Exercise mat having a three-dimensional surface texture

Patent metadata

Field	Value
Publication number	US-11826606-B2
Application number	US-202017077392-A
Country	US
Kind code	B2
Filing date	Oct 22, 2020
Priority date	Oct 28, 2019
Publication date	Nov 28, 2023
Grant date	Nov 28, 2023

Abstract

Examples of an exercise mat having a three-dimensional surface texture and methods for making same are disclosed. 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.

First claim

What is claimed is:

1. An exercise mat having a three-dimensional surface texture, comprising:
a first malleable layer formed from a polyurethane material and having an elastic fabric material attached to a lower surface thereof; and,
a second layer attached to the elastic fabric material of the first layer, the second layer formed from a thermoplastic elastomer material and having the three-dimensional surface texture formed on an upper surface thereof, the upper surface having the three-dimensional surface texture formed thereon facing and secured to the elastic fabric material of the first layer, wherein the first layer conforms to the three-dimensional surface texture of the second layer to thereby provide the three-dimensional surface texture on an upper surface of the first layer;
wherein the three-dimensional surface texture is formed by vacuum embossing conforming to a three-dimensional surface texture formed on a mold plate.

2. The exercise mat of claim 1 , further comprising a third layer attached to a lower surface of the second layer, the third layer formed from a rubber material.

3. The exercise mat of claim 2 , further comprising a polyester cotton cloth material sandwiched between the second and the third layers.

4. The exercise mat of claim 1 , wherein the elastic fabric material is a four-way stretch nylon material.

5. The exercise mat of claim 1 , wherein at least one edge portion of the exercise mat is contoured, beveled, or chamfered and wherein a thickness of the at least one edge portion gradually reduces from a greater thickness at a portion of the edge portion away from an edge of the exercise mat to a lesser thickness at the edge of the exercise mat.

6. The exercise mat of claim 1 , wherein the three-dimensional surface texture is one or more of a ridged pattern, a water drop wave pattern, and a tidal flow wave pattern.

7. The exercise mat of claim 6 , wherein the exercise mat has a thickness of 5 mm and the three-dimensional surface texture extends from 0 to 3 mm below a top surface of the exercise mat.

Assignees

• Lululemon Athletica Canada Inc

Inventors

• Morris Stephen Thomas Caulton
• Yu Colton Kai
• Cheng Warren Christopher Howren
• Boghosian Glenn Malcolm
• Kao Chen I

Classifications

• A63B21/4037 Primary

  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 title

• B29C59/022 Primary

  characterised by the disposition or the configuration, e.g. dimensions, of the embossments or the shaping tools therefor · CPC title

• B32B27/40

  comprising polyurethanes · CPC title

• B32B2262/0276

  Polyester fibres · CPC title

• B32B2274/00

  Thermoplastic elastomer material · CPC title