# US 2014/0154474 A1 · Hinged floor mat > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0154474 A1 - Document ID: US20140154474A1 - Status: Published application - Kind: A1 - Application number: 14/068,397 - Filed: 2013-10-31 - Published: 2014-06-05 - Earliest claimed: 2012-12-05 - Inventors: Edward S. Robbins, III - Web page: https://patentgrep.com/patent/US20140154474A1 ## CPC - B29C 43/222: {characterised by the shape of the surface} - A47G 27/0206: {to protect the underlying surface, e.g. temporary covers, disposable carpets, absorbent pads, wheelchair pads, hearth rugs} - B29C 2043/022: {having locally depressed lines, e.g. hinges} - Y10T 428/2457: Parallel ribs and/or grooves - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - A47G: HOUSEHOLD OR TABLE EQUIPMENT (book-ends A47B5/00; knives B26B) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A one-piece, unitary floor mat may include a continuous plastic sheet including upper and lower surfaces, and an outer perimeter that joins the upper and lower surfaces. A plurality of grooves may be disposed along the upper surface. Each groove may include two sloped surfaces joined to one another at a trough in a substantially V-shaped configuration. A plurality of channels may be disposed along the lower surface. Each channel may be substantially aligned with a single corresponding groove, and each groove may be substantially aligned with a single corresponding channel. A plurality of substantially planar elongate panels may be defined by the grooves and the channels. An upper surface of each panel may be defined by two adjacent grooves. A lower surface of each panel may be defined by two adjacent channels. Successive panels may be movable relative one another to roll the floor mat into a rolled configuration. ## Claims ### Claim 1 A one-piece, unitary floor mat comprising: a continuous plastic sheet comprising an upper surface, a lower surface, and an outer perimeter that joins the upper surface and the lower surface; a plurality of grooves disposed along the upper surface, each of the plurality of grooves comprising two sloped surfaces joined to one another at a trough in a substantially V-shaped configuration; a plurality of channels disposed along the lower surface, each channel being substantially aligned with a single corresponding groove, and each groove being substantially aligned with a single corresponding channel; and a plurality of substantially planar elongate panels defined by the grooves and the channels, an upper surface of each panel defined by two adjacent grooves and a lower surface of each panel defined by two adjacent channels. ### Claim 2 (depends on 1) The floor mat of claim 1, wherein the plurality of grooves and the plurality of channels are parallel to one another. ### Claim 3 (depends on 1) The floor mat of claim 1, further comprising a plurality of webs, each web disposed between one of the plurality of channels and a corresponding one of the plurality of grooves. ### Claim 4 (depends on 3) The floor mat of claim 3, wherein each web comprises a thickness of between about 0.02 inches and about 0.035 inches. ### Claim 5 (depends on 1) The floor mat of claim 1, wherein each panel comprises a thickness of between about 0.09 inches and about 0.105 inches. ### Claim 6 (depends on 1) The floor mat of claim 1, wherein each panel comprises a width of between about 1 inch and about 3 inches. ### Claim 7 (depends on 1) The floor mat of claim 1, wherein the widths of the plurality of panels are substantially equal to one another. ### Claim 8 (depends on 1) The floor mat of claim 1, wherein each channel comprises a depth of between about 0.06 inches and about 0.08 inches. ### Claim 9 (depends on 1) The floor mat of claim 1, wherein each channel comprises a width of between about 0.04 inches and about 0.06 inches. ### Claim 10 A one-piece, unitary floor mat comprising: a continuous plastic sheet comprising an upper surface, a lower surface, and an outer perimeter that joins the upper surface and the lower surface; a plurality of grooves in the upper surface; a plurality of channels in the lower surface, each channel positioned substantially opposite a single corresponding groove, and each groove positioned substantially opposite a single corresponding channel; a plurality of flexible segments cooperatively formed by the grooves and the channels, each flexible segment disposed between one of the plurality of grooves and a corresponding one of the plurality of channels and comprising a thickness of between about 0.02 inches and about 0.035 inches; and a plurality of substantially planar elongate panels defined by the flexible segments, each panel comprising a width of between about 1 inch and about 3 inches; wherein each flexible segment is deformable in a first direction to move the lower surfaces of two adjacent panels angularly closer to one another and deformable in a second direction to move the upper surfaces of two adjacent panels angularly closer to one another. ### Claim 11 (depends on 10) The floor mat of claim 10, wherein successive panels are movable relative one another to roll the floor mat into a rolled configuration in which the lower surface of one panel is adjacent to the upper surface of another panel. ### Claim 12 (depends on 10) The floor mat of claim 10, wherein each of the plurality of grooves comprises two sloped surfaces joined to one another at a trough in a substantially V-shaped configuration. ### Claim 13 (depends on 10) The floor mat of claim 10, further comprising a secondary surface covering applied to the upper surface of the unitary, one-piece floor mat. ### Claim 14 (depends on 10) The floor mat of claim 10, wherein each channel comprises a depth of between about 0.06 inches and about 0.08 inches. ### Claim 15 A method of forming a floor mat, the method comprising: extruding a plastic material into a nip region between a pair of rolls, the pair of rolls comprising at least one pattern roll comprising a plurality of projections protruding radially outward from an outer surface of the pattern roll, the plurality of projections extending longitudinally along the pattern roll and being substantially parallel to one another; extracting from the pair of rolls an extruded sheet comprising a plurality of channels formed in a lower surface of the extruded sheet, the plurality of channels reflective of the projections of the pattern roll; passing the extruded sheet through a cooling unit; and cutting the floor mat from the extruded sheet. ### Claim 16 (depends on 15) The method of claim 15, wherein, upon passing the extruded sheet through the cooling unit, a plurality of grooves is formed in an upper surface of the extruded sheet, and each groove is disposed opposite a corresponding channel. ### Claim 17 (depends on 16) The method of claim 16, wherein the pair of rolls comprises the pattern roll and a second roll, and the second roll is free of surface features corresponding to the grooves formed in the upper surface of the extruded sheet. ### Claim 18 (depends on 16) The method of claim 16, wherein a web is formed between each groove and the corresponding channel, and the web comprises a thickness of between about 0.02 inches and about 0.035 inches. ### Claim 19 (depends on 18) The method of claim 18, further comprising selecting a temperature of the cooling unit to control the thickness of the web. ### Claim 20 (depends on 15) The method of claim 15, wherein the projections are spaced from one another circumferentially about the pattern roll, and each projection is spaced from an adjacent projection by a distance of between about 1 inch and about 3 inches.