Note: Descriptions are shown in the official language in which they were submitted.
CA 02579536 2007-02-26
A LAMINATED ANTI-FATIGUE AREA RUG AND METHOD OF
MANUFACTURE
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to the field of laminated materials and more
particularly to a
laminated anti-fatigue rug.
Discussion of the Prior Art
Anti-fatigue carpets are well known in industry and commercial applications
where they
reduce leg and back fatigue from standing over long periods of time. Such rugs
tend to
be rubber or vinyl and do not possess aesthetic qualities that make them
suitable for
residential use. As well, the use of rubber and vinyl products to produce a
cushioning
effect is detrimental to the environment when compared to other materials that
have not
heretofore been used in such applications. Cork is one such material. The
benefits are
using cork as a floor covering include the following:
- Cork trees are stripped of their bark every 9 to 14 years, never cut,
ensuring that
its habitat remains undisturbed. Hence cork is an environmentally benign
material.
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- The natural structure and chemical composition of Cork contribute to its
beneficial properties: insulation, resiliency, impermeability, durability and
hypoallergenic and fire retardant tendencies.
- 90 % of cork tissue is gaseous; hence its density is extremely low,
supporting great
insulation - thermal and acoustic.
- When cork is subjected to pressure, the gas in the cells is compressed and
volume
reduces considerably. When released from pressure, cork recovers very rapidly
to
its original shape.
- The presence of Suberin, an intrinsic waxy substance, renders cork
impervious to
both liquid and gas. As a result, it will not rot and is considered the best
seal
available.
- Cork does not absorb dust, and consequently does not cause or contribute to
allergies.
- Cork is remarkably resilient. It is less affected by impact and friction
than any
other hard surface because of its cellular composition.
- Cork is a natural fire retardant. It does not release toxic gases during
combustion
thus flames will not spread.
- Maintenance is nominal.
However, most floor covering applications using cork are rigid flooring
laminates that
cannot be easily rolled up and stored like a cloth or synthetic carpet.
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Therefore, there is a need for an anti-fatigue rug that has good aesthetics,
is made from
environmentally sound materials and can be rolled for storage.
OBJECTS OF THE INVENTION
It is an object of the present invention to overcome the deficiencies noted in
the prior art.
It is a further object of the present invention to provide an improved anti-
fatigue rug that
is of more ecologically sound construction.
It is still another object of the present invention to provide an anti-fatigue
rug made from
cork that can be rolled and stored like a carpet.
SUMMARY
In one embodiment of the invention there is provided a laminated anti-fatigue
area rug
comprising a bottom laminate of anti-fatigue material having an upper bonding
surface
and a lower contact surface having anti-slip properties for stability. The
invention further
comprises a top laminate of cork having a lower bonding surface and an upper
wearing
surface having a transparent polyurethane coating. The invention still further
comprises a
middle bonding laminate to bond the top layer to the bottom layer.
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In another embodiment of the invention the upper wearing surface may have a
decorative
pattern.
The resulting laminated rug is sufficiently pliable so that it may be rolled
without
resulting in de-lamination or cracking of any laminate.
In one embodiment of the invention the bottom laminate comprises anti-fatigue
rubber
the composition of which is well known in the art of about 7 mm although this
may vary
to suit varies environmental conditions of use. The rubber can be natural or
synthetic
such as nitrile rubber or styrene-butadiene rubber (SBR).
In another embodiment of the invention the bottom laminate is anti-fatigue
vinyl foam
the composition of which is also well known in the art having a thickness of
about 7 mm
depending upon environmental conditions use.
In yet another embodiment of the invention the top laminate is cork comprising
a single
sheet of cork.
In another embodiment of the invention the cork laminate may be constructed
from cork
strips or tiles.
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In still another embodiment of the invention the middle bonding laminate
comprises
bonding material adapted to provide structural strength to the rug and having
anti-
puncture characteristics.
In a preferred embodiment of the invention, the bonding material comprises
reinforcement fiberglass tissue.
In another embodiment of the invention the bonding material comprises
reinforcement
fiberglass roving.
In one embodiment of the invention adhesive material is placed on the top and
the bottom
surfaces of the bonding material.
The constructed rug has a peripheral edge which may be reinforced by carpet
serging or a
strip of cork.
A method of manufacturing a laminated anti-fatigue area rug comprises the
steps of:
a. forming the bottom laminate having a predetermined size from anti-
fatigue material;
b. forming the top laminate having said predetermined size;
c. applying the middle bonding laminate to the lower bonding surface of the
top laminate using an adhesive;
CA 02579536 2007-02-26
d. placing the upper bonding surface of the top laminate into contact with the
middle bonding laminate;
e. trimming the peripheral edge so that it is clean; and,
f. fixing edging to the peripheral edge.
The method further comprises the step of providing a decorative pattern within
the upper
wearing surface of the top laminate.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the invention will
be
apparent from the following more particular description of the preferred
embodiments of
the invention as illustrated in the accompanying drawings in which like
reference
characters refer to the same parts throughout the different views. The
drawings are not
necessarily to scale, emphasis instead being placed upon illustrating the
principles of the
invention.
Figure 1 is a representation of one embodiment of my invention.
Figure 2 is a representation of a natural cork pattern that may be used in one
embodiment
of my invention.
Figure 3 is a representation of another natural cork pattern that may be used
in one
embodiment of my invention.
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Figure 4 is a representation of a human designed pattem that may be used on
one
embodiment of my invention.
Figure 5 is a representation of another human designed pattem that may be used
on one
embodiment of my invention.
Figure 6 is a representation of the laminates of one embodiment of my
invention.
Figure 7 is a representation of the surface patterns possible on one
embodiment of my
invention.
Figure 8 illustrates the patterns of cork tiles than can be used to create
human designs in
one embodiment of my invention.
Figure 9 illustrates the sizes and dimensions of rectangular cork tiles that
may be used in
one embodiment of my invention.
Figure 10 illustrates the sizes and dimensions of square cork tiles that may
be used on one
embodiment of my invention.
Figure 11 is an illustration of one embodiment of my invention with a
reinforcing strip
along its peripheral edge.
Figure 12 is an illustration of one embodiment of my invention using carpet
serging or
cork stripping to reinforce the edge of the rug.
DETAILED DESCRIPTION
Referring to Figure 1, my invention (10) is a laminated anti-fatigue area rug
comprising a
bottom laminate of anti-fatigue material (12) having an upper bonding surface
(14) and a
lower contact surface (16) having anti-slip properties for stability. My
invention further
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comprises a top laminate (18) of cork having a lower bonding surface (20) and
an upper
wearing surface (22) having a transparent polyurethane coating (24). The upper
wearing
surface (22) may have a decorative pattern (26 & 28) as illustrated in Figures
2 and 3
wherein the pattern is a natural cork pattern. As illustrated in Figures 4 and
5 the pattern
can be human designed (30 & 32).
Still referring to Figure 1, there further included a middle bonding laminate
(34) adapted
to bond the top layer to the bottom layer.
The laminated cork rug of my invention is sufficiently pliable so that it may
be rolled
without resulting in de-lamination or cracking of any laminate.
Referring to Figure 6, my invention is shown in a cut-away format with the
upper
surfaces of the laminates exposed. The bottom laminate (12) comprises anti-
fatigue
rubber the composition of which is well known in the art. Generally the
thickness of the
bottom laminate is about 7 mm although this may vary to suit varies
environmental
conditions of use. Rubber is recommended for commercial or industrial use
because of
its durable wear. Alternatively, the bottom laminate comprises anti-fatigue
vinyl foam
the composition of which is also well known in the art. The thickness of the
vinyl form is
also of about 7 mm depending upon environmental conditions use. Vinyl foam is
recommended for residential use because it gives the rug a softer feel. Both
the rubber
and vinyl bottom laminates are selected for their anti-slip characteristics
and their ability
to enhance the stability of the construction of the rug. The rubber used is
synthetic
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rubber such as styrene-butadiene rubber (BSR) or nitrile rubber. The rubber
laminate has
a textured bottom surface (16) for anti-slip resistance.
Referring to Figure 7, the top laminate of cork may be is comprised of a
single sheet of
cork (40). In another embodiment of the invention, the top laminate of cork
may be
comprised of a plurality cork strips (42). In yet another embodiment of the
invention the
top laminate of cork may be comprised of rectangular cork tiles (44) joined
together by
joining means. Patterns can be applied to the cork surface. Typically a human-
designed
pattenrn as illustrated in Figures 4 & 5 is applied using a mosaic of a
plurality of
individual cork tiles of various shapes (46) as illustrated in Figure 8.
Referring to Figure 9, cork strips are available in a variety of sizes to
create the desired
visual effect.
Referring to Figure 10, cork tiles are also available in a variety of sizes to
create the
desired visual effect.
When tiles are used as illustrated in Figure 10 with the effect shown in
Figure 7, Item 44,
the tiles are joined by joining means comprising a first bead of contact
cement placed on
a first edge of a first rectangular cork tile of and a second bead of contact
cement placed
on a second adjoining edge of a second rectangular cork tile. When the tiles
are joined a
seam is formed between them. The seam is covered by a strip of thin fiberglass
tape and
then the strip of thin fiberglass tape is sealed with a coat of sealant.
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Referring to Figure 1 and Figure 6, the middle bonding laminate (34) comprises
bonding
material adapted to provide structural strength to the rug and having anti-
puncture
characteristics. In a preferred embodiment of the invention, the bonding
material
comprises reinforcement fiberglass tissue. In another embodiment of the
invention the
bonding material comprises reinforcement fiberglass roving. Adhesive material
is placed
on the top (60) and the bottom (62) surfaces of the bonding material. In one
embodiment
of the invention the adhesive material is contact cement. In the preferred
embodiment,
the contact cement is environmentally benign having a water base. In another
embodiment of the invention where a rubber latex bottom laminate is used, the
appropriate bonding material is latex-based cement.
Referring to Figure 11 and Figure 12, my rag (10) includes a peripheral edge
(66) that is
reinforced by edging (68). In one embodiment of the invention the edging is
carpet
serging (70). In another embodiment of the invention the edging is a strip of
cork (72).
A method of manufacturing a laminated anti-fatigue area rng comprising a
bottom
laminate of anti-fatigue material having an upper bonding surface and a lower
contact
surface having anti-slip properties for stability; a top laminate of cork
having a lower
bonding surface and an upper wearing surface coated with a polyurethane
coating; a
middle bonding laminate adapted to bond the top layer to the bottom layer;
and, a
peripheral edge; comprises the steps of:
CA 02579536 2007-02-26
a. forming the bottom laminate having a predetermined size from anti-
fatigue material;
b. forming the top laminate having said predetermined size;
c. applying the middle bonding laminate to the lower bonding surface of the
top laminate using an adhesive;
d. placing the upper bonding surface of the top laminate into contact with the
middle bonding laminate;
e. trimming the peripheral edge so that it is clean; and,
f. fixing edging to the peripheral edge.
The method further comprises the step of providing a decorative pattein within
the upper
wearing surface of the top laminate.
Although the description above contains much specificity, these should not be
construed
as limiting the scope of the invention but as merely providing illustrations
of some of the
presently preferred embodiments of this invention. Thus the scope of the
invention
should be determined by the appended claims and their legal equivalents.
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