Patent Application
20250135270
The present invention relates to yoga mats and, more particularly, to a three-layer yoga mat and a method of making the same.
The practice of yoga typically involves performing poses and stretches on a hard and smooth floor with a portable mat used to provide cushioning and grip between the practitioner and the floor. However, to achieve sufficient grip between the practitioner and the mat and between the mat and the floor, as well as sufficient cushioning and portability, prior art designs consistently utilize either natural rubber or petroleum-derived materials. These materials are either not biodegradable or are commonly obtained from non-sustainable sources, or from sources where sustainable environmental and labor practices are difficult to verify.
Most other yoga mats on the market are made from plastic (PVC or TPE) or rubber. Plastics are manufactured through a polluting process and are not biodegradable. Rubber lacks a strong certification system, and the industry is known for instances of forced labor or contributing to deforestation. These materials are durable and provide adequate cushioning, but may also be toxic (PVC), require towels for grip when wet, and can harbor unpleasant odors.
Prior art mats use either one or two layers of material. One-layer mats use a single material to provide grip between practitioner and mat, grip between mat and floor, and cushion. Two-layer mats add a layer to provide increased grip between practitioner and mat. Both designs require a material for the bulk of the product mass that is flexible for rolling, has sufficient friction for providing grip, and that provides adequate cushion. This drastically limits the materials appropriate to use since few materials have all these properties at once.
As can be seen, there is a need for a three-layer yoga mat and a method of making the same.
The present invention uses three layers of material, allowing a greater variety of material types to be considered since the need to provide cushion and grip can now be split between two material types. The innovations embodied in the present invention allows the inventors to select materials that are both more sustainable and reduce odors.
The disclosed invention eliminates the rubber or petroleum-derived material components and replaces them with more sustainable, widely available commodity materials that improve upon the performance characteristics of the traditional materials.
The disclosed invention is different in both the materials used in its manufacture and in the method of manufacture. Rather than rely on two material layers like prior art, the disclosed invention uses three layers. This more easily allows for the use of organic materials, which increases the sustainability of the mat, helps reduce odors, and enables enhanced cushioning and grip.
In one aspect of the present invention, a three-layer yoga mat having a top layer upon which a practitioner applies the art of yoga, a bottom layer that faces and engages a flat supporting surface for the art of yoga, and a middle layer sandwiched between the top layer and the bottom layer. The middle layer includes a plurality of sheets that collectively have a lower relative density than the top and bottom layers, respectively.
In another aspect of the present invention, the three-layer yoga mat further includes wherein the bottom layer comprises non-synthetic cork; wherein the top layer comprises non-synthetic cork, whereby the three-layer yoga mat is reversible, wherein the non-synthetic cork is laminated to a non-synthetic textile backing, wherein each of the plurality of sheets comprises non-synthetic felt; further providing two fastening straps depending from two attachment points, respectively, wherein each attachment point is adjacent an edge of the three-layer yoga mat, and wherein each strap provides a fastener to detachably engage a loop attached to the three-layer yoga map adjacent the respective attachment point so that the three-layer yoga mat is securable in a rolled-up configuration; and a carrying strap having two ends connected to the edge of the three-layer yoga mat.
In yet another aspect of the present invention, a method of making a non-synthetic yoga mat includes the following: sandwiching or placing a non-synthetic middle layer between a non-synthetic top layer and a non-synthetic bottom layer, wherein the non-synthetic middle layer comprises a plurality of sheets that collectively have a lower relative density than the non-synthetic top layer and the non-synthetic bottom layer; and quilting the top, bottom, and middle layers together, wherein the non-synthetic middle layer comprises non-synthetic felt, and wherein the non-synthetic top and bottom layers comprise non-synthetic cork, or, alternatively, wherein the non-synthetic middle layer consists of non-synthetic felt, and wherein the non-synthetic top and bottom layers consist of non-synthetic cork laminated to a non-synthetic textile.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.
The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
Broadly, the present invention includes a three-layer yoga mat having a top layer upon which a practitioner applies the art of yoga, a bottom layer that faces and engages a flat supporting surface for the art of yoga, and a middle layer sandwiched between the top layer and the bottom layer. The middle layer includes a plurality of sheets that collectively have a lower relative density than either of the top and bottom layers.
Referring the
In one embodiment, the top layer 12 may be cork fabric consisting of a thin layer of cork laminated to a natural textile such as hemp, bamboo, cotton, or other natural fiber; the middle layer 10 may include one or more sheets of natural felt made from hemp, wool, bamboo or other natural fibers; and wherein the bottom layer 11 cork fabric may consist of a thin layer of cork laminated to a natural textile such as hemp, bamboo, cotton, or other natural fiber. The joining elements 14 and 16 may be stitching.
A process of making the present invention may include the following. The top, middle, and bottom layers 12, 10, and 11 may be stacked together as they are unrolled from separate rolls and then quilted together in a quilting machine using Tencel or other sustainable fiber thread as the joining elements 14 and 16. Some joining elements 14 transverse across the three-layer yoga mat 100 adjacent a periphery of the three-layer yoga mat 100. In some embodiments an edge band 20 is provided, wherein the edge band 20 is a separate piece of material that wraps around the edges of layers 10, 11, and 12 and then is separately stitched onto the mat 100.
The top layer 12 provides grip between the practitioner and the mat so that hands, feet or other body parts will not slip easily during poses and stretches. The middle layer 10 provides cushioning so that yoga poses requiring the practitioner to place their weight on knees, hips, or other body parts do not create discomfort. The lower density of the middle layer 10 (relative to the top and bottom layers 12 and 11) enables cushioning for the hands and feet of the mat user to sink into the surface more, thereby enhancing their grip. The lower density allows for the weight of the practitioner to sink into the middle layers, creating temporary concavities in the top layer where hands, feet, knees, etc., sink into the mat. These concavities help prevent the lateral movement of hands, feet, knees, etc., until weight is removed. The minimum coefficient of friction between dry skin and dry top layer 12 is at approximately 0.80 or higher and between wet skin and wet top layer 12 is approximately 1.00 or higher. The bottom layer 11 provides grip between the mat and the floor so that as the practitioner places their weight on the mat, friction between the bottom layer 11 and the floor are sufficient to prevent the yoga mat 100 from stretching, bunching, or sliding on the floor. The coefficient of static friction between the dry bottom layer of the mat 11 and a dry polished wood floor is approximately 0.35 or higher. The joining element holds these materials together tightly so that the top, middle, and bottom layers 12, 10, and 11 do not slip, stretch, or bunch relative to one another. The top and bottom layers 12, and 11 also provide some moisture absorption away from the practice surface, but naturally resist fungal and microbial growth that can lead to odors. The combined thickness, rigidity, and elasticity of the materials allow the yoga mat 100 to be rolled or folded during transportation and storage.
Referring to
Finally, any finishing components such as edge banding around the yoga mat 100 borders, labels, or aesthetic design elements can be added, including implementation of joining elements 14 for an edge banding component 209 that defines an edge band 214, as well as the following components: corner trim 210, label stitching 211 of a label 215, finishing 212. Thereafter a packing component 213 is available.
Any elements (including edge banding, labels, or aesthetic design elements) added after quilting and cutting mats to size are optional. Other elements that could be added to enhance performance or aesthetics may include: 1) edge banding to seal the edges and provide a more polished appearance; 2) designs or labeling for aesthetic or branding purposes; 3) tags to convey information about the product's composition, countries of origin, and/or care instructions; 4) coatings or material treatments such as natural waxes or oils that may increase grip, moisture resistance, durability, or resistance to bacterial or fungal growth; 5) crease points to allow for easy folding for increased portability; 6) natural dyes applied to the cork surfaces to enhance aesthetics; 7) additional internal fabric (or other material) layers that may improve the structure and shape of the mat; and/or 8) replacement of felt layers with an alternative cushioning material that may provide greater durability or which may allow the layers to be laminated together, eliminating the need for thread and quilting in the manufacture process.
The cork fabric layers can be interchangeable. Variations in the types of cork or cork dyes used may make one surface more desirable for either aesthetic or functional reasons as the top vs. the bottom, but these layers are mostly similar enough to be switched around, or to allow the mat to be reversible whereby either surface can be used facing up (for grip between the practitioner and the mat) or down (for grip between the mat and the floor). Referring to
Referring to
The present invention 100 is intended to be used in a manner nearly identical to existing yoga mats. It can be rolled or folded for storage and transport and then unrolled/unfolded and laid flat on the floor or ground with the practitioner positioned on top of the mat where they can perform strength, stretching, movement, and other exercises.
In addition to being used for yoga, the present invention 100 can also be used in any other type of strength, stretching, movement, meditation, or other similar exercises. It could potentially also be used as a sleeping pad, nap roll, prayer mat, beach cushion, picnic mat, dog bed, bench cushion, furniture cover, rug, or for other applications that take advantage of the mat's grip, the mat's cushioning, the mat's aesthetics, or other mat properties.
As used in this application, the term “about” or “approximately” refers to a range of values within plus or minus 10% of the specified number. And the term “substantially” refers to up to 80% or more of an entirety. Recitation of ranges of values herein are not intended to be limiting, referring instead individually to any and all values falling within the range, unless otherwise indicated, and each separate value within such a range is incorporated into the specification as if it were individually recited herein.
For purposes of this disclosure, the term “aligned” means parallel, substantially parallel, or forming an angle of less than 35.0 degrees. For purposes of this disclosure, the term “transverse” means perpendicular, substantially perpendicular, or forming an angle between 55.0 and 125.0 degrees. Also, for purposes of this disclosure, the term “length” means the longest dimension of an object. Also, for purposes of this disclosure, the term “width” means the dimension of an object from side to side. For the purposes of this disclosure, the term “above” generally means superjacent, substantially superjacent, or higher than another object although not directly overlying the object. Further, for purposes of this disclosure, the term “mechanical communication” generally refers to components being in direct physical contact with each other or being in indirect physical contact with each other where movement of one component affect the position of the other.
The use of any and all examples, or exemplary language (“e.g.,” “such as,” or the like) provided herein, is intended merely to better illuminate the embodiments and does not pose a limitation on the scope of the embodiments or the claims. No language in the specification should be construed as indicating any unclaimed element as essential to the practice of the disclosed embodiments.
In the following description, it is understood that terms such as “first,” “second,” “top,” “bottom,” “up,” “down,” and the like, are words of convenience and are not to be construed as limiting terms unless specifically stated to the contrary.
It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.
This application claims the benefit of priority of U.S. provisional application No. 63/593,386, filed Oct. 23, 2023, the contents of which are herein incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63593386 | Oct 2023 | US |
