Patent ID: 12220612

DETAILED DESCRIPTION

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.

In the context of the present disclosure, various terms are used in accordance with what is understood to be the ordinary meaning of those terms.

Disclosed embodiments include exercise mats and methods of making same. In various embodiments, the disclosure provides exercise mats that may be used in a fitness studio environment or at a user's home, either inside or outside, where shoes, weights and/or other equipment are being used during exercise. In various embodiments, the exercise mat may be particularly suitable for high intensity and/or high impact work-outs involving lateral training movements. During such movements, users are more prone to slipping, in addition to the mat slipping on a floor surface. The exercise mats as described herein address these issues. The exercise mats as disclosed herein are for placement on a flat surface by a user to provide cushioning, grip, support, stability or any combination thereof, allowing the user to more easily and effectively perform yoga and/or other exercises, including high intensity training and other exercises involving lateral training movements.

Referring toFIG.1and according to a first embodiment of the invention, an exercise mat10is shown. The exercise mat10comprises a top layer12. At least two textured gripping zones14and16are formed on an upper surface18of the top layer12. The at least two textured gripping zones14and16provide different levels of friction when a body is in sliding contact with the at least two textured gripping zones14and16of the upper surface18of the top layer12. In various embodiments, a friction level of a first textured gripping zone14in sliding contact with the body is lower than a friction level of a second textured gripping zone16in sliding contact with the body. This textured grip supports lateral training movements and provides increased traction to the user. In various embodiments, the term “body” refers to any entity that may be in sliding contact with the at least two textured gripping zones14and16of the upper surface18of the top layer12, and includes a user of the exercise mat10who may touch the exercise mat with any body part, such as hands, feet (with or without shoes) or torso, or any exercise equipment such as weights. The exercise mat10further comprises a bottom layer (not shown) joined to the top layer12. The bottom layer provides further cushioning to the user while the exercise mat10is in use.

Although a rectangular exercise mat is shown inFIG.1, the exercise mat10may have other shapes, such as square, circle or oval, or any other shape or design.

In various embodiments, the exercise mat10may also comprise one or more areas of no texture20, as shown inFIG.1.

In various embodiments, the second textured gripping zone16is positioned closer to one or more edges of the exercise mat10as shown inFIG.1, where the upper surface18of the top layer12has one or more textured gripping zones that have a higher friction level as compared to the first textured gripping zone14, and is closer to all four edges of the exercise mat10. The at least two textured gripping zones14and16may be positioned such that the friction level against the body in sliding contact with the at least two textured gripping zones14and16increases toward one or both of the vertical edges and/or toward one or both of the horizontal edges of the exercise mat10.

In various embodiments, the exercise mat10further comprises at least one additional textured gripping zone22. The at least one additional textured gripping zone22may be positioned between the first14and second16textured gripping zones. In such embodiments, the at least one additional textured gripping zone22provides a friction level greater than the first textured gripping zone14when in sliding contact with the body and smaller than the second textured gripping zone16when in sliding contact with the body. In some embodiments, the at least one additional textured gripping zone22may alternate with the second textured gripping zone16in any pattern. For example, the at least one additional textured gripping zone22may alternate concentrically with the second textured gripping zone16, as shown inFIG.1or they may alternative in horizontal or vertical lines. Each of the alternating textured gripping zones may be slightly different such that the friction level against the body in sliding contact with the top surface18of the top layer12of the exercise mat10increases towards one or more edges of the exercise or towards a perimeter of the exercise mat.

As shown inFIG.2, a friction level may increase gradually from the first textured gripping zone14toward the second textured gripping zone16, through the at least one additional texture gripping zone22. Alternatively, the at least two textured gripping zones14and16may be joined by a seamless transition.

The at least two textured gripping zones14and16, as well as the at least one additional textured gripping zone22, may comprise a plurality of semi-spheres24, as shown inFIG.2. A height of each of the plurality of semi-spheres24in the second textured gripping zone may be greater than a height of each of the plurality of semi-spheres24in the first textured gripping zone. In various embodiments, the height of each of the plurality of semi-spheres24in the at least two textured gripping zones14and16may be approximately the same. Alternatively or in addition, a diameter of each semi-sphere in the plurality of semi-spheres24in the second textured gripping zone16may be greater than a diameter of each semi-sphere in the plurality of semi-spheres24in the first textured gripping zone14(as shown inFIG.2), and/or a density of the plurality of semi-spheres24in the second textured gripping zone16may be greater than a density of the plurality of semi-spheres24in the first textured gripping zone14.

In various embodiments, the top layer12and/or the bottom layer may comprise a polyvinyl butyral, which may be recycled and/or used polyvinyl butyral. By being made of polyvinyl butyral, the exercise mats as disclosed herein may have higher abrasion resistance as compared to other mats. For example, the top layer12and/or the bottom layer comprise a polyvinyl butyral foam, such as a closed cell polyvinyl butyral foam, making the mat easier to clean and/or more stain resistant as compared to previous mats.

In various embodiments, a face surface of the bottom layer of the exercise mat may be at least partially textured to provide increased friction between the face of the bottom layer of the exercise mat and a surface against which the exercise mat is placed to decrease or prevent slippage of the exercise mat on the surface during use.

In various embodiments, the exercise mats as disclosed herein further comprise a middle layer between the top layer12and the bottom layer. For example, the middle layer may comprise a thermoplastic elastomer material. For such embodiments, the exercise mat10may be prepared by joining the top layer12and the middle layer, and then the at least two textured gripping zones are embossed on the top surface18of the top layer12as described in further detail below.

In various embodiments, a thickness of the exercise mats as disclosed herein may be between about 0.5 mm and about 6.5 mm, between about 0.5 mm and about 4.5 mm, between about 0.5 mm and about 3.5 mm, or any thickness therebetween. In various embodiments, the exercise mat has a thickness of about 6.5 mm.

In various embodiments, the exercise mats as disclosed herein may weight about 3.5 lbs.

In various embodiments, the exercise mats as disclosed herein have sufficient flexibility such that they can be rolled and/or folded for transport and/or storage.

The exercise mats as disclosed herein may be prepared by mixing a combination of ingredients, such as, for example, polyvinyl butyral, triglycol dioctate, stearic acid and water, as well as other optional additives such as foaming agents, fillers, plasticizing agents and the like. The materials may be mixed, melted and blended in an extruding machine or mixing machine. The exercise mats may then be formed through compression molding, using a mold comprising the at least two textured gripping zones for the top layer12, and a separate mold for the bottom layer. In various embodiments, the top layer12may further be treated with an antimicrobial agent, such as, for example, a silver-based antimicrobial agent and/or 3-trimethoxy propyl dimethyl octadecyl ammonium chloride.

The top layer12and the bottom layer are then joined, with an optional middle layer therebetween. For example, the layers may be joined using an adhesive or a bonding technique. In various embodiments, the layers may have thermoplastic bonding properties that cause adjacent layers to bond with one another when heated. Alternatively, the layers may be bonded using adhesives and/or mechanical connections. In addition, any combination of these methods or any other methods known to those of ordinary skill in the art may be used.

In various embodiments, the exercise mat10may be made using a vacuum embossing machine. The vacuum embossing machine may include a mold plate having an embossed top surface that has a female version of the textured gripping zones embossed thereon to form a male version of the textured gripping zones on the exercise mat10. The top layer12of the exercise mat10is attached to the middle layer, the middle layer comprising a thermoplastic elastomer material. The mat formed from joining the top and middle layers is cut to a desired size and shape, and is positioned on the mold plate having the embossed top surface, with the polyvinyl butyral side of the top layer facing the embossed top surface texture of the mold plate. The mold plate is inserted into a vacuum embossing machine and the mat is heated, for example, for about two minutes at a temperature of about 170° C., or alternatively, for about 1 to about 15 minutes at a temperature of about 120° C. to about 200° C., and with a suction pressure provided by the embossing machine such that the temperature and suction provided by the vacuum embossing machine softens the thermoplastic elastomer of the middle layer and conforms it to the textured gripping zones of the mold plate to form a corresponding surface texture through the polyvinyl butyral side of the top layer12. The mat can then be cooled, and the bottom layer is attached to form the exercise mat10.

Following production, the exercise mats as disclosed herein may comprise about 70% or more polyvinyl butyral, about 25% or more triglycol dioctate, about 3.5% or less stearic acid, and about 1.5% or less water.

EXAMPLES

These examples illustrate various aspects of the invention, evidencing different embodiments of the exercise mats as disclosed herein. Selected examples are illustrative of advantages that may be obtained compared to alternative exercise mats, and these advantages are accordingly illustrative of particular embodiments and not necessarily indicative of the characteristics of all aspects of the invention.

Example 1: Location on Exercise Mat Requiring Increased Friction Between a User and the Exercise Mat

In order to determine the locations on an exercise mat where a body requires increased friction, a heat map was generated while a user of the exercise mat engaged in high-intensity interval training. As shown inFIG.3, it was found that the user made contact with the exercise mat closer to one or more edges of the exercise mat. As a result, the second textured gripping zone16was position around a perimeter of the exercise mat10, to generate higher friction levels between the user and the exercise mat10when the user is in sliding contact with the second textured gripping zone16on the upper surface18of the top layer12.

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 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.

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.

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.

The example calculations, simulations, results, graphs, values, and parameters of the embodiments described herein are intended to illustrate and not to limit the disclosed embodiments. Other embodiments can be configured and/or operated differently than the illustrative examples described herein.