Patent ID: 8557072

Claim:
A method for making square rugs from recycled materials, comprising the steps of: a) making one piece of surface material by performing the steps of: preparing one flannelette-woven semi-finished product which includes one woven layer and a plurality of fluff protruding above the woven layer; applying heat to melt the woven layer at a proper temperature; and applying a proper pressure to press the flannelette-woven semi-finished product until each fluff is firmly secured to the woven layer; b) making one base material by performing the steps of: preparing one reinforcing material and one skid proof precursor material, wherein the reinforcing material is a piece of rigid cloth, and the skid proof precursor material is a sheet material made of material reclaimed from abandoned waste mixed with foaming agent; and placing the reinforcing material on the skid proof precursor material and heating them to cause the skid proof precursor material to foam and adhere to the reinforcing material, thereby forming a base material comprising the reinforcing material adhered to a resilient foam skid proof material, and c) laminating the surface material, the base material and a middle material together by performing the steps of: making one piece of middle precursor material by mixing material reclaimed from abandoned waste with foaming agent; extruding the middle precursor material between the surface material and the base material, and applying a proper pressure to laminate them together; and heating the laminated surface material, middle precursor material and the base material to cause the middle material to foam and adhere to the surface material and the base material, thereby forming a square rug comprising the surface material adhered to the base material by a resilient foam middle material.