Methods for making an exercise mat

• US 9,902,125 B2
• Filed: 03/22/2012
• Issued: 02/27/2018
• Est. Priority Date: 03/24/2011
• Status: Active Grant

• Current Assignee: Lululemon Athletica Canada Inc. (Lululemon Athletica, Inc.)
• Original Assignee: Lululemon Athletica Canada Inc. (Lululemon Athletica, Inc.)
• Inventors: Dandapure, Yogendra V., Douglas, Katherine, Boghosian, Glenn Malcolm, Kao, Chen I.
• Primary Examiner(s): Kurilla, Eric J
• Application Number:
  US13/427,615
• Publication Number:
  US 20120240336A1
• Time in Patent Office: 2,168 Days
• Field of Search: 5417-420, 5500, 5502, 5925
• CPC Class Codes: A63B 21/4037 Exercise mats for personal use, with or without hand-grips or foot-grips, e.g. for Yoga or supine floor exercises mats for absorbing shocks A63B6/00
• CPC Class Codes: A63B 2209/00 Characteristics of used materials
• CPC Class Codes: A63B 6/00 Mats or the like for absorbing shocks for jumping, gymnastics or the like
• CPC Class Codes: B32B 2266/06 Open cell foam
• CPC Class Codes: B32B 2274/00 Thermoplastic elastomer material
• CPC Class Codes: B32B 2307/51 Elastic
• CPC Class Codes: B32B 2307/56 Damping, energy absorption
• CPC Class Codes: B32B 2307/7145 Rot proof, resistant to bacteria, mildew, mould, fungi
• CPC Class Codes: B32B 2307/724 Permeability to gases, adsorption
• CPC Class Codes: B32B 2307/744 Non-slip, anti-slip
• CPC Class Codes: B32B 2471/04 Mats
• CPC Class Codes: B32B 25/045 of foam
• CPC Class Codes: B32B 25/10 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 25/14 comprising synthetic rubber copolymers B32B25/18 and B32B25/20 take precedence
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/40 comprising polyurethanes
• CPC Class Codes: B32B 3/266 characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric

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.

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.