ANTI-FATIGUE RUG WITH SEPARABLE RESILIENT CUSHION SYSTEM AND METHOD

TECHNICAL FIELD

The invention generally relates to floor mats or pads, and more particularly relates to an anti-fatigue rug and cushioning member combination.

BACKGROUND

Rugs, because of comfort, texture, appearance and warmth, are desired in many situations in a home, office, shop or other location. Typical underlayment for rugs can provide limited cushioning. Conventionally, such underlayment has been problematic because the rug can move or slip with respect to the underlayment. This underlayment is also limited in that it fails to provide adequate cushion to serve for anti-fatigue.

Anti-fatigue mats or pads of resilient foam or the like are now available. Although quality and grade of these mats varies widely, the mats typically have presented an underside and topside of slick plastic or polymer. The conventional mats have not served as underlayment for rugs, at least in part because the typical rug would slide, curl, bunch or otherwise displace from the mat.

It would, therefore, be a significant improvement in the art and technology to provide an ergonomic, anti-fatigue mat combined with a separable rug which is retained from shifting in respect to the mat. It would be a further improvement to provide an anti-fatigue mat that is water-resistant, and a rug that is stylish, more natural, and removable. It would also be an improvement to provide the rug and pad with wash-ability for cleaning and the like, as well as renewable or non-destructible engagements between the rug and the pad and the rug and floor, for restricting movement of the rug on the pad and floor.

SUMMARY

An embodiment of the invention is a system for a floor including a rug, loops connected to the rug, and hooks connected to the floor. In non-exclusive alternatives, the system additionally includes a sticky gel embedding the hooks.

Yet another embodiment of the invention is a system including a pad having a top of a high-friction surface and a bottom of a slip-resistant surface and a rug for friction engagement with the top of the pad and a connector of the rug to the floor.

Another embodiment of the invention is a system including a pad, a high-friction surface connected to the pad, a slip-resistant surface connected to the pad, and a rug engageable with the high-friction surface and a connector of the rug to the floor.

Yet another embodiment of the invention is a method. The method includes molding a foam pad with lead-in slope and central planar surface on a top of the pad and a generally smooth planar surface on a bottom of the pad, blanketing the foam pad with a water-resistant outer layer, forming a high-friction surface on the top of the pad, and providing a slip-resistant surface on the bottom of the pad.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is illustrated by way of example and not limitation in the accompanying figures, in which like references indicate similar elements, and in which:

FIG. 1 illustrates a front perspective view of a system of a rug and a cushion, according to certain embodiments of the invention;

FIG. 2 illustrates a cross-section view along line A-A′ of FIG. 1, of a rug engaged to a cushion and the floor, according to certain embodiments of the invention;

FIG. 3 illustrates a cross-section view along line A-A′ of FIG. 1, of a rug disengaged from a cushion and fasteners for connecting the rug to the floor, according to certain embodiments of the invention;

FIG. 4 illustrates a front perspective view of a rug engaged to a cushion, and a lifted corner of the rug showing a fastener, according to certain embodiments of the invention;

FIG. 5 illustrates a front side perspective view of a corner of a rug and a cushion, and a fastener of the rug, according to certain embodiments of the invention;

FIG. 6 illustrates a bottom view of a rug and top view of a cushion, according to certain embodiments of the invention;

FIG. 7 illustrates a front perspective view of a rug engaged to a cushion, and a lifted corner of the rug showing one part of a fastener attached to underside of the rug and another part of the fastener attached to a floor, according to certain embodiments of the invention;

FIG. 8 illustrates a side view of a two-part fastener of hooks integrated with adhesive polyurethane gel gripper and loops sewn onto the bottom of the rug, according to certain embodiments of the invention;

FIG. 9 illustrates a side view of a rug and cushion, the rug including a first part of a fastener that is loops of a hook and loop type fastener sewn onto the bottom of the rug and a second part of the fastener that is hooks of the hook and loop type fastener integrated with an adhesive polyurethane gel gripper, according to certain embodiments of the invention;

FIG. 10 illustrates a bottom view of another rug and top view of a cushion, according to certain embodiments of the invention;

FIG. 11 illustrates a front perspective view of another system of a rug and a cushion, according to certain embodiments of the invention;

FIG. 12 illustrates a cross-section view along line B-B′ of FIG. 10, of a rug engaged to a cushion and cushion sitting on a floor, according to certain embodiments of the invention;

FIG. 13 illustrates a front side perspective view of a corner of a rug and a cushion, and a fastener of the rug with counterpart fastener of the cushion, according to certain embodiments of the invention;

FIG. 14 illustrates a side of an edge of a rug disengaged from a cushion with fasteners for connecting the rug to the cushion, according to certain embodiments of the invention;

FIG. 15 illustrates a front perspective view of a rug engaged to a cushion, and a lifted corner of the rug showing a fastener of the rug and counterpart fastener of the cushion, according to certain embodiments of the invention;

FIG. 16 illustrates a cross-section view of an edge of a rug disengaged from a cushion with fasteners for connecting the rug to the cushion, according to certain embodiments of the invention;

FIG. 17 illustrates a method of manufacture of a rug, according to certain embodiments of the invention; and

FIG. 18 illustrates a method of manufacture of a rug and cushion, according to certain embodiments of the invention.

DETAILED DESCRIPTION

Referring to FIGS. 1-2, a system 100 includes a pad 102 connected to a rug 104. The pad 102 includes a high-traction surface 106 on a top side 108 of the pad 102. The pad 102 also includes a slip-resistant surface 110 on a bottom side 112 of the pad 102. In certain non-exclusive embodiments, the pad 102 is a polymer foam, such as for non-exclusive example, a molded urethane foam cushion partially or fully encased in vinyl for waterproofing. The pad 102, as formed, includes a three-dimensional shape forming a lead-in ramp 107 around periphery of the pad 102 and, within the lead-in ramp 107 edges, the top side 108 rises to a generally planar surface.

An underside of the rug 104 connects to the high-traction surface 106 of the pad 102, to inhibit the rug 104 from displacement with respect to the pad 102. The slip-resistant surface 110 of the pad 102 inhibits the rug 104 and pad 102 combination from sliding or moving along a floor 114 or generally planar support on which the combination is located. The rug 104 includes a top 111 that is aesthetically pleasing or otherwise designed. A bottom 113 of the rug 104 includes woven textile and, if applicable, backing. The rug 104, in non-exclusive embodiment, is sized larger than the pad 102, such that corners and edges of the rug 104 contact the floor 114 when places onto the pad 102.

The pad 102 has a texture on the top side 108 to provide the high-traction surface 106. A non-exclusive example of the high-traction surface 106 of the top side 108 of the pad 102 includes a high tack coating. The bottom side 112 of the pad 102 includes the slip-resistant surface 110 such as, for non-exclusive example, a rubberized or polymer surface. In non-exclusive embodiments, the foam cushion of the pad 102 is partially or fully wrapped in a vinyl or other material providing the slip-resistant surface 110 and water-resistance and the high-traction surface 106 of the top side 108 of the pad 102 is an applied texture to the wrap.

Referring to FIGS. 1-6, in conjunction, one or more fastener, for non-exclusive example, one or more combination of a Velcro™-style fastener and an adhesive polyurethane gel gripper (a/k/a “sticky gel”) 202a-d is located on the underside of the rug 104 and corresponding location on a floor. The combination Velcro™-style fastener and sticky gel 202a-d may be located on the underside of the rug 104, for non-exclusive example, at corners of the rug 104, along peripheral edges of the rug 104, intermittently along corners and edges of the rug 104, and/or otherwise. According to certain non-exclusive embodiments, the combination Velcro™-style fastener and sticky gel 202a-d is attached to underside of the rug 104 where the rug 104 extends beyond the pad 102. In use, the sticky gel 202a-d sticks to a floor 114 or undersurface to further retain the rug 104 in position on the floor 114 and pad 102.

Referring to FIG. 2, in conjunction with FIG. 1, in a system 200, as non-exclusive example, such as the system 100 of FIG. 1, in operation, the pad 102 is positioned on the floor 114 or other surface. The slip-resistant surface 110 of the pad 102 contacts the floor 114, such that the bottom side 112 of the pad 102 is located on the floor 114.

The rug 104 is then located atop and on the pad 102, with perimeter of the rug 104 extending at or beyond lateral extents of the pad 102. The underside of the rug 104 contacts the high-traction surface 106 of the pad 102. In non-exclusive embodiments which include sticky gel 202, such as located at corners of the rug 104 or periphery of the rug 104, the sticky gel 202 contacts and removably adheres to the floor 114 or other surface.

Referring to FIG. 3, a system 300, such as, for example, the systems 100 or 200 of FIGS. 1 and 2, respectively, includes in cross-section along A-A′ of FIG. 1 the pad 102 and the rug 104 removed from the pad 102. The pad 102 has the lead-in ramp 107, such as, for non-exclusive example, sloped or angled edges, around perimeter of the pad 102. The pad 102 includes a polymer foam shaped interior, which may be unitary or have varied layers or regions for varied specifications, cushioning, and other aspects. The polymer foam shaped interior, which may be molded or otherwise formed, is partially or fully wrapped or covered in a waterproof material 302, such as vinyl or other floor gripping surface.

The top side 108 of the pad 102 includes the high-traction surface 106. The high-traction surface 106 may be, as non-exclusive example, a roughed, ridged, figured, tacky or other outwardly displaced surface. In non-exclusive examples, the surface 106 includes a high tackiness. The surface 106 may be formed, for example, by coating the vinyl or other wrap of the foam cushion of the pad 102, with application of high tack coating or other tacky or configured material to the vinyl or other wrap.

The bottom side 112 of the pad 102 includes the slip-resistant surface 110. The slip-resistant surface 110 may be, as non-exclusive example, polymer surface, a rubber component or composition, or other surface capable of preventing slide or skid of the pad 102 on the floor 114 or other surface. In non-exclusive embodiments, the surface 110 includes a vinyl wrap partially or fully around the foam cushion of the pad 102. The surface 110 may be formed, for example, by partially or fully encasing the foam cushion of the pad 102 in the vinyl or other wrap which may be employed as a fabric enveloping the pad 102, formed around the pad 102, molded on the pad 102, or otherwise.

The rug 104 includes a top 111 of a textured, shagged or other surface of a typical rug, including but not limited to a fine quality rug. As non-exclusive example, the rug is a high-quality polyester material, with serged or bound edges for superior finish, and is stain-resistant and machine washable. The rug 104 includes a bottom 113 of woven textile and, if applicable, backing. The high-traction surface 106 of the pad 102 creates friction between the rug 104 and the pad 102, in order to stabilize and maintain the rug 104 in position atop the pad 102 and prevent slide or shift.

Although not necessarily included in all embodiments, one or more combination Velcro™-style fastener and sticky gel pad 202a, 202b can be fixed to the bottom 113 of the rug 104, such as at corners or periphery of the rug 104. The sticky gel pad 202a, 202b provides further tack of the rug 104 to the floor 114 and restricts movement on the pad 102. The combination Velcro™-style fastener and sticky gel pad 202a or 202b may be affixed to the bottom 113 of the rug 104 at virtually any location, such as, for example, at corners of the rug 104, along about periphery of the rug 104, or in other locations as desired in the implementation.

A variety of options may be possible for fixing or attaching the sticky gel pad 202a, 202b to the bottom 113 of the rug 104. As non-exclusive example, the loop side of a Velcro™-style fastener 202a may be sewn or stitched into the rug 104, such as, for example, into the edge binding of the rug 104. The hook side of a Velcro™-style fastener 202b can be molded into a sticky gel pad 202b. Other possibilities include attachment of the pad 202a, 202b by fastener, snap, connector, buckle, wedge, glue, or other. The attachment may include a combination of elements, or a single element.

According to certain non-exclusive embodiments, sticky gel pads 202a, 202b are employed with Velcro™-type hook and loop fasteners. The Velcro™-type hook and loop fasteners may be integrated in the combination Velcro™-style fastener and sticky gel pads 202a, 202b or otherwise. The pads 202a, 202b with hook and loop fastener components may be attached to the rug 104 in a variety of manners, such as glue, stitch or other.

Referring to FIG. 4, a system 400, such as, for non-exclusive example, the systems 100, 200 and/or 300, includes the pad 102 and the rug 104 in place atop the pad 102 with a lifted corner of the rug 104. The rug 104 extends, in a non-exclusive embodiment, at least over the entirety of the top side 106 of the pad 102. Variations to the arrangement are possible. The high-traction surface 106 of the top side 108 of the pad 102 restricts the rug 104 from shifting through friction, tackiness, combinations of these, or otherwise. In non-exclusive embodiment, the combination Velcro™-style fastener and sticky gel pad 202b is included in a bottom 113 and corner of the rug 104 which extends beyond the extent of the pad 102. The combination Velcro™-style fastener and sticky gel pad 202b can contact and removably adhere to a surface, such as the floor. The high-traction surface 106, with addition of the combination Velcro™-style fastener and sticky gel pad 202b, further prevents the rug 104 from movement with respect to the pad 102 and the floor.

Referring to FIG. 5, a system 500, such as, for non-exclusive example, the systems 100, 200, 300 and/or 400, shows the combination Velcro™-style fastener and sticky gel pad 202b connected to a corner of the rug 104 extending beyond the pad 102. In certain non-exclusive embodiments, stitches 502 sewn with the rug 104 border and combination Velcro™-style fastener and sticky gel pad 202b fix the pad 202b to the rug 104. Although the stitches 502 are shown for example, a wide variety of attachment or fixation devices are possible with the combination Velcro™-style fastener and sticky gel.

Referring to FIGS. 5 and 6, in conjunction, a system 600, such as, for non-exclusive example, the systems 100, 200, 300, 400, and/or 500, include sticky gel pads 202a-d at each corner of the rug 104 on the bottom of the rug 104 and corresponding part on the floor. The rug 104 is shown with a border 602 (or serged) edge sewn onto edges of the rug 104. In certain non-exclusive embodiments, the combination Velcro™-style fastener and sticky gel pads 202a-d are each sewn into a respective corner of the rug 104 together with the stitch 604 of the border 602. A top side 108 of the pad 102 includes the lead in ramp edges 107 and generally planar surface between the edges 107. The top side 108 has a high-traction surface 106.

Referring to FIG. 7, a system 700 includes a two part fastener 702, 704 connected to the rug 104 by a first connector 704 and to the floor 114 by a second connector 702. The first connector 704 is connected to the rug 104 in correspondence with the second connector 702 and its location on the floor 114, such that the first connector 704 connects to the second connector 702 when the rug 104 is positioned atop the pad 102. As non-exclusive example, the first connector 704 is stitched 706 to the bottom of the rug 104 and the second connector 702 removably fixes to a floor or other surface on which the rug 104 and pad 102 are positioned. In certain non- exclusive embodiments, the first connector 704 is a sewn-in Velcro™-style “loops” pad and the second connector 702 is a sticky gel pad with Velcro™-style “hooks” embedded. This two-part fastener “hooks” is embedded to retain the rug 104 more fixed with the pad 102 and inhibit slide or movement of the rug 104 and pad 102 on a floor or other surface.

Referring to FIGS. 8 and 9, in conjunction, a connector system 800, 900 for a rug 104 includes a first element 802 and a second element 804. The first element 802 is for attachment to the underside 113 of the rug 104, such as at corners, along periphery or otherwise on the rug 104. The second element 804 is for removable attachment to a floor 114 or surface on which a pad (not shown) and rug are positioned. The first element 802 includes a loop backing 806 of a hook and loop type fastener. The loop backing 806 includes series of loops 808. The loops 808 are sewn into the rug 104. The second element 804 includes a hook backing 812 of the hook and loop type fastener. The hook backing 812 includes hooks 814 for connecting to the loops 808 of the first element 802. The second element 804 includes sticky gel 816 in which the hooks 814 are embedded or otherwise integrated. When the first element 802 is attached to the rug 104, and the second element 804 is removably fixed to the floor 114, the first element 802 can be brought into contact with and pressed to the second element 804. This engages the hooks 814 to the loops 808.

The first element 802 can be disengaged from the second element 804 by lifting the rug 104 from the pad 102. For example, the rug 104 may be removed for cleaning or transfer to another location. The pad 102 may similarly be picked up and moved as desired or, if the rug 104 is for cleaning but the location should remain, the pad 102 may be left in place when the rug 104 is removed. Similarly, the second element 804 may be removed from the floor 114 or surface or, else, may be retained in place when the rug 104 is removed. When the second element 804 including sticky gel is retained with the rug 104, laundering or other cleaning of the rug 104 can clean and restore the stickiness of the sticky gel 816 of the second element 804. Because the loops 808 are engaged with the hooks 814 of the second element, the first element 802 is less likely to catch on other fabrics or items during laundering or movement of the rug 104.

Although any of a wide variety of fasteners are possible in embodiments, the particular system 800, 900 for operating as such fastener can be desirable to maintain the rug 104 and, consequently, the pad 102 in place on a floor or surface. The second element 804 is attached to the floor 114, and the first element 802 is attached to the rug 104. In the system 900, which is a non-exclusive embodiment, the first element 802 and the second element 804 are connected to the rug 104 and the floor 114, respectively. The first element 802 is in close proximity to the second element 804, but is not connected as would be applicable for the rug 104 and floor 114 combination in use.

In certain non-exclusive embodiments of the system 800, 900, the first element 802, and thus the rug 104, is selectively removable from connection to the second element 804, and consequently the floor 114 and pad 102. Embodiments include all possible arrangements and configurations of the first element 802 and the second element 804.

As non-exclusive example, the first element 802 includes a strip of piece of Velcro™, such as, for example, a loop segment of loops 808 of a Velcro™ connector. In the exemplary non-exclusive embodiment of the system 800, 900, a corresponding second element 804 includes a connecting piece of Velcro™, such as, for example, a hook segment of hooks 814 of a Velcro™ connector. The Velcro™ connectors can be employed with or without sticky gel according to certain non-exclusive embodiments.

In certain non-exclusive embodiments and alternatives, the first element 802 may be combined with a sticky gel pad. The sticky gel pad may be formed on the first element 802 so that the loops 808 are at least partially blanketed by the pad. The second element 804 may also be formed with a sticky gel pad, or not as desired. In any such embodiments, the Velcro™ connector, in combination with one or more sticky gel pad, removably attaches the rug 104 to the floor and retains the rug 104 on the pad 102.

In use of the foregoing embodiments, the pad is placed in desired location on a floor or other surface. The rug is then positioned on the pad. The high-traction surface of top of the pad limits the rug from moving on the pad, and the slip-resistant surface of bottom of the pad restricts the pad from sliding or shifting on the floor or other surface. If the embodiment includes fasteners for the rug and/or pad, such as sticky gel pads, Velcro™ connector, combinations of these, or other fasteners, restrictors or engagements, these fasteners are engaged between the rug and the floor, or even possibly the pad, as applicable. The fasteners further restrict the rug from shift on the floor and pad, trap the pad in connection to and within perimeter of the rug, and resist natural tendency of the rug to lift, curl or otherwise become potential hazard.

Referring to FIG. 10, a system 1000 includes a pad 102 and a rug 104. The pad 102 includes a high-traction surface 106 on a top side 108 of the pad 102. The pad 102 also includes a slip-resistant surface 110 (not shown) on a bottom side 112 of the pad 102. In certain non-exclusive embodiments, the pad 102 is a polymer foam, such as for non-exclusive example, a molded urethane foam cushion partially or fully encased in vinyl for waterproofing. The pad 102, as formed, includes a three-dimensional shape forming a lead-in ramp 107 around periphery of the pad 102 and, within the lead-in ramp 107 edges, the top side 108 rises to a generally planar surface.

An underside of the rug 104 connects to the high-traction surface 106 of the pad 102, to inhibit the rug 104 from displacement with respect to the pad 102. The slip-resistant surface 110 of the pad 102 inhibits the rug 104 and pad 102 combination from sliding or moving along a floor 114 or generally planar support on which the combination is located. The rug 104 includes a top 111 (not shown) that is aesthetically pleasing or otherwise designed. A bottom 113 of the rug 104 includes woven textile and, if applicable, backing.

The pad 102 has a texture on the top side 108 to provide the high-traction surface 106. A non-exclusive example of the high-traction surface 106 of the top side 108 of the pad 102 includes a high tack coating. The bottom side 112 of the pad 102 includes the slip-resistant surface 110 such as, for non-exclusive example, a generally smooth polymer surface. In non-exclusive embodiments, the foam cushion of the pad 102 is partially or fully wrapped in a vinyl providing the slip-resistant surface 110 and water proofing and the high-traction surface 106 of the top side 108 of the pad 102 is an applied texture to the wrap.

According to certain non-exclusive embodiments, sticky gel 1002 or other removable adherent or connector, with or without additional hook and loop fasteners, is located around perimeter of the rug 104 on the underside 113. This sticky gel 1002 or other connector contacts the floor or other surface (not shown) around the pad 102 placed thereon. The sticky gel 1002 or other connector may be sewn in or otherwise fixed to the underside 113 of the rug 104, such as, for non-exclusive example, by stitches 602 of a serge or border edge of the rug 104. In such non-exclusive embodiments, the sticky gel 1002 serves added function of creating a substantially water impermeable ring fixture around the rug 104 and pad 102.

Referring to FIG. 11, another system 1100 includes a pad 102 and rug 104. The pad 102 includes a high-traction surface 106 on a top side 108 of the pad 102. The pad 102 includes to slip-resistant surface 110 on a bottom side 112 of the pad 102. The pad 102 includes a lead-in ramp 107 around periphery of the pad 102. An underside of the rug 104 connects to the high-traction surface 106 of the pad 102. The slip-resistant surface 110 of the pad 102 inhibits the rug 104 and pad 102 combination from sliding or moving along a floor 114. The rug 104 includes a top 111 that is aesthetically pleasing or otherwise designed. A bottom 113 of the rug 104 includes woven textile and, if applicable, backing.

According to certain non-exclusive embodiments, one or more fastener, for non-exclusive example, sticky gel 1102, with or without additional hook and loop or other fasteners, is located on the high-traction surface 106 of the pad 102. As non-exclusive example, the sticky gel 1102 (and, if applicable, hook and loop fastener) is located at corners of the top side 108 of the pad 102, or around edges or periphery of the pad 102, or otherwise. In such embodiments, the sticky gel 1102 (and, if applicable, hook and loop fastener) in combination with the high-traction surface 106 keep the rug 104 from slipping on the pad 102, trap the pad 102 within perimeter of the rug 104, and resist natural tendency of the rug 104 with stiff corners to lift or curl and become trip hazard and the like.

In the case of hook and loop fasteners, a counterpart, such as the hook portion, is located on the high-traction surface 106 of the pad, and a second counterpart, such as the loop portion, is located on the underside of the rug 104 in corresponding position. As non-exclusive example, the sticky gel 1102 (and, if applicable, hook and loop fastener) is located at corners of the top side 108 of the pad 102, or around edges or periphery of the pad 102, or otherwise. In such embodiments, the sticky gel 1102 (and, if applicable, hook and loop fastener) in combination with the high-traction surface 106 keep the rug 104 from slipping on the pad 102, trap the pad 102 within perimeter of the rug 104, and resist natural tendency of the rug 104 with stiff corners to lift or curl and become trip hazard and the like.

Referring to FIG. 12, in conjunction with FIG. 11, in a system 1200, as non-exclusive example, such as the system 1100 of FIG. 1, in operation, the pad 102 is positioned on the floor 114 or other surface. The slip-resistant surface 110 of the pad 102 contacts the floor 114, such that the bottom side 112 of the pad 102 is located on the floor 114. The rug 104 is then located atop and on the pad 102, with perimeter of the rug 104 extending at or beyond lateral extents of the pad 102. The underside of the rug 104 contacts the high-traction surface 106 of the pad 102. In non-exclusive embodiments which include sticky gel 1102, such as located at corners of the pad 102 or periphery of the pad 102, the underside of the rug 104 also contacts the sticky gel 1102 of the pad 102. If applicable, hook and loop fasteners, alone or in combination with the sticky gel 1102, maintain the rug 104 positioned on the pad 102.

Referring to FIG. 13, a system 1300, such as, for example, the systems 1100 or 1200 of FIGS. 11 and 12, respectively, includes in cross-section along B-B′ of FIG. 11 the pad 102 and the rug 104 removed from the pad 102. The pad 102 has the lead-in ramp 107, such as, for non-exclusive example, sloped or angled edges, around perimeter of the pad 102. The pad 102 includes a polymer foam shaped interior, which may be unitary or have varied layers or regions for varied specifications, cushioning, and other aspects. The polymer foam shaped interior, which may be molded or otherwise formed, is partially or fully wrapped or covered in a waterproof material 302, such as vinyl or other floor gripping surface.

The bottom side 112 of the pad 102 includes the slip-resistant surface 110. The slip-resistant surface 110 may be, as non-exclusive example, a slick polymer surface, a rubber component or composition, or other surface capable of preventing slide or skid of the pad 102 on the floor 114 or other surface. In non-exclusive embodiments, the surface 110 includes a vinyl wrap around the foam cushion of the pad 102. The surface 110 may be formed, for example, by encasing the foam cushion of the pad 102 in the vinyl or other wrap which may be employed as a fabric enveloping the pad 102, formed around the pad 102, molded on the pad 102, or otherwise.

The rug 104 includes a top 111 of a textured, shagged or other surface of a typical rug, including but not limited to a fine quality rug. As non-exclusive example, the rug is a high-quality polyester material, with bound or serged edges for superior finish, and is stain-resistant and machine washable. The rug 104 includes a bottom 113 of woven textile and, if applicable, backing. The high-traction surface 106 of the pad 102 creates friction between the rug 104 and the pad 102, in order to stabilize and maintain the rug 104 in position atop the pad 102 and prevent slide or shift.

One or more sticky gel pad 1102a, 1102b can be fixed to the top side 108 of the pad 102, such as on or integrated in the high-traction surface 106. The sticky gel pad 1102a, 1102b provides further tack of the rug 104 to the pad 102. The sticky gel pad 1102a or 1102b may be affixed to the top side 108 at virtually any location, such as, for example, at corners of the pad 102, along about periphery of the pad 102, or in other locations as desired in the implementation.

According to certain non-exclusive embodiments, sticky gel pads 1102a, 1102b (or as otherwise affixed to the pad 102) are employed with Velcro-type hook and loop fasteners. The Velcro-type hook and loop fasteners may be attached to the pad 102 in a variety of manners, such as glue, stitch or other. Likewise, attachment of the corresponding hook and loop fasteners to the rug 104 may be in any of a wide variety of manners, including, as non-exclusive example, glue, stitch, or other.

Referring to FIGS. 14 and 15, in conjunction, a system 1400, 1500, such as, for non-exclusive example, the systems 1100, 1200 and/or 1300, includes the pad 102 and the rug 104 in place atop the pad 102 with a lifted corner of the rug 104. The rug 104 extends, in a non-exclusive embodiment, at least over the entirety of the top side 106 of the pad 102. Variations to the arrangement are possible. The high-traction surface 106 of the top side 108 of the pad 102 restricts the rug 104 from shifting through friction, tackiness, gel stickiness, combinations of these, or otherwise.

In the non-exclusive embodiment, the system 1400, 1500 includes a two part fastener 1502, 1504 connected to the rug 104 by a first connector 1504 and to the pad 102 by a second connector 1502. The first connector 1504 is connected to the rug 104 in correspondence with the second connector 1502 and its location on the pad 102, such that the first connector 1504 connects to the second connector 1502 when the rug 104 is positioned atop the pad 102.

Referring to FIG. 16, in conjunction with FIGS. 14 and 15, although any of a wide variety of fasteners are possible in embodiments, a particular system 16 for operating as such fastener includes a first piece 1602 and a second piece 1604. The first piece 1602 is attached to the rug 104, and the second piece 1604 is attached to the pad 102. In the system 1600, which is a non-exclusive embodiment, the first piece 1602 and the second piece 1604, in cross-section along B-B′ of FIG. 13, are connected to the rug 104 and the pad 102, respectively. The first piece 1602 is in close proximity to the second piece 1604, but is not connected as would be applicable for the rug 104 and pad 102 combination in use.

In the system 1600, the first piece 1602, and thus the rug 104, is selectively removable from connection to the second piece 1604, and consequently the pad 102. Embodiments include all possible arrangements and configurations of the first piece 1602 and the second piece 1604. As non-exclusive example, the first piece 1602 includes a strip 1609 of a piece of Velcro™, such as, for example, a loop segment of loops 1608 of a Velcro™ connector. In the exemplary non-exclusive embodiment of the system 1600, a corresponding section 1610 of a connecting piece of Velcro™, such as, for example, a hook segment of hooks 1612 of a Velcro™ connector.

In certain non-exclusive embodiments and alternatives, the section 1610 may be combined with a sticky gel pad 1614. The sticky gel pad 614 may be formed on the section 1610 so that the hooks 1612 are at least partially blanketed by the pad 1614. In such embodiments, the Velcro™ connector (the first piece 1602 and the second piece 1604), in combination with the sticky gel pad 1614, removably attaches the rug 104 to the pad 102. Similarly, although not necessary in embodiments, the section 1609 may be integrated or otherwise combined with a sticky gel pad 1606, for removable connection to the section 1610 and sticky gel pad 1614.

In use of the foregoing embodiments, the pad is placed in desired location on a floor or other surface. The rug is then positioned on the pad. The high-traction surface of top of the pad limits the rug from moving on the pad, and the slip-resistant surface of bottom of the pad restricts the pad from sliding or shifting on the floor or other surface. If the embodiment includes fasteners for the rug and/or pad, such as sticky gel pads, Velcro™ connector, combinations of these, or other fasteners, restrictors or engagements, these fasteners are engaged between the rug and the pad, as applicable. The fasteners further restrict the rug from shift on the pad, trap the pad in connection to and within perimeter of the rug, and resist natural tendency of the rug to lift, curl or otherwise become potential hazard.

Referring to FIG. 17, a method 1700 is a non-exclusive embodiment of manufacture of the certain of the foregoing systems. The method 1700 includes forming 1702 a three-dimension foam pad with lead-in ramps on edges and desired cushion interior. The forming 1702 may include by molding the foam pad. Alternately, the forming 1702 may include die cut, or other steps, alone or in combination, as desired and for the particular embodiment. The foam pad may be, for non-exclusive example, an anti-fatigue type cushion or other gel, rubber, vinyl or composition pad. The pad may include layers, sections, segments, or other parts or pieces to provide desired feel and cushion. Shapes of the pad may vary as desired for use under the rug.

Once the foam pad is formed 1702, an outer layer may be configured 1704 on the foam pad. The outer layer may be, for non-exclusive example, a rubber, vinyl or other sheet or blanket that is connected to or manufactured for conformance to the outer surface of the foam pad. This outer layer renders the pad waterproof or water-resistant, as the foam cushion of the pad could otherwise absorb moisture (and potentially mildew, harbor bacteria and so forth) if spilled or otherwise subjected to the pad. The outer layer may also, but need not necessarily, provide the slip-resistant surface on bottom of the pad. The outer layer of the top of the pad provides a surface for further preparation. In certain no-exclusive alternatives, steps 1702 and 1704 may be combined by inserting the outer layer in the mold.

To the outer layer of the top of the pad is applied 1706 or otherwise formed the high-traction surface. According to certain non-exclusive embodiments, the high-traction surface includes a sprayed film or coating of material to the outer layer of the top of the pad. A non-exclusive example of such material includes high tack coating, although a wide variety of other materials and application processes are possible. The high-traction surface provides a high-friction connection between the rug and the pad, when the rug is placed in contact on the high-traction surface.

According to certain non-exclusive embodiments, a combination of Velcro-style fasteners and sticky gel pads, such as, for non-exclusive example, conforming generally to corners of the rug, are provided 1708. The combination of Velcro-style fasteners and sticky gel pads may be stitched 1710 or otherwise connected to corners of the rug where the rug extends beyond the pad. Sticky gel adhesive properties can be tuned as desired, from semi-active to very aggressive tack, in addition to amounts of such gel can be varied, each for desired effect. The fasteners can allow for the rug to be removed from the pad, and for the rug and pad to be cleaned by washing or otherwise. Machine wash of the pad with sticky gel will revive the tackiness of the sticky gel.

In certain non-exclusive embodiments, fasteners may include both Velcro™ type connectors and sticky gel connectors. In the examples, the Velcro™ loops are sewed or otherwise attached to the rug in desired location, such as at corners or perimeter of underside of the rug. In non-exclusive alternatives, Velcro™ hooks, either alone or molded into sticky gel pads, may correspond to Velcro™ loops connectors attached to the rug. These may be adhered, removably or otherwise, to a floor or other surface for connection to corresponding connector of the rug. The Velcro™ and sticky gel, in combination with the high-traction surface, allows for good retention of the rug to the floor and pad, and where sticky gel is included and if attached to the rug around perimeter, may serve as water seal. In certain non-exclusive alternatives, the rug and attachment method may be used with the pad.

Referring to FIG. 18, a method 1800 is a non-exclusive embodiment of manufacture of certain of the foregoing systems. The method 1800 includes forming 1802 a three-dimension foam pad with lead-in ramps on edges and desired cushion interior. The forming 1802 may include by molding the foam pad. Alternately, the forming 1802 may include die cut, or other steps, alone or in combination, as desired and for the particular embodiment. The foam pad may be, for non-exclusive example, an anti-fatigue type cushion or other gel, rubber, vinyl or composition pad. The pad may include layers, sections, segments, or other parts or pieces to provide desired feel and cushion. Shapes of the pad may vary as desired for use under the rug.

Once the foam pad is formed 1802, an outer layer may be configured 1804 on the foam pad. The outer layer may be, for non-exclusive example, a rubber, vinyl or other sheet or blanket that is connected to or manufactured for conformance to the outer surface of the foam pad. This outer layer renders the pad water-resistant, as the foam cushion of the pad could otherwise absorb moisture (and potentially mildew, harbor bacteria and so forth) if spilled or otherwise subjected to the pad. The outer layer provides the slip-resistant surface on bottom of the pad. The outer layer of the top of the pad provides a surface for further preparation. In certain non-exclusive alternatives, steps 1803 and 1804 may be combined by inserting the outer layer into the mold.

To the outer layer of the top of the pad is applied 1806 or otherwise formed the high-traction surface. According to certain non-exclusive embodiments, the high-traction surface includes a sprayed film or coating of material to the outer layer of the pad. A non-exclusive example of such material includes high tack coating, although a wide variety of other materials and application processes are possible. The high-traction surface provides a high-friction connection between the rug and the pad, when the rug is placed in contact on the high-traction surface.

According to certain non-exclusive embodiments, fasteners may be provided 1808 on the high-traction surface of the pad, and if and as applicable, on corresponding underside of the rug. If the fasteners include a Velcro™ type connector, opposing pieces of loops, on the one hand, and hooks, on the other hand, are connected to the rug and pad. If the fasteners include a sticky gel type connector molded into the Velcro™ type connector, the sticky gel can be provided to the high-traction surface of the pad in desired location, such as, for example, corners of the pad, along edges of the pad, and otherwise. Similarly, such fasteners may include a sticky gel type connector molded in the Velcro™ type connector attached 1812 to the rug. Sticky gel adhesive properties can be tuned as desired, from semi-active to very aggressive tack, in addition to amounts of such gel can be varied, each for desired effect. The fasteners can allow for the rug to be removed from the pad, and for the rug and pad to be cleaned by washing or otherwise. Machine wash of the pad with sticky gel will revive the tackiness of the sticky gel.

In the case of hook and loop fasteners, a counterpart, such as the hook portion, is located on the high-traction surface 106 of the pad, and a second counterpart, such as the loop portion, is located on the underside of the rug 104 in corresponding position. As non-exclusive example, the sticky gel (and, if applicable, hook and loop fastener) is located at corners of the top side 108 of the pad 102, or around edges or periphery of the pad 102, or otherwise. In such embodiments, the sticky gel (and, if applicable, hook and loop fastener) in combination with the high-traction surface 106 keep the rug 104 from slipping on the pad 102, trap the pad 102 within perimeter of the rug 104, and resist natural tendency of the rug 104 with stiff corners to lift or curl and become trip hazard and the like. In certain non-exclusive alternatives, the rug and attachment method may be used without the pad.

As will be understood, wide variation is possible in the foregoing embodiments. Various engagements between rug and pad are possible to prevent slip, shift, and allow for desired separability of the rug from the pad. Where sticky gel is employed, the gel can be revived if grip diminishes. Further, sticky gel together with Velcro™ fasteners can protect the loop and hook pieces of the fasteners from exposure during machine washing and the like. Also, sticky gel allows the rug to be removed from the pad without movement of the pad which is retained with the slip-resistant surface of the pad on the floor or other surface.

In other alternatives, a plastic corner piece may be added to the rug, and sticky gel would stick well to smooth plastic. Other alternatives include that the rug is a textile rug top wear surface with a bottom or backing that is high-friction, that sticky gel is applied to the rug corners, that the sticky gel is molded into, sewn in, glued on, or otherwise attached to the rug, and/or that sticky gel is applied to entire perimeter or other portions of the rug. The sticky gel can additionally or alternatively be used on the high-friction surface of the pad, at corners of the pad, on entire perimeter or other portions of the pad, or otherwise, including that sticky gel may be employed on bottom of the pad to enhance the slip-resistance of the pad. The pad, itself, may be foam, gel, a combination of foam and gel, layers, segments, sections and other configurations.

If Velcro™ hooks are included, these may be attached to the floor or other surface or else molded into the foam, outer layer, or other portion of the pad, as applicable, and corresponding portion of the rug could include Velcro™ loops. The connectors or fasteners between pad and rug may be widely varied, including, for non-exclusive example, mechanical fasteners, such as snaps, molded-in pins of the pad that attach to the bottom of the rug, magnetic connectors on rug and pad, elastic loops of the rug stretched around pad, and others. Attachment of the connectors or fasteners to the rug and/or pad, respectively, can be widely varied in configuration.

In yet other alternatives, the rug may be comprised of vinyl, weave (such as Nylon), rubber, natural materials (such as Hemp and Bamboo), and any similar or equivalent wear, comfort or performance surface. Further, the pad may be made from varied materials and in variety of manners, such as die-cut flat foam, gel-foam combination, multi-density foam, gel only, combinations such as foam-gel-foam and gel-foam-gel, and others. The high-traction surface and slip-resistant surface of the pad can, similarly, be comprised of various materials and be manufactured in variety of manners, including Latex, vinyl, rubber, thermo plastic rubber, foam, combinations and others. Although certain features, elements, processes, materials, methods and others are disclosed, wide variation is possible in the embodiments.

In the foregoing, the invention has been described with reference to specific embodiments. One of ordinary skill in the art will appreciate, however, that various modifications, substitutions, deletions, and additions can be made without departing from the scope of the invention. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications substitutions, deletions, and additions are intended to be included within the scope of the invention. Any benefits, advantages, or solutions to problems that may have been described above with regard to specific embodiments, as well as device(s), connection(s), step(s) and element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced, are not to be construed as a critical, required, or essential feature or element.

ANTI-FATIGUE RUG WITH SEPARABLE RESILIENT CUSHION SYSTEM AND METHOD

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