-pluralities of both
magnetic
and conformal adhering underside portions are integrated into an
interconnecting
rubberized mat matrix;
FIG. 24 is a conformal adhering variant of magnetically attracting mat of FIG.
21;
FIG. 25 is a side cutaway view of an injection mold process for creating a mat
having a plurality of underside embedded magnetic attracting portions or
strips
consistent with the mat designs of FIGS. 21-22;
FIG. 26 is a similar side cutaway view of an injection mold process for
creating a
mat having underside embedded conformal adhering portions/strips consistent
with the mat design of FIG. 24;
FIG. 27 is a similar side cutaway view of an injection mold process for
creating a
mat having underside sub-pluralities of both magnetic and conformal adhering
portions/strips consistent with the mat design of FIG. 23;
FIG. 28 is an illustration of an injection molding process for creating a mat
which
is a variant of FIG. 25 and in which the magnetic adhering underside
portions/strips are embedded within the rubberized mat such that their
exterior
undersides are flush with the rubberized interconnecting matrix;
FIG. 29 is an underside perspective of a mat such as also depicted in FIG. 20
and
illustrating a plurality of spatially disposed magnetic strips integrated into
the
mat underside, such as which can also be represented by the injection mold
assembly of FIG. 25;
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FIG, 30 is a similar underside perspective of a mat such as shown in FIG. 29
and
in which the magnetic strips are replaced by conformal adhering strips;
FIG. 31 is a further underside perspective of a mat combining the magnetic and
conformal adhering strips in alternating pluralities;
FIG. 32 is a yet further underside perspective of an injection molded mat with
underside configured adhering strips which can be further represented by the
injection mold assembly of FIG. 28;
FIG. 33 is an underside perspective of a further example of a combination
magnetic strip and conformal adhering anti-skid mat, the design including
living
hinges extending between the respective strips;
FIG. 34 is a succeeding version to FIG. 33 of a further related version of
conformal adhering underside associated with an anti-skid mat; and
FIG. 35 is a yet further underside looking perspective of a combination
variant of
anti-skid mat with conformal adhering and magnetic attracting strips.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As will be described in further detail with reference to the following
illustrations,
the present invention discloses a variety of different mat configurations,
including
both magnetically adhering mats and non-magnetic conformal adhering mats, as
well as mats including combinations of both magnetic and non-magnetic
adhering properties. As will be further described, the mats are constructed of
any
suitable nonskid surface material, and which incorporate any of magnetic or
non-
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magnetic attracting undersides for placement upon any type of sloped or
inclined
ferritic and non-ferritic substrate such as a roof or other support surface.
In use, and as will be described with further reference to the following
embodiments, the concepts of the invention are illustrated by the following
figures. The figures are only meant to illustrate the concepts for the
invention
and in no way are intended to limit the scope of the invention in any manner.
The invention also discloses a plurality of similar configured mats which are
continuously applied and repositioned in order to provide nonskid support to a
user standing on a roof such as typically exhibiting any degree of angle or
pitch,
with the mats providing adequate magnetic holding forces against a magnetic
attracting metal roof in either of wet and dry conditions. As will be
additionally
described, the mat can integrate any type of hinged or flex capability which
.. enables the mat to conform to any irregular surface associated with such as
a
sheet metal roof construction.
Referring to FIG. 1, a side perspective is depicted of a sheet metal roof
construction 2 according to one known configuration, and such as which can be
of ferrite or other similar metal which exhibits desired magnetic attracting
properties. Further shown in the selected example of the roofing construction
2 is
any arrangement of structure associated with such as a stamped or otherwise
configured sheet metal, this including such as alternating ribs 4, between
which
are located valleys with any further surfacing profiles 6. As will be
described in
reference to succeeding variants, the sheet metal configurations with which
the
present invention can be utilized can vary from that shown.
Referring to FIG. 2, an illustration is, as an example of a fully assembled
safety
mat 10 according to one non-limiting variant arranged in a pre-applied
position
CA 2992904 2018-01-25
relative to the metal roof 2. The safety mat exhibits a generally planar shape
with any length and width dimension, and which can include, without
limitation,
any desired thickness such as in a range of 1/8" to 1/2".
In one non-limiting variant, the individual mats can exhibit dimensions
provided
in any plurality in order to cover a suitable area of the metal sheeting of
the roof
necessary for safely supporting the user thereupon. Without limitation, the
shape, thickness and configuration of the mat is capable of being modified in
order to provide a maximum degree of adhering (further defined as antiskid or
shear force limiting) support upon the roof surface. This can include without
limitation such as reconfiguring the individual magnetic sections in a
quartered
diamond or other suitable shape. Reference is also made to blown up view 12
depicted in FIG. 16.
Material constructions associated with the mat can include any suitable
flexible
material having sufficient nonskid surface properties, such as without
limitation
neoprene or other polymer based materials. Neoprene or poly-chloroprene is a
family of synthetic rubbers that are produced by polymerization of
chloroprene.
Neoprene exhibits good chemical stability and maintains flexibility over a
wide
temperature range and, in the present application, provides the advantages of
exhibiting good exterior and antiskid characteristics in either wet or dry
conditions, along with limited stretchability. The purpose of the surface
material
used, regardless of construction, is to provide both nonskid support to the
user
when standing thereupon as well as to provide the necessary flexibility during
application and successive repositioning upon the ferritic metal roof.
The mat 10 further includes a magnetic adhering underside layer, such as again
best represented by the grid shaped material 14 depicted in FIG. 16. As will
be
described in further detail with reference to subsequent embodiments as in the
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CA 2992904 2018-01-25
underside view of magnetic strips 16 in FIG. 7. The construction of the mat is
such that the backing magnetic layer can include, without limitation, and
number
of individual magnetic elements, such as flexible magnetic sheets or materials
which can be integrated into the mat at spaced intervals in underside facing
manner. Reference is also made to FIGS. 14A-14B and FIGS. 15A-15B.
Alternately, a continuous magnetic (underside) layer 18 can be provided as
illustrated in FIG. 13 and which is attached to an underside of neoprene
strips or
other suitable surfacing (antiskid) material such as by gluing, heat bonding
or
the like.
FIGS. 3-5 are successive illustrations of the safety mat 10 in each of pre-
applied,
intermediate applied and installed/adhering positions upon the metal roof 2.
As
best shown in FIG. 5, the flexible construction of the mat 10 is such that,
upon it
being magnetically adhered to the exterior surface of the roof 2, it exhibits
a
plurality of hinged or pivot locations, see at 22 which enables the mat to
conform
to the surface profile of the metal roof 2, as well as the subsequent roof
design 2'
of FIG. 6 (commercially referred to as corrugated steel roofing) which
exhibits a
continuous reverse angled and corrugated appearance (see angled portions 3, 5,
7, et seq.) without the existence of any flattened locations.
The present invention contemplates the individual mats capable of exhibiting
any
flexible profile or configurations, and as such as which can be tailored where
necessary in order to adequately conform the mat to the given surface profile
of
the roof 2. To this end, the flexible material incorporated into the mat
construction can exhibit any arrangement of fold lines or bends, such as which
are also known as living hinges, in order to accommodate the specified profile
of
the metal roof 2 and in order to provide an adequate and nonskid platform for
the user. The magnetic underside layer can further include any corresponding
spacing or reconfiguration, such as including providing the attracting layer
as a
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plurality of individual magnetic strips in spaced fashion, and in order to
match
the profile of the metal roof surface.
The full magnetic attracting underside layer 18, such as again shown in FIG.
13,
can (without limitation) also be configured with a grid design such as
incorporating a multi (four) sided outer form or perimeter 24, between which
extend individual strips or lengths of nonskid portions 26 the configuration
of
which facilitates bending or articulating when placed upon any irregular or
peak/valley surface profile associated with the corrugated steel roof. The
underside layer 18 can also be adhered (such as by gluing as depicted by
adhesive layers or strips 28 and 30 in FIG. 12) to the underside of the skid-
resistant (e.g. neoprene) mat 10, in order to provide the desired properties
of
grip and flexible/hinged construction of the mat 10 to accommodate a given
metal roof surface profile.
FIGS. 8-10 present a further series of environmental perspective views
illustrating the application of the mat 10 onto the sheet metal roofing
construction 2, consistent with that previously depicted in FIG. 2-5,
according to
the known art and which again exhibits multiple and reverse angled bends, this
best shown in the assemble view of FIG. 10 and by which a user 1 is capable of
standing upon the slip-resistant exterior surface of the mat 10 without the
mat
shearing or slipping relative to the metal roof, again due to the consistent
magnetic attracting profile established across the magnetic surface area of
the
mat with the underlying roof. As previously described, the construction of the
mats are such that they provide adequate non-slipping magnetic attracting
forces when placed upon the metal roof surface, with the antiskid upper
surface
further establishing secure footing to the user standing there upon, such as
in
the instances of either wet or dry weather.
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Aside from providing a solid foothold provided by the magnetically adhering
mats
further assists in reducing body stress and accidents. The mats are further
designed to be easily moved and repositioned across the metal roof by the user
using a plurality of mats while supported thereupon.
The present invention further provides an effective method for applying a
plurality of mats upon a metal roof surface, depicted in FIG. 7, such as
including
the steps of reposition-ably adjusting any plurality of individual mats in end-
to-
end and/or side-by-side fashion upon the metal roof, and as such as to permit
the user to walk between any desired points in a more secure fashion. The
elevations or peaks of the metal roof sheeting 4 in FIG. 5 are accommodated by
the design of the living hinge 14, mat 10, FIG. 5 by conforming to the peaks,
providing better surface contact, thereby, further assisting in providing
antiskid
support to the user.
Proceeding to FIGS. 11A-11B and FIG. 12, a series of perspective, side and
exploded views are respectively shown of a safety mat 20 according to a
further
embodiment, which includes an upper-most nonskid material layer 32, an
intermediate adhesive layer 33 and a plurality of subset spaced and underside
attached magnetic strips 34, the intermediate 33 and underside magnetic strips
34 as shown each including an adhesive covering as depicted at 28 and 30. The
upper layer 32 can again exhibit any nonskid rubberized consistency and can
exhibit any thickness, such as 1/8". The intermediate adhesive coated layer 33
can further include, without limitation, any type of tear-resistant material,
also
termed a rip-stop fabric, such as exhibits flexural properties. In combination
with
the upper surface attached neoprene or neoprene coated material layer 32 (also
understood to include any other potential skid-resistant and flexible
material) the
intermediate rip-stop 33 adhesive layer 30 and the lower attached magnetic
strips 34 provide any desired degree of flex/bend in application.
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FIG. 7 illustrates, generally at 36, a further assembly protocol utilizing the
safety
mats according to any of the embodiments described herein, with a plurality of
four such mats 10 being referenced. Consistent with the previous figure
descriptions of FIGS, 8-10, a plurality of mats 10 can be placed in successive
and
spaced fashion to provide a more secure walkway surface for an individual upon
the typically (but not necessarily) peaked and angled profile established by
the
metal roofing construction, a further configuration of which is shown at 38,
FIG.
7.
The metal roof 36 as shown FIG. 7 further includes a plurality of alternately
configured and spaced apart side profiles, these depicted by semi-circular
shaped
profiles or configuration 38, and over which the mats 10 are capable of
closely
and snugly adhering, again due in part to the flexible nature of both the
upper
skid-resistant layer 32, in FIG. 11A-11B, intermediate rip-stop fabric layer
33,
adhesively affixed layer 30, affixed to lower magnetic strips 34, which can
again
be spaced apart as shown in FIGS. 11-12. The spaced arrangement and location
of the magnetic strips can further be configured for other metal roofing
profiles,
Without limitation, the mat 10 in FIGS. 14B and 15B can be configured such
that
the magnetic strips 34 can include flexural patterning so that they provide
enhanced gripping upon the flattened or irregular metal surfaces associated
with
the type of metal roofing installations such as faux and non-traditional
patterning. As with previous variants, and as will be further described, the
.. spaced apart configuration of the magnetic strips define living hinge
locations 14
the configuration and arrangement of which can further be modified in order to
maintain enhanced magnetic grip while requiring minimal lift force for moving
and replacing mats.
CA 2992904 2018-01-25
It is further understood that any of the number, arrangement and/or profile of
the magnetic strips can be modified as in sectional view 12, FIG. 15A with the
scope of the invention in order to provide any desired gripping
characteristics
such as the quartered diamond pattern 14 shown in the enlarged view of FIG.
16, for a given surface configuration of a metal roof.
FIG. 16 is a sectional illustration taken from FIG. 15A and once again showing
a
quartered diamond style of pattern of individual magnets associated with each
of
a more flexible magnetic bottom layer (see selected strip, portion or layer as
defined at phantom outline 12 of FIG. 15 A). Such a pattern can be limited to
just the magnetic strips, or can be further integrated into the upper
rubberized
neoprene layers. This in order to provide an increased degree of flex or bend
and
thereby establish greater or enhanced surface area contact when placed upon an
existing steel roof 2. Although not shown, it is further understood that
existing
metal roofing 2, apart from exhibiting any of the profiles shown herein, can
further be produced with any of a texturized or otherwise decorated surface
which can exhibit an imitation steel roofing pattern not limited to any of
cedar
shake, terra cotta, slate tile, asphalt-like shingle or the like.
FIG. 17, is a non-limiting embodiment illustration of a single layer chemical,
self-
assembled or extruded programmable particle material, and/or 3D printer
produced representation of the invention in a sheet mat for mat 40 and which
can again include any desired dimensions with a suitable thickness (typically
at
least 1/8 of an inch or more). The unique construction of the mat 40 is
further
understood to provide combined magnetic adherence to the metal roof surface,
as well as adequate nonskid shear-resistant surface mat embodiment support to
a user, similar to that established by any of the multi-layer configurations
described herein.
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With further reference to the subsequent description of FIGS. 25-28, it is
understood that any suitable injection molding or extrusion process can be
employed for creating the desired mat configuration. It is further envisioned
that,
as part of the matrix or construction of such as single layer mat, a flexural
grid
or other internal support can be integrated into the material construction in
order
to provide enhanced strength while retaining the desired flex hinge aspects.
FIG. 18 is an illustration of another single layer mat design, generally at
42,
incorporating a first plurality of skid-resistant strips/portions 44 (these
additionally providing living hinge functionality) in combination with an
alternating second plurality of flex-hinged connecting and magnetic
strips/portions, at 46, the mat configuration of FIG. 18 being particularly
suited
for providing nonskid support when placed upon the continuous reverse-angled
roof design 2 of FIG. 6, it being understood that other configurations are
.. envisioned for supporting upon and gripping other roof surfaces not limited
to
those depicted herein.
Similar to FIG. 17, the single layer design of FIG. 18 can be produced in a
suitable material forming process, such in this instance, contemplating the
magnetic strips being pre-placed in their desired spaced apart manner within a
mold interior, following which the skid-resistant strips are injected in-
between. A
variation of this design can further envision the spaced magnetic strips 46
being
embedded within a thicker skid-resistant layer 44 (the magnetic strips
effectively
seating within underside facing pockets created within the injection molded or
like formed rubberized layer).
Without limitation, the present invention contemplates any mat design, having
one or more layers, which are constructed of any rubberized or other skid-
resistant material, further any mesh, weave, injection molding, 3D printing,
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extrusion, or other flexible article, and which further include
magnetic/adhering
aspects which are either incorporated into a single layer design or configured
as
additional strips or portions adhered to an underside surface of the mat, this
in
order to provide both enhance gripping to the metal roof surface as well as to
accommodate the variances in the surface configuration of the metal. To this
end, the design of the mat and its magnetic adhering portions can be modified
in
any way desired in order to establish flex locations between any such peaks
and
valleys in the metal roofing in order to maximize the effective surface area
of
magnetic attraction in order to minimize instance of slippage or shear of the
mat
.. when placed upon the ferritic metal roof.
For the purpose of constructing one style mat as is shown in FIG. 12, includes
a
cut 21"×32" sheet of neoprene nonskid rubber, a sheet of equal size tear
or
abrasion resistant fabric (such as ripstop), cut (see quantity of four at 34
each
such as 5"×21" in dimension) strips of 5/32" flexible magnetic sheeting.
Using flexible PVC glue, a layer of adhesive is applied to a bottom side of
the
neoprene sheeting and a layer of adhesive to one side of the ripstop fabric.
The
adhesive layer sides are then placed together along their opposing and
aligning
edges. A layer of adhesive is applied to the non-magnetic side of the magnetic
strips and then to the underside of the ripstop fabric underside. Magnets are
then
adhered at outside edges of corresponding length and place remaining strips
evenly from each other creating the living hinge 22, as in FIG. 11A, and as
depicted in FIG. 1-5. This design of the completed mat 10 may be used on a
steel sheet metal roof with peak or rib lines separated by 7" to 9" on center.
Proceeding to FIG. 19, an illustration is generally shown at 48 of a plurality
of
microscopic sized synthetic polymer fibers, see further at 50, 52, 54, et seq
(such also contemplating the use of nylon or carbon fibers of varying
stiffness).
As will be further disclosed in reference to FIGS. 23, 24 and 30-35, the stiff
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fibers are configured to project from an underside surface of a rubberized or
other draping/conforming conforming anti-skid mat according to a variety of
further variants.
For purposes of accurately replicating the setae/spatulae configuration of
such as
a Gecko pad, the tubular shaped fibers 50, 52, 54 can each further include
intermittent branching or leafing structures, see further as shown at 53, 55,
57
branching off similarly constructed micro-fibril tubular base structures as
again
shown in FIG. 19. It is understood that the precise structure of the
microfibers,
as further described below, can be varied from that shown while substantially
maintaining their conformal adhering properties.
The stiff fibers replicate the conformal/draping adhesion properties of
setae/spatulae microscopic bristles incorporated into a gecko toe pad. Without
limitation, the synthetic fibers shown can include any scale or size, such in
one
non-limiting instance each averaging a given height measured in micrometers
and a further width measured in nanometers, with a corresponding dimensional
ratio of 10:1 to 50:1 between the respective height and width measurements.
These dimensional ratios can also apply to measurements in micron scale (e.g.
fibers that in one non-limiting instance can be less than 1 micron in diameter
and
20 microns in height which averages to less than 1/5 the thickness of a sheet
of
paper).
In terms of scale, a typical microfiber is approximately 100 times smaller
than a
human hair such that approximately 40 million such fibers can be situated upon
a one square centimeter surfaces area (or 250 million fibers per square inch).
As
will be further described, the microfibers (in combination with the
flexible/draping aspect of the underlying base layer material) engage any even
or
uneven surface profile such as associated with a sloped roofing application,
and
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by which such an opposing and compressive load (e.g. the mat placed upon the
roof surface such that the microfibers contact the roof surface) upon coming
into
contact with the bristles 50, 52, 54, et seq. causes the same to be
deflected/bent
into individual surface area increasing contact with the underlying roof
surface
area.
As is further known, Van der Waal forces of frictional resistance operate
under
the principal of establishing surface molecular bonding between the constantly
moving electron clouds associated between opposing surface molecules, the
weakest version of these also being known as London dispersion forces and
which are constituted by persisting slight charge imbalances between the
respective electron clouds which create the attraction force. This surface
molecular bonding is enhanced by increasing the effective contact area
established between the respective materials (i.e. the term "draping
adhesion")
.. and which is further evidenced by enhancing the size and concurrent area of
conformal contact established between the stiff microfibers and the opposing
roof
surface to provide anti-skid adhesion of the mat relative to the roof. In this
fashion, the known physical properties of draping adhesion can be applied to a
variety of anti-skid mat applications as described below and which provide for
.. adequate holding and retaining forces applied to such a mat supported upon
a
sloping roof surface of any material construction (not limited to
metallic/magnetic attracting), such a roof surface also potentially including
any
type of material also having any irregular surface profile.
Proceeding to FIG. 20, an illustration is provided generally at 56 of a
textured
and anti-slip exterior surface of a mat according to a further variant, such
as
which can exhibit a diamond or other pattern of anti-slip protruding portions
at
58, 60, 62, et seq. exhibited on its upwardly/exteriorly facing surface (also
referenced as a diamond deck rubber top side). The mat and the surface anti-
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skid textured, embossed or protrusion patterns can be constructed of any
rubberized, flexible and anti-skid material, such as which includes a thin
planar
and rectangular shaped sheet of dimensions consistent with that previously
described and which can be rolled or unrolled, and further which, in
combination
.. with flex or hinge lines, is configured upon its adhering undersides with
either or
both of magnetic or conformal attracting portions.
Proceeding to FIGS, 21-22, a pair of sectional partial plan views are
respectively
shown at 64 and 66, respectively, of additional mat designs, each illustrating
pluralities of magnetic portions embedded within a mat (such as further
similar
to as depicted in FIG. 20 and which is inverted to depict a roof surface
conforming underside). FIG. 22 depicts a plurality of hexagonal/polygonal edge
portions, each having a thin and wafer like body profile shown at 68, 70, 72
et
seq., and which are embedded with or adhered to an underside of a connecting
rubberized mat 74, such that the individual magnetic attracting portions are
dimensioned to be in contact with the opposing roof surface, the underside
adhering portions also being spaced relative to one another in a desired
manner
with suitable separation distances therebetween.
FIG. 22 further depicts a corresponding plurality of circular edge portions,
each
having profiles shown at 76, 78, 80, et seq., and which are likewise embedded
within (or adhered to an underside surface of) a flexible planar and
rubberized
mat 82. For purposes of the disclosure, the term polygonal in reference to the
individual underside adhering portions is intended to include any closed
perimeter shape having any number of sides ranging from a triangle (three
sided) to a circle (defined for purposes of this disclosure as a closed
perimeter
polygon exhibiting an infinite number of sides).
FIG. 23 illustrates a variant, generally at 64, of FIG. 21 in which sub-
pluralities
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of both magnetic (previously at 68, 70, 72, et seq.) and conformal adhering
(see
further at 84, 86, 88, et seq.) underside portions are integrated into an
interconnecting rubberized mat matrix, see at 74'. The magnetic portions,
consistent with that previously described, can include any type of ferritic or
other
rare earth magnets, with the conformal adhering portions including micro-
bunches of the polymeric fibers depicted in FIG. 19 and which are embedded
into
the individual hexagonal support portions (as further described in succeeding
illustrations it is also understood that the conformal adhering portions can
also
be secured directly to the undersides of the flexible mat in elongated strips
or
other patterns).
FIG. 24 is a conformal adhering variant of the magnetically attracting mat of
FIG,
21, and which is generally depicted at 90, by which all of the hexagonal (or
circular or other shaped) portions are replaced by exclusively conformal
adhering
portions 84, 86, 88, et seq. embedded within a rubberized mat 92. Additional
variants contemplate any of different shaping, spacing or distribution of the
individual underside supported portions (both magnetic attracting and
conformal
adhering) and it is further envisioned that additional features such as
underside
grit surfacing and/or individual skid resistant portions can also be
integrated into
the mat underside along with any of the alternating variants of FIGS. 21-24,
Proceeding to FIGS. 25-28, a series of side cutaway views are shown of related
injection mold processes for creating and manufacturing rubberized mats such
as
depicted in any of FIGS. 21-24 (as well as for example those to be
subsequently
depicted in FIG. 29 et seq.). In each example, a pair of upper 96 and lower 98
mold halves are provided which mate in order to define an internal cavity
corresponding to a negative of the elongated mat to be produced.
A supply of material, such depicted at 100 and including again any of a rubber
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material, is injected under pressure through a passageway 102 communicating
with the mold cavity interior. It is further understood that, while a single
channel
102 is depicted for purposes of ease of illustration, a plurality of
concurrently fed
channels is also contemplated in order to fill the interior channel in a
manner in
which the plasticized/rubberized material surrounds an encapsulates a pre-
placed
plurality of the individual elements which are supported upon the bottom mold
half prior to closing and loading of the mold.
The channel shown can also be reconfigured as any number of material
communicating channels integrated into the opposing facing surfaces of the
mold
halves which surround the negative interior shaped cavity, such also including
aligning recessed locations which enhance both quick and even filling of the
interior with the flowable material. Additional aspects of the interior
architecture
of the mold halves which define the negative cavity can also include
configuring
the upwardly facing bottom mold half surface 104 with raised width extending
locations, see at 101, 103, 105, et seq., which define an arrangement of
underside flex hinges in the completed mat body 74.
As shown in FIG. 25, the plurality of individual elements can again include
the
.. magnetic portions 68, 70, 72, et seq., depicted in FIG. 21 and which are
seated
within mating recessed pockets configured within the upwardly facing surface
104 of the bottom mold half. As also previously referenced, the preplaced
portions can also include elongated strips or sheets of material (see in
particular
FIGS. 29-32) which are supported within the recess configured placement
locations defined within the bottom mold half), it being understood that the
closed perimeter individual portions of FIGS. 21-25 also reference the
elongated
strips of FIG. 29 et seq. As further shown, the upper surface of the injection
molded mat 74 can again include a diamond back embossment pattern (see
again protrusions 58, 60, 62, et seq.).
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FIG. 26 is a similar side cutaway view, generally at 106, of an injection mold
process for creating a mat having underside embedded conformal adhering
portions/strips, see again at 84, 86, 88 consistent with the mat design of
FIG.
24. FIG. 27 is a similar side cutaway view, generally at 108, of an injection
mold
process for creating a mat having underside sub-pluralities of both magnetic
and
conformal adhering portions/strips consistent with the mat design of FIG. 23.
FIG. 28 is an illustration, generally at 110, of a further related variant of
an
injection molding process for creating a mat which is similar to FIG. 25 and
in
which the magnetic adhering underside portions 68, 70, 72, et seq. shown are
embedded within a modification 74' of the rubberized mat such that their
exterior
undersides are flush with the underside of the rubberized interconnecting
matrix.
Proceeding to FIG. 29, an underside perspective is generally shown at 112 of a
mat such as also depicted in FIG. 20 and illustrating a plurality of spatially
disposed magnetic strips, see at 114, 116, 118, et seq., integrated into an
underside of a mat, the injection molding of which can also be represented by
the injection mold assembly of FIG. 28 (depicting the flush underside profile)
and
in which the individual polygonal shaped portions are replaced by the
elongated
strips. A plurality of hinge lines 120, 122, 124, et seq. are depicted and,
consistent with previous described embodiments, allow the mat to conform to
irregular roof surface profiles in a manner which maximizes the effective
surface
contact area between the mat underside and the roof exterior.
FIG. 30 is a similar underside perspective, at 126, of a mat such as shown in
FIG. 29 and in which the magnetic strips are replaced by conformal adhering
strips 128, 130, 132, et seq. While the strips are shown in smaller width
dimension, it is again understood that their relative dimensions can also
vary,
such as to equal that depicted in reference to the magnetic strips 114, 116,
118,
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et seq. in FIG. 29 (see also alternate adhering strip pattern of FIG. 32), and
further so that alternating hinge lines can be configured therebetween
(corresponding to placement locations 134, 136, 138, et seq.).
FIG. 31 is a further underside perspective, at 140, of a mat combining
magnetic
(142, 144, 146, et seq.) and conformal adhering (148, 150, 152, et seq.)
strips
in alternating pluralities, and such as which can be further represented by
the
injection mold assembly of FIG. 27. FIG. 32 is a yet further underside
perspective of an injection molded mat, at 154, with underside configured
adhering strips 156, 158, 160, et seq., arranged in a pattern similar to that
shown in FIG. 31 in combination with an arrangement of alternating hinge lines
162, 164, 166, et seq.
FIGS. 33-35 present a series of underside perspectives of further variants of
mat
designs and which provide either or both magnetic attracting and conformal
adhering portions arranged in varying patterns. FIG. 33 is an underside
perspective, at 168, of a further example of a combination magnetic strips
(see
quad or corner situated sub-pluralities of strips at 170, 172, in combination
with
conformal adhering anti-skid portions (see central main micro-fibril adhesion
material 176 with communicating and lateral extending wings 178/180). The
conformal adhesion materials again include the microfibers depicted in FIG. 19
integrated into the mat design. Living hinges (see at 182, 184, 186, et seq.)
are
configured between the respective sub-pluralities of magnetic strips and
provide
some degree of flex or bend to the overall mat.
FIG. 34 is a succeeding version to FIG. 33, see at 188, of a further related
version of conformal adhering underside associated with an anti-skid mat
including a further possible variant of magnetic strips 170, 172, 174, et seq.
in
combination with additional hinge-like interposed conformal adhering portions
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190, 192, 194, et seq. Finally, FIG. 35 is a yet further underside looking
perspective, at 196, of a combination variant of anti-skid mat as generally
depicted in FIG. 33 and with the conformal adhering (190, 192, 194, et seq.)
and
magnetic attracting (170, 172, 174, et seq.) strips in a further combination
arrangement with additional integrated hinge lines 198, 200, 202, et seq.
The arrangement of the mats shown in FIGS. 33-35, in combination with those
previously depicted, represent additional and non-limiting examples of a
variety
of different patterns or styles associated with the anti-skid mats and which
can
include either or both of magnetic attracting and/or conformal adhering
microfiber surfaces which can further be provided with designed hinge lines to
maximize surface conformation of the mat when placed in plural fashion upon a
rooftop location in order to provide a secure walkway surface. In any of the
above described and illustrated applications, the anti-skid mats provide a
combination of features including high retaining (i.e. frictional anti-skid)
force,
easy release from roof surface, and reusability.
Having described my invention, other and additional preferred embodiments will
become apparent to those skilled in the art to which it pertains and without
deviating from the scope of the appended claims.
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