Note: Descriptions are shown in the official language in which they were submitted.
EXERCISE MAT HAVING A THREE-DIMENSIONAL SURFACE
TEXTURE
TECHNICAL FIELD
[0001] This application relates to the field of mats, and more specifically,
to exercise mats and the
like.
BACKGROUND
[0002] Consumers are demanding improved mats for yoga and other activities.
One problem with
existing mats is that they often provide inadequate support for a user's body.
Another problem is
that the upper surface or face of existing mats is often slippery. A further
problem with existing
.. mats is that they are often heavy and hard to roll-up or otherwise
transport especially thicker mats
that do provide adequate support.
SUMMARY OF THE APPLICATION
[0003] In one aspect, an exercise mat having a three-dimensional surface
texture is provided. The
exercise mat may have a first malleable layer formed from a polyurethane
material with an elastic
fabric material attached to a lower surface thereof. A second layer may be
attached to the elastic
fabric material of the first layer. The second layer may be formed from a
thermoplastic elastomer
material and may have the three-dimensional surface texture formed on an upper
surface thereof
to which the first layer conforms. The exercise mat may also include a third
rubber layer attached
to the second layer. In another aspect, methods for making an exercise mat
having a three-
dimension surface texture are provided.
[0004] In addition to the aspects and embodiments described above, further
aspects and
embodiments will become apparent by reference to the drawings and study of the
following
detailed description.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Throughout the drawings, reference numbers may be re-used to indicate
correspondence
between referenced elements. The drawings are provided to illustrate example
embodiments
described herein and are not intended to limit the scope of the application.
Sizes and relative
positions of elements in the drawings are not necessarily drawn to scale. For
example, the shapes
of various elements and angles may be not drawn to scale, and some of these
elements may be
arbitrarily enlarged and positioned to improve drawing legibility.
[0006] FIG. 1 is a top view illustrating an example exercise mat having a
three-dimensional
surface texture, the exercise mat shown in a flat or rolled-out position.
[0007] FIG. 2 is a left side view thereof, the right side view being a minor
image thereof.
[0008] FIG. 3 is a perspective view thereof, the exercise mat shown in a
partially rolled-up
position.
[0009] FIG. 4 is a left side detail view illustrating a portion of the left
side of the exercise mat of
FIG. 1.
[0010] FIG. 5 is perspective view thereof.
[0011] FIG. 6 is a top view illustrating an example exercise mat having
another three-dimensional
surface texture, the exercise mat shown in a flat or rolled-out position.
[0012] FIG. 7 is a perspective view thereof.
[0013] FIG. 8 is a right side detail view illustrating a portion of the right
side of the exercise mat
of FIG. 6.
[0014] FIG. 9 is an exploded view thereof.
[0015] FIG. 10 is a block diagram illustrating an example vacuum embossing
machine.
[0016] FIG. 11 is a perspective view illustrating an example exercise mat
having contoured edges.
[0017] FIG. 12 is a cross-sectional perspective detail view thereof.
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DETAILED DESCRIPTION
[0018] In the following description, details are set forth to provide an
understanding of the
application. In some instances, certain structures, techniques, and methods
have not been described
or shown in detail in order not to obscure the application.
[0019] FIG. 1 is a top view illustrating an example exercise mat 100 having a
three-dimensional
surface texture 170, 500, the exercise mat 100 shown in a flat or rolled-out
position 1001. FIG. 2
is a left side view thereof, the right side view being a mirror image thereof.
FIG. 3 is a perspective
view thereof, the exercise mat 100 shown in a partially rolled-up position
1002. FIG. 4 is a left
side detail view illustrating a portion of the left side 110 of the exercise
mat 100 of FIG. 1. FIG. 5
is perspective view thereof. FIG. 6 is a top view illustrating an example
exercise mat 100 having
another three-dimensional surface texture 170, 700, the exercise mat 100 shown
in a flat or rolled-
out position 1001. FIG. 7 is a perspective view thereof. FIG. 8 is a right
side detail view illustrating
a portion of the right side 120 of the exercise mat 100 of FIG. 6. FIG. 9 is
an exploded view thereof.
FIG. 10 is a block diagram illustrating an example vacuum embossing machine
900. FIG. 11 is a
perspective view illustrating an example exercise 100 mat having contoured
edges 1125. And,
FIG. 12 is a cross-sectional perspective detail view thereof.
[0020] FIGS. 1 to 9, 11, and 12 illustrate an exercise mat 100 according to
embodiments of the
application. The exercise mat 100 may be placed on a flat surface or floor 300
by a user to provide
cushioning, grip, support, or stability, or any combination thereof, allowing
the user to more easily
and effectively perform yoga or other exercises. The exercise mat 100 may be
used in the flat,
unrolled, or rolled-out position 1001 and may be transported in the rolled or
rolled-up position
1002. The exercise mat 100 may comprise several layers 400 of varying
materials and structures
disposed atop one another as will be further described below.
[0021] FIG. 1 and 6 are top views of the example exercise mat 100. According
to one embodiment,
the exercise mat 100 is rectangular in shape and has a first or left side 110,
a second or right side
120, a third or upper side 130, a fourth or lower side 140, a top surface 150,
and a bottom surface
160. These views show a rectangular exercise mat 100 of sufficient size to
support a typical user's
body through a wide range of yoga positions. Example sizes may include, but
are not limited to, a
width of 66 cm or approximately 66 cm and a length of 180 cm or approximately
180 cm. FIGS.
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and 8 are side views of the exercise mat 100. As illustrated in FIGS. 5 and 8,
the thickness of the
exercise mat 100 can be significantly less than its length and width. Example
thicknesses may
include, but are not limited to, a thickness of 5 mm or approximately 5 mm.
Note that all of the
dimensions provided herein are for illustration purposes only and persons
skilled in the art would
5 understand that the mat 100 may be longer/wider/thicker or
shorter/narrower/thinner than the
example dimensions provided without departing from the scope of the
application. Although a
rectangular exercise mat 100 is shown in FIGS. 1 to 9, 11, and 12, it will be
understood to one
skilled in the art that the exercise mat 100 may be differently shaped, such
as being a square,
triangle, circle, or oval, or any other shape or design.
[0022] The exercise mat 100 has a three-dimensional texture 170 embossed,
molded, or formed in
the top surface 150. In FIGS. 1-5, the three-dimensional texture 170 has a
horizontal ridged pattern
500 that may extend, for example, from 0 to 2.5 mm or approximately 0 to 2.5
mm below the top
surface 150. In FIGS. 6-8, the three-dimensional texture 170 has a water drop
wave pattern 700
that may extend, for example, from 0 to 3 mm or approximately 0 to 3 mm below
the top surface
150. In FIGS. 11-12, the three-dimensional texture 170 further includes a
tidal flow wave pattern
1500 that may extend, for example, from 0 to 2 mm or approximately 0 to 2 mm
below the top
surface 150. Although ridged, water drop wave, and tidal flow wave patterns
500, 700, 1500 are
shown in FIGS. 1 to 9, 11, and 12, it will be understood by one skilled in the
art that the three-
dimensional texture 170 of the top surface 150 of the exercise mat 100 may
have any other pattern,
shape, or design. The three-dimensional texture 170 can provide tactile
feedback enabling a user
to determine their position, such as the location and/or direction of the user
with respect to the
exercise mat 100. In addition, the three-dimensional texture 170 can enhance
the support (e.g., grip
and/or slip) properties of the exercise mat 100. According to one embodiment,
the exercise mat
100 may have three layers 410, 420, 430. The three layers 410, 420, 430 are
separated in FIG. 9 to
illustrate their arrangement. It should be noted that although three layers
410, 420, 430 are shown
and described herein, in some embodiments, only one or two of the layers 400
may be used. In
addition, in some embodiments, additional layers 400 may be added to the
first, second, or third
layers 410, 420, 430 that are shown and described.
[0023] According to one embodiment, the top or first layer 410 is a malleable
layer having an
upper surface 411 and a lower surface 412. The first layer 410 is formed from
a polyurethane
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("PU") material. An elastic fabric material 440 may be attached to the PU
material over the lower
surface 412 of the first layer 410. According to one embodiment, the elastic
fabric material 440
may be a four-way stretch nylon material. Note that the upper surface 411 of
the first layer 410
corresponds to the top surface 150 of the exercise mat 100.
[0024] The first layer 410 may be formed of a material that absorbs or wicks
away moisture,
keeping the first layer 410 dry during exercise. The first layer 410 may
provide a level of friction
that gives sufficient grip (e.g., in wet and/or dry conditions) to a user
without restricting the user's
movement. The first layer 410 may also be made of a suitable material which
can help the exercise
mat 100 hold its shape, provide cushioning, provide flexibility, or provide
support, or any
combination thereof; or a material that bonds well with other exercise mat
layers 400; or any
combination thereof.
[0025] According to one embodiment, the middle or second layer 420 has an
upper surface 421
and a lower surface 422. The upper surface 421 of the second layer 420 is
attached to the elastic
fabric material 440 on the lower surface 412 of the first layer 410. The
second layer 420 is formed
from a thermoplastic elastomer ("TPE") material. The upper surface 421 of the
second layer 420
has a three-dimensional texture 175 molded, embossed, or formed thereon. As
the first layer 410
is a malleable layer, it conforms to the three-dimensional texture 175 of the
upper surface 421 of
the second layer 410 and hence the three-dimensional texture 175 of the second
layer 420 defines
the three-dimensional texture 170 of the top surface 150 of the exercise mat
100.
[0026] The second layer 420 may provide structural integrity and cushioning
for the exercise mat
100. The second layer 420 may be made of a suitable material which can help
the exercise mat
100 hold its shape, provide cushioning, provide flexibility, or provide
support, or any combination
thereof; or a material that bonds well with other exercise mat layers 400; or
any combination
thereof. In addition, the three-dimensional texture 170 can provide tactile
feedback allowing a user
to determine their position, such as the location and/or direction of the user
on the exercise mat
100.
[0027] According to one embodiment, the bottom or third layer 430 has an upper
surface 431 and
a lower surface 432. The upper surface 431 of the third layer 430 is attached
to the lower surface
422 of the second layer 420. The third layer 430 is formed from a rubber
material. According to
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Date Recue/Date Received 2020-10-22
one embodiment, the exercise mat 100 may further include a polyester cotton
cloth material 450
sandwiched between the second and the third layers 420, 430. Note that the
lower surface 432 of
the third layer 410 corresponds to the bottom surface 160 of the exercise mat
100.
[0028] The third layer 430 may provide friction and/or traction (e.g., in wet
and/or dry conditions),
so that when it is placed in contact with the floor 300 by a user, the
exercise mat 100 does not slide
when the user uses the exercise mat 100 (e.g., for yoga or another exercise).
The third layer 430
may also provide cushioning for a user of the exercise mat 100. In some
embodiments, the third
layer 430 may be provided with a textured surface to enhance grip. In some
embodiments, the third
layer 430 may also be made of a suitable material which can help the exercise
mat 100 hold its
.. shape, provide cushioning, provide flexibility, provide wear and tear
resistance, or provide support,
or any combination thereof; or a material that bonds well with other exercise
mat layers 400; or
any combination thereof. The third layer 430 may also be perforated (e.g.,
with punched holes) to
allow moisture to pass through and for quick drying of the exercise mat 100.
It should be noted
that any of the layers 400 described herein may also be perforated.
[0029] According to one embodiment, as illustrated in FIGS. 5 and 8, the
thickness of the exercise
mat 100 may be 5 mm or approximately 5 mm. The third layer 430 may be 2 mm or
approximately
2 mm thick and the first and second layers 410, 420 may be 3 mm or
approximately 3 mm thick at
the highest point of the three-dimensional texture pattern 170. Of course, the
exercise mat 100 and
its various layers 400 may have other thicknesses as well to achieve different
flexibility or
cushioning requirements for the exercise mat 100.
[0030] Advantageously, use of the three-dimensional texture pattern 170
reduces the weight of the
exercise mat 100, reduces the size (i.e., outside diameter) of the exercise
mat 100 when in the
rolled-up position 1002, improves the grip and moisture management properties
of the exercise
mat 100, improves the tactile sensation/feedback and stability of the exercise
mat 100, and
maintains the same level of cushioning or approximately the same level of
cushioning as prior
exercise mats not having three-dimensional texture patterns.
[0031] The various layers 400 described above may be attached to one another
using any suitable
technique or method. In one embodiment, the layers may have thermoplastic
bonding properties
that cause adjacent layers to bond with one another when heated.
Alternatively, the layers 400 may
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be bonded using adhesives and/or mechanical connections. In addition, any
combination of these
methods or any other method may be used.
[0032] According to one embodiment, the exercise mat 100 may be made using a
vacuum
embossing machine 900 such as that shown in FIG. 10. The vacuum embossing
machine 900 may
include a mold plate 910 having an embossed top surface 920. The embossed top
surface 920 may
have a female version of the three-dimensional surface texture embossed
thereon to form a male
version of the three-dimension surface texture 170 on the final exercise mat
100. An example
method for making an exercise mat 100 having a three-dimensional surface
texture 170 using the
vacuum embossing machine 900 may include the following steps.
[0033] First, a first layer 410 of the exercise mat 100 is prepared by pouring
liquid polyurethane
onto an elastic fabric 440 and curing the polyurethane. Second, a second layer
420 that comprises
a thermoplastic elastomer is attached to a fabric side 412 of the first layer
410. Third, a mat made
from the first and second layers 410, 420 is cut to a desired size and shape.
Fourth, the mat is
positioned on a mold plate 910 having an embossed top surface 920 with a
polyurethane side 411
of the first layer 410 facing the embossed top surface 920, the embossed top
surface 920 being
embossed with a predetermined three-dimensional surface texture.
[0034] Fifth, the mold plate 910 is inserted into a vacuum embossing machine
900 and the mat is
heated, for example, for two minutes or approximately two minutes at a
temperature of 170 degrees
Celsius or approximately 170 degrees Celsius. Alternatively, the mat 100 may
be heated, for
example, for 1 to 15 minutes at a temperature of 120 to 200 degrees Celsius
and with a certain or
predetermined suction pressure provided by the embossing machine 900. Sixth,
the mat is cooled
for 5 minutes or approximately 5 minutes to produce the final exercise mat
100. In the above
method, the temperature and suction provided by the vacuum embossing machine
900 softens the
thermoplastic elastomer of the second layer 420 conforming it to the
predetermined three-
dimensional surface texture of the embossed top surface 920 of the mold plate
910 and forms a
corresponding predetermined three-dimensional surface texture 170 through the
polyurethane side
411 of the first layer 410. The method may further include attaching a third
layer 430 that
comprises a rubber material to the second layer 420.
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[0035] As illustrated in FIGS. 11 and 12, the exercise mat 100 has a central
portion 1110 and one
or more edge portions (e.g., 1130) extending from the central portion 1100 to
respective edges
(e.g., 1120) of the exercise mat 100. The edges (e.g., 1120) may be proximate
the sides (e.g., 120)
of the exercise mat 100. According to one embodiment, at least one edge
portion 1130 of the
exercise mat 100 may be beveled, chamfered, or otherwise contoured 1135 to
form a contoured
edge portion or contoured edge 1125. For example, the thickness of the
exercise mat 100 may
gradually reduce 1135 from a greater thickness 1111 in the central portion
1110 of the exercise
mat 100 across the edge portion 1130 to a lesser thickness 1121 at the edge
1120 of the exercise
mat 100 to form the contoured edge 1125. As another example, the thickness of
the second layer
420 of the exercise mat 100 may gradually reduce 1135 from a greater thickness
1111 in the central
portion 1110 of the exercise mat 100 across the edge portion 1130 to a lesser
thickness 1121 at the
edge 1120 of the exercise mat 100 to form the contoured edge 1125. The second
layer 420 may be
eliminated or reduced to zero thickness at or proximate the edge 1120. As a
further example, the
second layer 420 may reduce in thickness 1130 from 3 mm or approximately 3 mm
in the central
.. portion 1110 of the exercise mat 100 to 1 mm or approximately 1 mm at the
edge 1120 of the
exercise mat 100 to form the contoured edge 1125. Advantageously, the
contoured edges 1125
reduce the possibility of a user or other person tripping over the mat 100
when in use. In addition,
the contoured edges 1125 increase the sense of flow between the exercise mat
100 and the
surrounding environment or floor 300.
[0036] While particular elements, embodiments and applications of the present
application have
been shown and described, it will be understood, that the scope of the
application is not limited
thereto, since modifications can be made by those skilled in the art without
departing from the
scope of the present application, particularly in light of the foregoing
teachings. Thus, for example,
in any method or process disclosed herein, the acts or operations making up
the method/process
may be performed in any suitable sequence and are not necessarily limited to
any particular
disclosed sequence. Elements and components can be configured or arranged
differently,
combined, and/or eliminated in various embodiments. The various features and
processes
described above may be used independently of one another, or may be combined
in various ways.
All possible combinations and subcombinations are intended to fall within the
scope of this
application. Reference throughout this disclosure to "some embodiments," "an
embodiment," or
the like, means that a particular feature, structure, step, process, or
characteristic described in
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Date Recue/Date Received 2020-10-22
connection with the embodiment is included in at least one embodiment. Thus,
appearances of the
phrases "in some embodiments," "in an embodiment," or the like, throughout
this disclosure are
not necessarily all referring to the same embodiment and may refer to one or
more of the same or
different embodiments. Indeed, the novel methods and systems described herein
may be embodied
in a variety of other forms; furthermore, various omissions, additions,
substitutions, equivalents,
rearrangements, and changes in the form of the embodiments described herein
may be made
without departing from the spirit of the application.
[0037] Various aspects and advantages of the embodiments have been described
where
appropriate. It is to be understood that not necessarily all such aspects or
advantages may be
achieved in accordance with any particular embodiment. Thus, for example, it
should be
recognized that the various embodiments may be carried out in a manner that
achieves or optimizes
one advantage or group of advantages as taught herein without necessarily
achieving other aspects
or advantages as may be taught or suggested herein.
[0038] Conditional language used herein, such as, among others, "can,"
"could," "might," "may,"
"e.g.," and the like, unless specifically stated otherwise, or otherwise
understood within the context
as used, is generally intended to convey that certain embodiments include,
while other
embodiments do not include, certain features, elements and/or steps. Thus,
such conditional
language is not generally intended to imply that features, elements and/or
steps are in any way
required for one or more embodiments or that one or more embodiments
necessarily include logic
for deciding, with or without operator input or prompting, whether these
features, elements and/or
steps are included or are to be performed in any particular embodiment. No
single feature or group
of features is required for or indispensable to any particular embodiment. The
terms "comprising,"
"including," "having," and the like are synonymous and are used inclusively,
in an open-ended
fashion, and do not exclude additional elements, features, acts, operations,
and so forth. Also, the
term "or" is used in its inclusive sense (and not in its exclusive sense) so
that when used, for
example, to connect a list of elements, the term "or" means one, some, or all
of the elements in the
list.
[0039] The example calculations, simulations, results, graphs, values, and
parameters of the
embodiments described herein are intended to illustrate and not to limit the
disclosed
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Date Recue/Date Received 2020-10-22
embodiments. Other embodiments can be configured and/or operated differently
than the
illustrative examples described herein.
Date Recue/Date Received 2020-10-22
