# Patent

## Title
Methods for making an exercise mat

## Abstract

Methods for making an exercise mat, comprising: preparing at least one first layer, the at least one first layer comprising polyurethane; and preparing at least one second layer, the at least one second layer comprising at least one thermoplastic elastomer.

## Background
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application No. 61/467,233, filed Mar. 24, 2011 which is incorporated by reference in its entirety.


BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A depicts a top-down view of an exercise mat, according to an embodiment of the present invention.
FIG. 1B depicts a side view of an exercise mat, according to an embodiment of the present invention.
FIGS. 2-3 depict embodiments of an exercise mat with three structural layers, according to one embodiment of the present invention.


DESCRIPTION OF EMBODIMENTS OF THE INVENTION
FIGS. 1A and 1B depict an exercise mat 100, according to an embodiment of the present invention. The exercise mat 100 may be placed on a flat surface by a user to provide cushioning, grip, support, or stability, or an combination thereof, allowing the user to more easily and effectively perform yoga or other exercises. The exercise mat 100 can comprise several layers of varying materials and structures disposed atop one another. FIG. 1A is a top view of the exercise mat 100. This view depicts 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, widths of 26 inches to 30 inches and lengths of 70 inches to 78 inches. Although a rectangular exercise mat 100 is shown in FIG. 1A, it should be noted that the exercise mat 100 may have other shapes, such as a square, circle, or oval, or any other shape or design.
FIG. 1B is a side view of the exercise mat 100. As illustrated in FIG. 1B, 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, thicknesses of 2.0 mm to 7.0 mm.
FIG. 2 is a view of an exercise mat 100 with three layers, according to one embodiment of the present invention. The three layers are separated in FIG. 2 to illustrate their arrangement. It should be noted that although three layers are explained with respect to FIG. 2, in some embodiments only one or two of the layers may be used. In addition, in some embodiments, additional layers may be added to the one, two, or three layers that are pictured.
The exercise mat 100 can comprise a top layer 210. In some embodiments, the top layer 210 can have an open cell structure. This structure can allow the top layer 210 to absorb or wick away moisture, keeping the top layer 210 dry during exercise. The top layer 210 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 top layer 10 may be made of: polyurethane; another suitable flexible material such as a woven or non woven polyester/polyurethane blend fabric made with nano fibers; or micro fibers with wicking properties; thermoplastic elastomer (TPE); natural rubber; synthetic rubber; or any combination thereof. The top layer 210 may also be treated with an antimicrobial agent. Examples of antimicrobial agents include silver based antimicrobial or 3-trimethoxy silyl propyl dimethyl octadecyl ammonium chloride, but other antimicrobial agents may also be employed. (It should be noted that any layer of any mat described herein may also be treated with an antimicrobial agent.) The top layer 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 100 layers; or any combination thereof. In one embodiment, the top layer 210 may be 0.35 to 0.95 millimeters thick, although this may vary in other embodiments to achieve different flexibility or cushioning requirements for the exercise mat 100.
The exercise mat 100 of the embodiment in FIG. 2 can have a middle layer 220. The middle layer 220 can provide structural integrity and cushioning for the exercise mat 100. The middle layer 220 may be made of, for example: a non-woven polyester cotton blended fabric; a 50% polyester 50% cotton blend; a woven or non woven fabric made of either 100% cotton or 100% polyester or a blend of cotton and polyester; thermoplastic elastomers; a polyvinyl chloride; polyurethane; a foam material made of natural rubber, synthetic rubber, or nylon spandex, or any combination thereof; 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 100 layers; or any combination thereof. In some embodiments of the invention, the middle layer 220 may be 0.2-2.0 millimeters thick, although this may vary in other embodiments with different flexibility or cushioning requirements for the exercise mat 100.
The exercise mat 100 of the embodiment in FIG. 2 can also have a bottom layer 230. This bottom layer 230 can provide friction and/or traction (e.g., in wet and/or dry conditions), so that when it is placed in contact with a floor by a user, the exercise mat 100 does not slide when the user utilizes the exercise mat 100 (e.g., for yoga or another exercise). The bottom layer 230 can also provide cushioning for a user of the exercise mat 100. In some embodiments, the bottom layer 230 may be provided with a textured surface to enhance grip. The bottom layer 230 may be made of a thermoplastic elastomer, polyvinyl chloride, polyurethane, natural rubber, synthetic rubber or another material which provides cushioning and/or grip, or any combination thereof. In other embodiments, the bottom layer 230 may be made of rubber, including natural rubber, synthetic rubber, or a blend of the two, or mix of natural rubber, synthetic rubber and thermoplastic elastomers as well as the above-mentioned materials, or any combination thereof. In some embodiments, the bottom layer 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 100 layers; or any combination thereof. The bottom layer 230 may also be perforated (e.g., with punched holes as shown in FIG. 3) to allow moisture to pass through and for quick drying of exercise mat 100. (It should be noted that any layers described herein may also be perforated.) In one embodiment, the bottom layer 230 may be 1.5 to 5.5 millimeters thick, although this may vary in other embodiments with different flexibility or cushioning requirements for the exercise mat 100.
Note that the terms “top layer” and “bottom layer” in the embodiments above are used for ease of explanation only Either the top layer 210 or the bottom layer 230 may be placed in contact with a floor by a user, with the opposite side forming an exercise surface for the user. This may allow a user to use different layer characteristics to enhance different exercises and/or to suit personal preferences. For example, a user may use the top layer 210, which may have moisture absorbing and/or antimicrobial properties, as an exercise surface when the user anticipates sweating. The user may use the bottom layer 230, which may have high friction and/or cushioning properties, as an exercise surface when the user does not anticipate sweating.
The various layers described above may be bonded to one another using any suitable bonding technique. In one embodiment, the layers may have thermoplastic bonding properties that cause adjacent layers to bond with one another when heated. In one example heat bonding process, liquid polyurethane may be cured on non woven fabric and rubber may be vulcanized on the other side of the non woven fabric at or near, for example, 180 degrees Celsius. In another bonding process, liquid polyurethane may be cured on non woven fabric and a thermoplastic elastomer may be glued to the other side of the non woven fabric with a non toluene lamination adhesive (e.g., a non-toluene lamination adhesive, such as but not limited to 635NT) and/or other suitable adhesive. Alternatively, layers may be bonded using other adhesives and/or mechanical connections. In addition, any combination of these methods or any other method may be utilized.
In some embodiments, the exercise mat 100 can also be made by preparing a top layer and a bottom layer. The top layer is made by pouring a liquid form of polyurethane into a mold. The bottom layer may be made by passing a thermoplastic elastomer through a calendaring process (e.g., to be mixed and/or flattened) and/or a vulcanization process. The top layer and the bottom layer may then be passed through an oven so the thermoplastic elastomer laminates to the polyurethane to make the mat material. The mat material may then be rolled and/or cut into desired shape(s). The mat material and/or exercise mat 100 may be aired for a certain time period (e.g., to remove the rubber smell).
In some embodiments, the liquid form of polyurethane may be poured onto a middle layer comprising fabric (e.g., woven, non-woven), and the top layer, the middle layer, and the bottom layer may be passed through the oven so the thermoplastic elastomer laminates to the fabric.
Various Embodiments
The following embodiments are some of many embodiments that can be utilized.
In some embodiments, the exercise mat can comprise: at least one top layer, the at least one top layer comprising polyurethane; and at least one bottom layer adjacent to the at least one top layer, the at least one bottom layer comprising at least one thermoplastic elastomer. The exercise mat can also further comprise at least one middle layer disposed between the at least one top layer and the at least one bottom layer. Additionally, the at least one top layer of the exercise mat can also comprise: polyurethane; texture; at least one antimicrobial agent; or at least one open cell structure; or any combination thereof. The at least one middle layer of the exercise mat can also comprise: polyurethane; polyester nano fibers; polyester microfibers; non-woven fabric; at least one open cell structure; rubber foam material; woven fabric; cotton material; polyester material; at least one thermoplastic elastomer; polyvinyl chloride material; perforations; or at least one antimicrobial agent; or any combination thereof. The at least one bottom layer of the exercise mat can also comprise: texture; perforations; synthetic rubber; natural rubber; a polynivyl chloride, plyurethane, or at least one antimicrobial agent; or any combination thereof. Additionally, the at least top one layer is operable as an exercise surface and as a floor contact surface; and/or the at least one bottom layer is operable as an exercise surface and as a floor contact surface.
In other embodiments, the exercise mat can comprise: at least one top layer made of polyurethane and having at least one open cell structure, wherein the at least one top layer comprises at least one antimicrobial agent; at least one perforated bottom layer comprising at least one thermoplastic elastomer; and at least one middle layer comprising at least one woven polyester cotton blended fabric disposed between the at least one top layer and the at least one bottom layer. The at least one middle layer can also comprise: polyurethane; polyester nano fibers; polyester microfibers; nonwoven fabric; woven fabric; at least one open cell structure; rubber foam material; cotton material; polyester material; cotton polyester blend material; at least one thermoplastic elastomer; polyvinyl chloride material; perforations; or at least one antimicrobial agent; or any combination thereof. The at least one bottom layer can comprises: texture; synthetic rubber; natural rubber; at least one antimicrobial agent; or any combination thereof. Additionally, the at least top one layer can be operable as an exercise surface and as a floor contact surface; and/or the at least one bottom layer can be operable as an exercise surface and as a floor contact surface.
In other embodiments, the exercise mat can comprise: at least one top layer, the at least one top layer comprising polyurethane; and at least one bottom layer adjacent to the at least one top layer, the at least one bottom layer comprising at least one synthetic rubber and at least one natural rubber. The exercise mat can further comprise at least one middle layer disposed between the at least one top layer and the at least one bottom layer. The at least one top layer can also comprise; at least one antimicrobial agent; or at least one open cell structure; or any combination thereof. The at least one middle layer can also comprise: polyurethane; polyester nano fibers; polyester microfibers; non-woven fabric; at least one open cell structure; rubber foam material; woven fabric; cotton material; polyester material; at least one thermoplastic elastomer; polyvinyl chloride material; perforations; or at least one antimicrobial agent; or any combination thereof. The at least one bottom layer can also comprise: texture; perforations; synthetic rubber; natural rubber; or at least one antimicrobial agent; or any combination thereof. The at least one top layer can be operable as an exercise surface and as a floor contact surface; and/or the at least one bottom layer can be operable as an exercise surface and as a floor contact surface.
In other embodiments, the exercise mat can comprise: at least one top layer having at least one open cell structure, wherein the at least one top layer comprises at least one antimicrobial agent; at least one perforated bottom layer comprising at least one thermoplastic elastomer; and at least one middle layer comprising at least one woven polyester cotton blended fabric disposed between the at least one top layer and the at least one bottom layer. The at least one middle layer can also comprise: polyurethane; polyester nano fibers; polyester microfibers; non-woven fabric; at least one open cell structure; rubber foam material; at least one thermoplastic elastomer; polyvinyl chloride material; perforations; or at least one antimicrobial agent; or any combination thereof. The at least one bottom layer can also comprise: texture; synthetic rubber; natural rubber; at least one antimicrobial agent; or any combination thereof. The at least top one layer can be operable as an exercise surface and as a floor contact surface; and/or the at least one bottom layer can be operable as an exercise surface and as a floor contact surface.
In some embodiments, a method for making an exercise mat can comprise: pouring at least one polyurethane layer; pouring at least one layer comprising synthetic rubber and natural rubber; and utilizing heat bonding to connect the at least one polyurethane layer and the at least one layer comprising synthetic rubber and natural rubber. The heat bonding can be done utilizing a continuous laminating process. Glue may not need to be utilized to connect the at least one polyurethane layer and the at least one layer comprising synthetic rubber and natural rubber. The at least one polyurethane layer can be cured on one side of non-woven fabric and the at least one layer comprising synthetic rubber and natural rubber can be vulcanized on an opposite side of the non-woven fabric. The vulcanization can be done at or near 180 Celsius.
In other embodiments, a method for making an exercise mat can comprise: pouring at least one polyurethane layer; pouring at least one thermoplastic layer; and utilizing at least one laminate to connect the at least one polyurethane layer and the at least one thermoplastic layer.
The at least one laminate can be at least one non-toluene lamination adhesive. The at least one polyurethane layer can be cured on one side of non-woven fabric and the at least one thermoplastic layer can be laminated on an opposite side of the non-woven fabric.
In some embodiments, a method for making an exercise mat can comprise: preparing at least one top layer comprising at least one liquid form of polyurethane, the at least one liquid form of polyurethane being poured into at least one mold; preparing at least one bottom layer comprising at least one thermoplastic elastomer, the at least one thermoplastic elastomer being passed through at least one calendaring process; and preparing the mat material by passing the at least one top layer and the at least one bottom layer through at least one oven so the at least one thermoplastic elastomer laminates to the at least one polyurethane. The at least one liquid form of polyurethane can be poured onto at least one middle layer comprising fabric, and the at least one top layer, the at least one middle layer, and the at least one bottom layer can be passed through the at least one oven so the at least one thermoplastic elastomer laminate to the fabric to make the mat material. The fabric can be woven or non-woven. The at least one thermoplastic elastomer can be passed through the at least one calendaring process in order to be mixed and/or flattened. The thermoplastic elastomer can vulcanize.
While various embodiments have been described above, it should be understood that they have been presented by way of example, and not limitation. It will be apparent to persons skilled in the relevant art(s) that various changes in form and detail can be made therein without departing from the spirit and scope. In fact, after reading the above description, it will be apparent to one skilled in the relevant art(s) how to implement alternative embodiments. Thus, the present embodiments should not be limited by any of the above-described embodiments.
In addition, it should be understood that any figures which highlight the functionality and advantages, are presented for example purposes only. The disclosed methodology and system are each sufficiently flexible and configurable, such that it may be utilized in ways other than that shown.
Although the term “at least one” may often be used in the specification, claims and drawings, Applicant notes that the terms “a”, “an”, “the”, “said”, etc. also signify “at least one” or “the at least one” in the specification, claims and drawings.
Finally, it is the applicant's intent that only claims that include the express language “means for” or “step for” be interpreted under 35 U.S.C. 112, paragraph 6.Claims that do not expressly include the phrase “means for” or “step for” are not to be interpreted under 35 U.S.C. 112, paragraph 6.

## Claims

1. A method for making an exercise mat, comprising:
preparing at least one first layer of the exercise mat using liquid polyurethane;
curing the at least one first layer on one side of a fabric;
preparing at least one second layer comprising at least one thermoplastic elastomer, the at least one thermoplastic elastomer being passed through at least one calendaring process; and
after the at least one first layer has cured, utilizing heat treatment to:
connect the at least one first layer and the at least one second layer by heat bonding the at least one second layer to an opposite side of the fabric; and
vulcanize the at least one second layer.

2. The method of claim 1, wherein the heat bonding is done utilizing a continuous laminating process.

3. The method of claim 1, wherein glue is not utilized to connect the at least one first layer and the at least one second layer.

4. The method of claim 1, wherein the fabric comprises a non-woven fabric.

5. The method of claim 1, wherein vulcanization is done at or near 180 Celsius.

6. The method of claim 1, further comprising treating at least one of the at least one first layer and the at least one second layer with an anti-microbial agent.

7. The method of claim 1, wherein the exercise mat made by the method comprises a moisture-wicking and/or absorbent exercise mat.

8. The method of claim 1, wherein the at least one first layer, when cured, comprises an open cell structure.

9. The method of claim 1, wherein the fabric comprises a woven fabric.

10. The method of claim 1, wherein the fabric comprises a polyester-cotton blended fabric.

11. The method of claim 1, wherein the fabric comprises a polyester fabric.

12. The method of claim 1, wherein the fabric comprises a cotton fabric.

13. The method of claim 1, wherein the liquid polyurethane is applied on one side of the fabric.

14. The method of claim 1, wherein the liquid polyurethane is poured onto one side of the fabric.

15. A method for making an exercise mat, comprising:
preparing at least one top layer of the exercise mat using liquid polyurethane;
curing the at least one top layer on one side of at least one middle layer comprising a fabric;
preparing at least one second layer comprising at least one thermoplastic elastomer, the at least one thermoplastic elastomer being passed through at least one calendaring process; and
after the at least one top layer has cured:
utilizing heat treatment to connect the at least one top layer and the at least one bottom layer by bonding the at least one bottom layer to an opposite side of the fabric of the at least one middle layer and vulcanizing the at least one bottom layer; and
utilizing at least one laminate to connect the at least one top layer and the at least one bottom layer.

16. The method of claim 15, wherein the at least one laminate is at least one non- toluene lamination adhesive.

17. The method of claim 15, wherein the fabric comprises a non-woven fabric.

18. The method of claim 15, further comprising treating at least one of the at least one first layer and the at least one third layer with an anti-microbial agent.

19. The method of claim 15, wherein the exercise mat made by the method comprises a moisture-wicking and/or absorbent exercise mat.

20. The method of claim 15, wherein the at least one first layer, when cured, comprises an open cell structure.

21. The method of claim 15, wherein the fabric comprises a woven fabric.

22. The method of claim 15, wherein the fabric comprises a polyester-cotton blended fabric.

23. The method of claim 15, wherein the fabric comprises a polyester fabric.

24. The method of claim 15, wherein the fabric comprises a cotton fabric.

25. The method of claim 15, wherein the liquid polyurethane is applied on one side of the fabric.

26. The method of claim 15, wherein the liquid polyurethane is poured onto one side of the fabric.

27. The method of claim 15, wherein glue is not utilized to connect the at least one top layer and the at least one bottom layer.

28. The method of claim 15, wherein the vulcanizing is done at or near 180 Celsius.