SECUREABLE FLOOR MAT WITH DOUBLE-SIDED ADHESIVE

BACKGROUND

Floor mats may be used in fitness centers, gyms, and/or homes to dampen noise and vibrations, protect the floor, and/or provide other desirable qualities, such as sturdiness, stability, durability, rigidity, cushioning, and/or easy care and maintenance. Securing mechanisms may be used to keep a floor mat in a desired position. However, known solutions are difficult to use and/or provide unsatisfactory results. For example, some conventional securing mechanisms are not capable of withstanding much force and, as a result, do not keep the floor mat in a desired position very well. Meanwhile, other conventional securing mechanisms are not suitable for repeated reapplications and, thus, make it difficult and/or cumbersome to reposition a floor mat. Indeed, some such securing mechanisms can be so strong that, if the floor mat were removed, it would cause damage to the floor mat and/or floor.

SUMMARY

Examples described herein enable keeping a floor mat in a desired position in a user-friendly, reusable manner. In one aspect, a floor mat is provided. The floor mat includes a first panel including one or more first lower layers and a first upper layer at least partially overlying the one or more first lower layers, and a second panel including one or more second lower layers and a second upper layer at least partially overlying the one or more second lower layers. The first upper layer has a first configuration that includes a double-sided adhesive, and the second upper layer has a second configuration that complements the first configuration and includes a fabric strip. The double-sided adhesive is configured to engage the fabric strip such that the first panel is securely coupleable to the second panel.

In another aspect, a securing mechanism is provided for use with a floor mat including a first panel and a second panel. The securing mechanism includes a flap coupled to the first panel. The flap includes an arm portion and a double-sided adhesive coupled to a lower surface of the arm portion. The securing mechanism further includes a fabric strip coupled to an upper surface of the second panel.

In yet another aspect, a method is provided for making a floor mat. The method includes positioning a first upper layer over one or more first lower layers to form a first panel, and positioning a second upper layer over one or more second lower layers to form a second panel. The first upper layer has a first configuration that includes a double-sided adhesive, and the second upper layer has a second configuration that complements the first configuration and includes a fabric strip. The double-sided adhesive is configured to engage the fabric strip such that the first panel is securely coupleable to the second panel.

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWING

The present disclosure will be best understood by reference to the following Detailed Description when read in conjunction with the accompanying drawing, wherein:

FIG. 1 shows a perspective view of a section of an example floor mat;

FIG. 2 shows an exploded view of the section of the floor mat shown in FIG. 1;

FIG. 3 shows a schematic view of an example first upper layer that may be used in a floor mat, such as the floor mat shown in FIG. 1;

FIG. 4 shows a schematic view of an example second upper layer that may be used with the first upper layer shown in FIG. 3;

FIG. 5 shows a schematic view of another example first upper layer that may be used in a floor mat, such as the floor mat shown in FIG. 1;

FIG. 6 shows a schematic view of an example second upper layer that may be used with the first upper layer shown in FIG. 5; and

FIG. 7 shows a flowchart of an example method for making a floor mat, such as the floor mat shown in FIG. 1.

Like parts are marked throughout the drawing, as well as throughout the Detailed Disclosure, with the same reference characters. The figures are not necessarily drawn to scale and certain figures may be shown in exaggerated or generalized form in the interest of clarity and conciseness. Although specific features may be shown in some of the figures and not in others, this is for convenience only.

DETAILED DESCRIPTION

The present disclosure is directed to a floor mat (e.g., gym mat, exercise mat, etc.). Examples described herein include a first panel and a second panel coupleable to the first panel. The first panel includes one or more first lower layers and a first upper layer with a first configuration. The second panel includes one or more second lower layers and a second upper layer with a second configuration. The first upper layer and second upper layer complement each other such that they are configured to securely couple the first panel to the second panel. For example, one upper layer may include a double-sided adhesive while the other upper layer may include a fabric strip. This enables the examples described herein to reliably keep a floor mat in a desired position in a user-friendly, reusable manner. The following non-limiting examples are provided to further illustrate the present invention.

FIGS. 1 and 2 show an example floor mat 100. As shown in FIG. 1, the floor mat 100 may extend longitudinally a length 101 between a proximal end 102 and a distal end 103, laterally a width 104 between a left side 105 and a right side 106, and vertically a height 107 between a lower surface 108 and an upper surface 109. The floor mat 100 includes at least a first panel 110 and a second panel 120 that are coupleable to each other to form the floor mat 100. FIG. 1 shows the floor mat 100 in an assembled configuration, in which the first panel 110 and second panel 120 are coupled to each other, and FIG. 2 shows the floor mat 100 in a disassembled configuration, in which the first panel 110 and second panel 120 are not coupled to each other.

In some examples, the first panel 110 includes one or more first lower layers 132 and a first upper layer 134 at least partially overlying the first lower layers 132. Similarly, the second panel 120 may include one or more second lower layers 136 and a second upper layer 138 at least partially overlying the second lower layers 136. In some examples, the first lower layers 132, first upper layer 134, second lower layers 136, and/or second upper layer 138 are comprised of a foam material. Additionally or alternatively, the first lower layers 132, first upper layer 134, second lower layers 136, and/or second upper layer 138 may be comprised of any material that enables the floor mat 100 to function as described herein.

The first upper layer 134 has a first configuration. For example, the first upper layer 134 may include a core portion 141 and an arm portion 142 extending laterally inward (e.g., toward the second panel 120) from the core portion 141. In some examples, the core portion 141 of the first upper layer 134 has a footprint that is the same as or at least substantially similar to that of the first lower layers 132. For example, the core portion 141 and first lower layers 132 may extend longitudinally a common length (e.g., length 101) and be aligned such that the core portion 141 and first lower layers 132 are flush at the proximal end 102 and at the distal end 103. Similarly, the core portion 141 and first lower layers 132 may extend laterally a common width 143 and be aligned such that the core portion 141 and first lower layers 132 are flush at a lateral or outer side (e.g., left side 105) and at a medial or inner side 144. Additionally, the core portion 141 may have a height 145 that is equal or at least substantially similar to that of the first lower layers 132. Alternatively, the core portion 141 and/or first lower layers 132 may have any shape, size, and/or configuration that enables the first panel 110 to function as described herein.

In some examples, the arm portion 142 extends longitudinally a length that is equal to that of the core portion 141 and/or first lower layers 132 and is aligned such that the arm portion 142 is flush with the core portion 141 and/or first lower layers 132 at the proximal end 102 and at the distal end 103. In some examples, the arm portion 142 of the first upper layer 134 extends laterally inward beyond the inner side 144 of the core portion 141 and/or first lower layers 132 to create an overhang spanning an overhang distance 146. As shown in FIGS. 1 and 2, an upper surface of the arm portion 142 may be flush with an upper surface of the core portion 141 such that an upper surface of the first upper layer 134 is at least substantially planar. Additionally, as shown in FIG. 2, a height 147 of the arm portion 142 and an overhang height 148 may be collectively equal or at least substantially similar to the height 145 of the core portion 141. Alternatively, the arm portion 142 may have any size, shape, and/or configuration that enables the first upper layer 134 to function as described herein.

The second upper layer 138 has a second configuration different from the first configuration of the first upper layer 134. For example, the second upper layer 138 may include a core portion 151 and a step portion 152 extending laterally inward (e.g., toward the first panel 110) from the core portion 151. In some examples, the second upper layer 138 complements the first upper layer 134 such that the second panel 120 is securely coupleable to the first panel 110. For example, as shown in FIG. 2, the step portion 152 of the second upper layer 138 may extend laterally beyond a medial or inner side 153 of the core portion 151 and/or second lower layers 136 to create a step spanning a step distance 154 that is equal or at least substantially similar to the overhang distance 146. Moreover, as also shown in FIG. 2, the second upper layer 138 may have a riser height 155 that is equal or at least substantially similar to the height 147 of the arm portion 142. In some examples, a height 156 (shown in FIG. 2) of the step portion 152 is equal or at least substantially similar to the overhang height 148 of the first upper layer 134. Additionally, the core portion 151 and/or step portion 152 may extend longitudinally a length that is equal or at least substantially similar to that of the core portion 141 and/or arm portion 142 of the first upper layer 134.

In some examples, the second upper layer 138 has a footprint that is the same as or at least substantially similar to that of the second lower layers 136. For example, the core portion 151, step portion 152, and/or second lower layers 136 may extend longitudinally a common length (e.g., length 101) and be aligned such that the core portion 151, step portion 152, and/or second lower layers 136 are flush at the proximal end 102 and at the distal end 103. Similarly, the core portion 151 and step portion 152 collectively may extend laterally a width 157 that is equal to that of the second lower layers 136 and be aligned with the second lower layers 136 such that the core portion 151 is flush with the second lower layers 136 at a lateral or outer side (e.g., right side 106) and the step portion 152 is flush with the second lower layers 136 at the inner side 153. Additionally, the core portion 151 may have a height 158 that is equal or at least substantially similar to that of the second lower layers 136 and greater than the height 156 of the step portion 152. As shown in FIGS. 1 and 2, a lower surface of the core portion 151 may be flush with a lower surface of the step portion 152 such that a lower surface of the second upper layer 138 is at least substantially planar. Alternatively, the core portion 151, step portion 152, and/or second lower layers 136 may have any shape, size, and/or configuration that enables the second panel 120 to function as described herein.

When the floor mat 100 is in the assembled configuration (shown in FIG. 1), an upper surface of the core portion 151 of the second upper layer 138 may be flush with the upper surface of the core portion 141 and/or arm portion 142 of the first upper layer 134 such that the upper surface 109 of the floor mat 100 is at least substantially planar. In some examples, the first panel 110 and second panel 120 extend vertically a common height (e.g., height 107) such that the first panel 110 and second panel 120 are flush at the lower surface 108 and at the upper surface 109 when the floor mat 100 is in the assembled configuration. For example, a height of the first lower layers 132 (e.g., height 145) may be equal or at least substantially similar to that of the second lower layers 136, and a height of the first upper layer 134 (e.g., height 145) may be equal or at least substantially similar to that of the second upper layer 138 (e.g., height 158). In some examples, the first panel 110 and second panel 120 extend longitudinally a common length (e.g., length 101) such that the first panel 110 and second panel 120 are flush at the proximal end 102 and at the distal end 103 when the floor mat 100 is in the assembled configuration and the first panel 110 and second panel 120 are aligned with each other. As shown in FIG. 1, the width 104 of the floor mat 100 may be equal or at least substantially similar to the sum of the width 143 of the core portion 141 of the first upper layer 134 and the width 157 of the core portion 151 of the second upper layer 138. Alternatively, the first panel 110 and/or second panel 120 may have any shape, size, and/or configuration that enables the floor mat 100 to function as described herein.

FIG. 3 shows an example first upper layer 200 (e.g., first upper layer 134) that may be used in the floor mat 100. For example, the first upper layer 200 may be used in the first panel 110 to at least partially extend over the first lower layers 132. The first upper layer 200 may have a first configuration that is different from that of the first lower layers 132. For example, the first upper layer 200 has an upside-down L-shaped configuration including a core portion 210 (e.g., core portion 141) and an arm portion 220 (e.g., arm portion 142) extending at least substantially perpendicular to the core portion 210 to create an overhang spanning an overhang distance 222 (e.g., overhang distance 146). Alternatively, the arm portion 220 may be part of a flap that is coupled to a conventional panel for use in securely coupling the panel to another panel.

The arm portion 220 includes and/or is coupled to a double-sided adhesive 230. For example, as shown in FIG. 3, an upper side of the double-sided adhesive 230 may be coupled to a lower surface 232 of the arm portion 220 such that a lower side of the double-sided adhesive 230 is oriented to face downward. The upper side of the double-sided adhesive 230 is configured to provide a strong and reliable grip, allowing the double-sided adhesive 230 to remain securely coupled to the arm portion 220. The lower side of the double-sided adhesive 230 is also configured to provide a strong and reliable grip, allowing the double-sided adhesive 230 to be securely coupled to another object (e.g., second panel 120) in a user-friendly, reusable manner. For example, a force coupling the double-sided adhesive 230 to the lower surface 232 of the arm portion 220 may be greater than a force with which the double-sided adhesive 230 is configured to couple the double-sided adhesive 230 to the other object. In some examples, the lower side of the double-sided adhesive 230 is configured to be detached from the other object without damaging the other object or leaving any residue.

FIG. 4 shows an example second upper layer 300 (e.g., second upper layer 138) that may be used in the floor mat 100. For example, the second upper layer 300 may be used in the second panel 120 to at least partially extend over the second lower layers 136. The second upper layer 300 has a second configuration that is different from the first configuration of the first upper layer 200 and from that of the second lower layers 136. For example, the second upper layer 300 has a right-side-up L-shaped configuration including a core portion 310 (e.g., core portion 151) and a step portion 320 (e.g., step portion 152) extending at least substantially perpendicular to the core portion 310 to create a step spanning a step distance 322 (e.g., step distance 154). To facilitate assembling the floor mat 100, an upper surface 324 of the step portion 320 is configured to engage the lower side of the double-sided adhesive 230 (shown in FIG. 3) of the first upper layer 200 (shown in FIG. 3).

In some examples, the step portion 320 includes and/or is coupled to a fabric strip 330. For example, the fabric strip 330 may be coupled to an upper surface 324 of the step portion 320. Alternatively, the fabric strip 330 may be coupled to a conventional panel for use in securely coupling the panel to another panel. In some examples, the fabric strip 330 is comprised of a nylon material and/or has an interwoven construction. Additionally or alternatively, the fabric strip 330 may be comprised of any material and/or have any construction that enables the second upper layer 300 to function as described herein.

In some examples, the fabric strip 330 has a footprint that is the same as or at least substantially similar to that of the step portion 320. For example, the fabric strip 330 may extend longitudinally a length equal to that of the step portion 320 and be aligned with the step portion 320 such that the fabric strip 330 is flush with the step portion 320 at the proximal end 102 and at the distal end 103. Similarly, the fabric strip 330 may extend laterally a width equal to that of the step portion 320 and be aligned with the step portion 320 such that the fabric strip 330 is flush with the step portion 320 at a lateral or outer side 332 and at a medial or inner side 334.

To facilitate assembling the floor mat 100, an upper surface 336 of the fabric strip 330 is configured to engage the lower side of the double-sided adhesive 230 (shown in FIG. 3) of the first upper layer 200 (shown in FIG. 3). In some examples, the adhesive material of the double-sided adhesive 230 (shown in FIG. 3) is configured to bond with the fabric strip 330 in a manner that is more secure than a hook-and-loop connection and yet still allows the double-sided adhesive 230 and fabric strip 330 to be separated relatively easily and smoothly. For example, a force coupling the double-sided adhesive 230 to the fabric strip 330 may be greater than a force provided by a conventional hook-and-loop connection. In some examples, the tensile strength of the double-sided adhesive 230-fabric strip 330 connection is five times stronger than that of a conventional hook-and-loop connection.

The fabric strip 330 facilitates protecting the step portion 320 from the double-sided adhesive 230. For example, without the fabric strip 330, the double-sided adhesive 230 could directly engage the upper surface 324 of the step portion 320 such that separating the double-sided adhesive 230 therefrom could potentially cause damage thereto. In some examples, a force coupling the double-sided adhesive 230 to the fabric strip 330 is less than that coupling the double-sided adhesive 230 directly to the upper surface 324 of the step portion 320.

In some examples, the fabric strip 330 is coupled to the step portion 320 using a double-sided adhesive 340. For example, as shown in FIG. 4, a lower side of the double-sided adhesive 340 may be coupled to the upper surface 324 of the step portion 320, and an upper side of the double-sided adhesive 340 may be coupled to a lower side of the fabric strip 330 such that an upper side of the fabric strip 330 is oriented to face upward. The double-sided adhesive 340 is configured to provide a strong and reliable grip, allowing the fabric strip 330 to remain securely coupled to the step portion 320 of the second upper layer 300. Alternatively, the fabric strip 330 may be coupled to the step portion 320 in any manner that enables the floor mat 100 to function as described herein.

FIG. 5 shows another example first upper layer 400 (e.g., first upper layer 134) that may be used in the floor mat 100. Except as otherwise described below, it should be understood that the first upper layer 400 is substantially similar to, and function in substantially the same manner as, the first upper layer 200 described above.

As shown in FIG. 5, the arm portion 220 may include and/or be coupled to a fabric strip 410. For example, the fabric strip 410 may be coupled to the lower surface 232 of the arm portion 220. Except as otherwise described below, it should be understood that the fabric strip 410 is substantially similar to, and function in substantially the same manner as, the fabric strip 330 described above.

In some examples, the fabric strip 410 has a footprint that is the same as or at least substantially similar to that of the arm portion 220. For example, the fabric strip 410 may extend longitudinally a length equal to that of the arm portion 220 and be aligned with the arm portion 220 such that the fabric strip 410 is flush with the arm portion 220 at the proximal end 102 and at the distal end 103. Similarly, the fabric strip 410 may extend laterally a width equal to that of the arm portion 220 and be aligned with the arm portion 220 such that the fabric strip 410 is flush with the arm portion 220 at a lateral or outer side 412 and at a medial or inner side 414.

In some examples, the fabric strip 410 is coupled to the arm portion 220 using a double-sided adhesive 420. For example, as shown in FIG. 5, an upper side of the double-sided adhesive 420 may be coupled to the lower surface 232 of the arm portion 220, and a lower side of the double-sided adhesive 420 may be coupled to an upper side of the fabric strip 410 such that a lower side of the fabric strip 410 is oriented to face downward. The double-sided adhesive 420 is configured to provide a strong and reliable grip, allowing the fabric strip 410 to remain securely coupled to the arm portion 220 of the first upper layer 400. Alternatively, the fabric strip 410 may be coupled to the arm portion 220 in any manner that enables the floor mat 100 to function as described herein.

FIG. 6 shows an example second upper layer 500 (e.g., second upper layer 138) that may be used in the floor mat 100. Except as otherwise described below, it should be understood that the second upper layer 500 is substantially similar to, and function in substantially the same manner as, the second upper layer 300 described above.

As shown in FIG. 6, the step portion 320 may include and/or be coupled to a double-sided adhesive 510. For example, the double-sided adhesive 510 may be coupled to the upper surface 324 of the step portion 320. Except as otherwise described below, it should be understood that the double-sided adhesive 510 is substantially similar to, and function in substantially the same manner as, the double-sided adhesive 230 described above.

To facilitate assembling the floor mat 100, a lower surface 416 of the fabric strip 410 (shown in FIG. 5) is configured to engage the upper side of the double-sided adhesive 510. The fabric strip 410 (shown in FIG. 5) facilitates protecting the arm portion 220 (shown in FIG. 5) from the double-sided adhesive 510.

FIG. 7 shows a method 600 for making a floor mat (e.g., floor mat 100). In some examples, the method 600 includes positioning a first upper layer (e.g., first upper layer 134, first upper layer 200, first upper layer 400) over one or more first lower layers (e.g., first lower layer 132) to form a first panel (e.g., first panel 110) at operation 610. As shown in FIGS. 1 and 2, the first lower layers may be aligned to have a common footprint.

In some examples, the method 600 includes positioning a second upper layer (e.g., second upper layer 138, second upper layer 300, second upper layer 500) over one or more second lower layers (e.g., second lower layers 136) to form a second panel (e.g., second panel 120) at operation 620. As shown in FIGS. 1 and 2, the second lower layers may be aligned to have a common footprint.

The first upper layer and second upper layer are configured to enable the first panel to be securely coupled to the second panel in a user-friendly, reusable manner. In some examples, a double-sided adhesive (e.g., double-sided adhesive 230) is coupled to a lower surface of a portion of the first upper layer (e.g., arm portion 142, arm portion 220), and a fabric strip (e.g., fabric strip 330) is coupled to an upper surface of a portion of the second upper layer (e.g., step portion 152, step portion 320). In such examples, a double-sided adhesive (e.g., double-sided adhesive 340) may be used to couple the fabric strip to the upper surface of the portion of the second upper layer. In other examples, a fabric strip (e.g., fabric strip 410) is coupled to a lower surface of a portion of the first upper layer (e.g., arm portion 142, arm portion 220), and a double-sided adhesive (e.g., double-sided adhesive 510) is coupled to an upper surface of a portion of the second upper layer (e.g., step portion 152, step portion 320). In such examples, a double-sided adhesive (e.g., double-sided adhesive 420) may be used to couple the fabric strip to the lower surface of the portion of the first upper layer.

To assemble the floor mat, the double-sided adhesive on one panel may be positioned to engage the fabric strip on the other panel. In this manner, the adhesive material of the double-sided adhesive on one panel may bond with the nylon material of the fabric strip on the other panel and not with the foam material of the other panel. The fabric strip enables the floor mat to be reusable. For example, when the floor mat is in the assembled configuration, the tensile strength of the connection between the double-sided adhesive and the fabric strip is less than that of the connection between the double-sided adhesive and the underlying (or overlying) panel. Accordingly, when the floor mat is disassembled by moving one panel away from the other panel, the double-sided adhesive on one panel disengages from the fabric strip on the other panel.

This written description uses examples to disclose aspects of the disclosure and also to enable a person skilled in the art to practice the aspects, including making or using the above-described systems and executing or performing the above-described methods. The examples described herein are configured to facilitate reliably keeping a floor mat in a desired position in a user-friendly, reusable manner. The examples described herein also protect the floor mat from being damaged.

Having described aspects of the disclosure in terms of various examples with their associated operations, it will be apparent that modifications and variations are possible without departing from the scope of the disclosure as defined in the appended claims. That is, aspects of the disclosure are not limited to the specific examples described herein, and all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

Components of the systems and/or operations of the methods described herein may be utilized independently and separately from other components and/or operations described herein. Moreover, the methods described herein may include additional or fewer operations than those disclosed, and the order of execution or performance of the operations described herein is not essential unless otherwise specified. That is, the operations may be executed or performed in any order, unless otherwise specified, and it is contemplated that executing or performing a particular operation before, contemporaneously with, or after another operation is within the scope of the disclosure. Although specific features of various examples of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a figure may be referenced and/or claimed in combination with any feature of any other figure.

When introducing elements of the present disclosure, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. References to an “embodiment” or an “example” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments or examples that also incorporate the recited features. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. The phrase “one or more of the following: A, B, and C” means “at least one of A and/or at least one of B and/or at least one of C.”

The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

SECUREABLE FLOOR MAT WITH DOUBLE-SIDED ADHESIVE

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