CA2579536A1 - A laminated anti-fatigue area rug and method of manufacture - Google Patents
A laminated anti-fatigue area rug and method of manufacture Download PDFInfo
- Publication number
- CA2579536A1 CA2579536A1 CA 2579536 CA2579536A CA2579536A1 CA 2579536 A1 CA2579536 A1 CA 2579536A1 CA 2579536 CA2579536 CA 2579536 CA 2579536 A CA2579536 A CA 2579536A CA 2579536 A1 CA2579536 A1 CA 2579536A1
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- Canada
- Prior art keywords
- rug
- laminate
- cork
- bonding
- fatigue
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 230000002929 anti-fatigue Effects 0.000 title claims abstract description 29
- 238000000034 method Methods 0.000 title claims description 6
- 238000004519 manufacturing process Methods 0.000 title claims description 5
- 239000007799 cork Substances 0.000 claims abstract description 55
- 239000000463 material Substances 0.000 claims abstract description 35
- 229920001971 elastomer Polymers 0.000 claims abstract description 13
- 239000005060 rubber Substances 0.000 claims abstract description 13
- 239000000853 adhesive Substances 0.000 claims abstract description 11
- 230000001070 adhesive effect Effects 0.000 claims abstract description 11
- 239000011152 fibreglass Substances 0.000 claims abstract description 11
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 claims abstract description 9
- 229920002554 vinyl polymer Polymers 0.000 claims abstract description 8
- 239000011527 polyurethane coating Substances 0.000 claims abstract description 5
- 238000005336 cracking Methods 0.000 claims abstract description 4
- 230000002093 peripheral effect Effects 0.000 claims description 13
- 238000007688 edging Methods 0.000 claims description 9
- 239000004568 cement Substances 0.000 claims description 8
- 230000002787 reinforcement Effects 0.000 claims description 6
- 239000011324 bead Substances 0.000 claims description 4
- 239000006260 foam Substances 0.000 claims description 4
- 238000005304 joining Methods 0.000 claims description 4
- 238000009964 serging Methods 0.000 claims description 4
- 229920003051 synthetic elastomer Polymers 0.000 claims description 4
- 239000005061 synthetic rubber Substances 0.000 claims description 4
- 229920000459 Nitrile rubber Polymers 0.000 claims description 3
- 238000003475 lamination Methods 0.000 claims description 3
- 229920003048 styrene butadiene rubber Polymers 0.000 claims description 3
- 238000009966 trimming Methods 0.000 claims description 3
- 239000000565 sealant Substances 0.000 claims description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 2
- 239000004744 fabric Substances 0.000 abstract description 2
- 238000003860 storage Methods 0.000 abstract description 2
- 239000000203 mixture Substances 0.000 description 6
- 230000007613 environmental effect Effects 0.000 description 4
- 238000010276 construction Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000003063 flame retardant Substances 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 229920000126 latex Polymers 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 230000000007 visual effect Effects 0.000 description 2
- 206010020751 Hypersensitivity Diseases 0.000 description 1
- 229930183415 Suberin Natural products 0.000 description 1
- 235000009430 Thespesia populnea Nutrition 0.000 description 1
- 244000299492 Thespesia populnea Species 0.000 description 1
- 230000007815 allergy Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000001413 cellular effect Effects 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 230000001627 detrimental effect Effects 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 238000009408 flooring Methods 0.000 description 1
- 230000000774 hypoallergenic effect Effects 0.000 description 1
- 239000002648 laminated material Substances 0.000 description 1
- 239000004816 latex Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 239000002341 toxic gas Substances 0.000 description 1
Classifications
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47G—HOUSEHOLD OR TABLE EQUIPMENT
- A47G27/00—Floor fabrics; Fastenings therefor
- A47G27/02—Carpets; Stair runners; Bedside rugs; Foot mats
- A47G27/0212—Carpets; Stair runners; Bedside rugs; Foot mats to support or cushion
- A47G27/0231—Carpets; Stair runners; Bedside rugs; Foot mats to support or cushion for fighting fatigue
Landscapes
- Health & Medical Sciences (AREA)
- General Health & Medical Sciences (AREA)
- Hospice & Palliative Care (AREA)
- Laminated Bodies (AREA)
- Floor Finish (AREA)
Abstract
A laminated anti-fatigue area rug comprises a bottom laminate of anti-fatigue material being rubber or vinyl having anti-slip properties for stability, a top laminate of cork with an upper wearing surface having a polyurethane coating and a middle bonding laminate of fiberglass cloth and adhesive material to bond the layers together. There resulting rug is sufficiently flexible that it may be rolled for storage without cracking the cork or delaminating.
Description
A LAMINATED ANTI-FATIGUE AREA RUG AND METHOD OF
MANUFACTURE
BACKGROUND OF THE INVENTION
Field of the Invention This invention relates to the field of laminated materials and more particularly to a laminated anti-fatigue rug.
Discussion of the Prior Art Anti-fatigue carpets are well known in industry and commercial applications where they reduce leg and back fatigue from standing over long periods of time. Such rugs tend to be rubber or vinyl and do not possess aesthetic qualities that make them suitable for residential use. As well, the use of rubber and vinyl products to produce a cushioning effect is detrimental to the environment when compared to other materials that have not heretofore been used in such applications. Cork is one such material. The benefits are using cork as a floor covering include the following:
- Cork trees are stripped of their bark every 9 to 14 years, never cut, ensuring that its habitat remains undisturbed. Hence cork is an environmentally benign material.
- The natural structure and chemical composition of Cork contribute to its beneficial properties: insulation, resiliency, impermeability, durability and hypoallergenic and fire retardant tendencies.
- 90 % of cork tissue is gaseous; hence its density is extremely low, supporting great insulation - thermal and acoustic.
- When cork is subjected to pressure, the gas in the cells is compressed and volume reduces considerably. When released from pressure, cork recovers very rapidly to its original shape.
- The presence of Suberin, an intrinsic waxy substance, renders cork impervious to both liquid and gas. As a result, it will not rot and is considered the best seal available.
- Cork does not absorb dust, and consequently does not cause or contribute to allergies.
- Cork is remarkably resilient. It is less affected by impact and friction than any other hard surface because of its cellular composition.
- Cork is a natural fire retardant. It does not release toxic gases during combustion thus flames will not spread.
- Maintenance is nominal.
However, most floor covering applications using cork are rigid flooring laminates that cannot be easily rolled up and stored like a cloth or synthetic carpet.
MANUFACTURE
BACKGROUND OF THE INVENTION
Field of the Invention This invention relates to the field of laminated materials and more particularly to a laminated anti-fatigue rug.
Discussion of the Prior Art Anti-fatigue carpets are well known in industry and commercial applications where they reduce leg and back fatigue from standing over long periods of time. Such rugs tend to be rubber or vinyl and do not possess aesthetic qualities that make them suitable for residential use. As well, the use of rubber and vinyl products to produce a cushioning effect is detrimental to the environment when compared to other materials that have not heretofore been used in such applications. Cork is one such material. The benefits are using cork as a floor covering include the following:
- Cork trees are stripped of their bark every 9 to 14 years, never cut, ensuring that its habitat remains undisturbed. Hence cork is an environmentally benign material.
- The natural structure and chemical composition of Cork contribute to its beneficial properties: insulation, resiliency, impermeability, durability and hypoallergenic and fire retardant tendencies.
- 90 % of cork tissue is gaseous; hence its density is extremely low, supporting great insulation - thermal and acoustic.
- When cork is subjected to pressure, the gas in the cells is compressed and volume reduces considerably. When released from pressure, cork recovers very rapidly to its original shape.
- The presence of Suberin, an intrinsic waxy substance, renders cork impervious to both liquid and gas. As a result, it will not rot and is considered the best seal available.
- Cork does not absorb dust, and consequently does not cause or contribute to allergies.
- Cork is remarkably resilient. It is less affected by impact and friction than any other hard surface because of its cellular composition.
- Cork is a natural fire retardant. It does not release toxic gases during combustion thus flames will not spread.
- Maintenance is nominal.
However, most floor covering applications using cork are rigid flooring laminates that cannot be easily rolled up and stored like a cloth or synthetic carpet.
Therefore, there is a need for an anti-fatigue rug that has good aesthetics, is made from environmentally sound materials and can be rolled for storage.
OBJECTS OF THE INVENTION
It is an object of the present invention to overcome the deficiencies noted in the prior art.
It is a further object of the present invention to provide an improved anti-fatigue rug that is of more ecologically sound construction.
It is still another object of the present invention to provide an anti-fatigue rug made from cork that can be rolled and stored like a carpet.
SUMMARY
In one embodiment of the invention there is provided a laminated anti-fatigue area rug comprising a bottom laminate of anti-fatigue material having an upper bonding surface and a lower contact surface having anti-slip properties for stability. The invention further comprises a top laminate of cork having a lower bonding surface and an upper wearing surface having a transparent polyurethane coating. The invention still further comprises a middle bonding laminate to bond the top layer to the bottom layer.
OBJECTS OF THE INVENTION
It is an object of the present invention to overcome the deficiencies noted in the prior art.
It is a further object of the present invention to provide an improved anti-fatigue rug that is of more ecologically sound construction.
It is still another object of the present invention to provide an anti-fatigue rug made from cork that can be rolled and stored like a carpet.
SUMMARY
In one embodiment of the invention there is provided a laminated anti-fatigue area rug comprising a bottom laminate of anti-fatigue material having an upper bonding surface and a lower contact surface having anti-slip properties for stability. The invention further comprises a top laminate of cork having a lower bonding surface and an upper wearing surface having a transparent polyurethane coating. The invention still further comprises a middle bonding laminate to bond the top layer to the bottom layer.
In another embodiment of the invention the upper wearing surface may have a decorative pattern.
The resulting laminated rug is sufficiently pliable so that it may be rolled without resulting in de-lamination or cracking of any laminate.
In one embodiment of the invention the bottom laminate comprises anti-fatigue rubber the composition of which is well known in the art of about 7 mm although this may vary to suit varies environmental conditions of use. The rubber can be natural or synthetic such as nitrile rubber or styrene-butadiene rubber (SBR).
In another embodiment of the invention the bottom laminate is anti-fatigue vinyl foam the composition of which is also well known in the art having a thickness of about 7 mm depending upon environmental conditions use.
In yet another embodiment of the invention the top laminate is cork comprising a single sheet of cork.
In another embodiment of the invention the cork laminate may be constructed from cork strips or tiles.
The resulting laminated rug is sufficiently pliable so that it may be rolled without resulting in de-lamination or cracking of any laminate.
In one embodiment of the invention the bottom laminate comprises anti-fatigue rubber the composition of which is well known in the art of about 7 mm although this may vary to suit varies environmental conditions of use. The rubber can be natural or synthetic such as nitrile rubber or styrene-butadiene rubber (SBR).
In another embodiment of the invention the bottom laminate is anti-fatigue vinyl foam the composition of which is also well known in the art having a thickness of about 7 mm depending upon environmental conditions use.
In yet another embodiment of the invention the top laminate is cork comprising a single sheet of cork.
In another embodiment of the invention the cork laminate may be constructed from cork strips or tiles.
In still another embodiment of the invention the middle bonding laminate comprises bonding material adapted to provide structural strength to the rug and having anti-puncture characteristics.
In a preferred embodiment of the invention, the bonding material comprises reinforcement fiberglass tissue.
In another embodiment of the invention the bonding material comprises reinforcement fiberglass roving.
In one embodiment of the invention adhesive material is placed on the top and the bottom surfaces of the bonding material.
The constructed rug has a peripheral edge which may be reinforced by carpet serging or a strip of cork.
A method of manufacturing a laminated anti-fatigue area rug comprises the steps of:
a. forming the bottom laminate having a predetermined size from anti-fatigue material;
b. forming the top laminate having said predetermined size;
c. applying the middle bonding laminate to the lower bonding surface of the top laminate using an adhesive;
d. placing the upper bonding surface of the top laminate into contact with the middle bonding laminate;
e. trimming the peripheral edge so that it is clean; and, f. fixing edging to the peripheral edge.
The method further comprises the step of providing a decorative pattern within the upper wearing surface of the top laminate.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of the preferred embodiments of the invention as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
Figure 1 is a representation of one embodiment of my invention.
Figure 2 is a representation of a natural cork pattern that may be used in one embodiment of my invention.
Figure 3 is a representation of another natural cork pattern that may be used in one embodiment of my invention.
Figure 4 is a representation of a human designed pattem that may be used on one embodiment of my invention.
Figure 5 is a representation of another human designed pattem that may be used on one embodiment of my invention.
Figure 6 is a representation of the laminates of one embodiment of my invention.
Figure 7 is a representation of the surface patterns possible on one embodiment of my invention.
Figure 8 illustrates the patterns of cork tiles than can be used to create human designs in one embodiment of my invention.
Figure 9 illustrates the sizes and dimensions of rectangular cork tiles that may be used in one embodiment of my invention.
Figure 10 illustrates the sizes and dimensions of square cork tiles that may be used on one embodiment of my invention.
Figure 11 is an illustration of one embodiment of my invention with a reinforcing strip along its peripheral edge.
Figure 12 is an illustration of one embodiment of my invention using carpet serging or cork stripping to reinforce the edge of the rug.
DETAILED DESCRIPTION
Referring to Figure 1, my invention (10) is a laminated anti-fatigue area rug comprising a bottom laminate of anti-fatigue material (12) having an upper bonding surface (14) and a lower contact surface (16) having anti-slip properties for stability. My invention further comprises a top laminate (18) of cork having a lower bonding surface (20) and an upper wearing surface (22) having a transparent polyurethane coating (24). The upper wearing surface (22) may have a decorative pattern (26 & 28) as illustrated in Figures 2 and 3 wherein the pattern is a natural cork pattern. As illustrated in Figures 4 and 5 the pattern can be human designed (30 & 32).
Still referring to Figure 1, there further included a middle bonding laminate (34) adapted to bond the top layer to the bottom layer.
The laminated cork rug of my invention is sufficiently pliable so that it may be rolled without resulting in de-lamination or cracking of any laminate.
Referring to Figure 6, my invention is shown in a cut-away format with the upper surfaces of the laminates exposed. The bottom laminate (12) comprises anti-fatigue rubber the composition of which is well known in the art. Generally the thickness of the bottom laminate is about 7 mm although this may vary to suit varies environmental conditions of use. Rubber is recommended for commercial or industrial use because of its durable wear. Alternatively, the bottom laminate comprises anti-fatigue vinyl foam the composition of which is also well known in the art. The thickness of the vinyl form is also of about 7 mm depending upon environmental conditions use. Vinyl foam is recommended for residential use because it gives the rug a softer feel. Both the rubber and vinyl bottom laminates are selected for their anti-slip characteristics and their ability to enhance the stability of the construction of the rug. The rubber used is synthetic rubber such as styrene-butadiene rubber (BSR) or nitrile rubber. The rubber laminate has a textured bottom surface (16) for anti-slip resistance.
Referring to Figure 7, the top laminate of cork may be is comprised of a single sheet of cork (40). In another embodiment of the invention, the top laminate of cork may be comprised of a plurality cork strips (42). In yet another embodiment of the invention the top laminate of cork may be comprised of rectangular cork tiles (44) joined together by joining means. Patterns can be applied to the cork surface. Typically a human-designed pattenrn as illustrated in Figures 4 & 5 is applied using a mosaic of a plurality of individual cork tiles of various shapes (46) as illustrated in Figure 8.
Referring to Figure 9, cork strips are available in a variety of sizes to create the desired visual effect.
Referring to Figure 10, cork tiles are also available in a variety of sizes to create the desired visual effect.
When tiles are used as illustrated in Figure 10 with the effect shown in Figure 7, Item 44, the tiles are joined by joining means comprising a first bead of contact cement placed on a first edge of a first rectangular cork tile of and a second bead of contact cement placed on a second adjoining edge of a second rectangular cork tile. When the tiles are joined a seam is formed between them. The seam is covered by a strip of thin fiberglass tape and then the strip of thin fiberglass tape is sealed with a coat of sealant.
Referring to Figure 1 and Figure 6, the middle bonding laminate (34) comprises bonding material adapted to provide structural strength to the rug and having anti-puncture characteristics. In a preferred embodiment of the invention, the bonding material comprises reinforcement fiberglass tissue. In another embodiment of the invention the bonding material comprises reinforcement fiberglass roving. Adhesive material is placed on the top (60) and the bottom (62) surfaces of the bonding material. In one embodiment of the invention the adhesive material is contact cement. In the preferred embodiment, the contact cement is environmentally benign having a water base. In another embodiment of the invention where a rubber latex bottom laminate is used, the appropriate bonding material is latex-based cement.
Referring to Figure 11 and Figure 12, my rag (10) includes a peripheral edge (66) that is reinforced by edging (68). In one embodiment of the invention the edging is carpet serging (70). In another embodiment of the invention the edging is a strip of cork (72).
A method of manufacturing a laminated anti-fatigue area rng comprising a bottom laminate of anti-fatigue material having an upper bonding surface and a lower contact surface having anti-slip properties for stability; a top laminate of cork having a lower bonding surface and an upper wearing surface coated with a polyurethane coating; a middle bonding laminate adapted to bond the top layer to the bottom layer;
and, a peripheral edge; comprises the steps of:
a. forming the bottom laminate having a predetermined size from anti-fatigue material;
b. forming the top laminate having said predetermined size;
c. applying the middle bonding laminate to the lower bonding surface of the top laminate using an adhesive;
d. placing the upper bonding surface of the top laminate into contact with the middle bonding laminate;
e. trimming the peripheral edge so that it is clean; and, f. fixing edging to the peripheral edge.
The method further comprises the step of providing a decorative pattein within the upper wearing surface of the top laminate.
Although the description above contains much specificity, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Thus the scope of the invention should be determined by the appended claims and their legal equivalents.
In a preferred embodiment of the invention, the bonding material comprises reinforcement fiberglass tissue.
In another embodiment of the invention the bonding material comprises reinforcement fiberglass roving.
In one embodiment of the invention adhesive material is placed on the top and the bottom surfaces of the bonding material.
The constructed rug has a peripheral edge which may be reinforced by carpet serging or a strip of cork.
A method of manufacturing a laminated anti-fatigue area rug comprises the steps of:
a. forming the bottom laminate having a predetermined size from anti-fatigue material;
b. forming the top laminate having said predetermined size;
c. applying the middle bonding laminate to the lower bonding surface of the top laminate using an adhesive;
d. placing the upper bonding surface of the top laminate into contact with the middle bonding laminate;
e. trimming the peripheral edge so that it is clean; and, f. fixing edging to the peripheral edge.
The method further comprises the step of providing a decorative pattern within the upper wearing surface of the top laminate.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of the preferred embodiments of the invention as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
Figure 1 is a representation of one embodiment of my invention.
Figure 2 is a representation of a natural cork pattern that may be used in one embodiment of my invention.
Figure 3 is a representation of another natural cork pattern that may be used in one embodiment of my invention.
Figure 4 is a representation of a human designed pattem that may be used on one embodiment of my invention.
Figure 5 is a representation of another human designed pattem that may be used on one embodiment of my invention.
Figure 6 is a representation of the laminates of one embodiment of my invention.
Figure 7 is a representation of the surface patterns possible on one embodiment of my invention.
Figure 8 illustrates the patterns of cork tiles than can be used to create human designs in one embodiment of my invention.
Figure 9 illustrates the sizes and dimensions of rectangular cork tiles that may be used in one embodiment of my invention.
Figure 10 illustrates the sizes and dimensions of square cork tiles that may be used on one embodiment of my invention.
Figure 11 is an illustration of one embodiment of my invention with a reinforcing strip along its peripheral edge.
Figure 12 is an illustration of one embodiment of my invention using carpet serging or cork stripping to reinforce the edge of the rug.
DETAILED DESCRIPTION
Referring to Figure 1, my invention (10) is a laminated anti-fatigue area rug comprising a bottom laminate of anti-fatigue material (12) having an upper bonding surface (14) and a lower contact surface (16) having anti-slip properties for stability. My invention further comprises a top laminate (18) of cork having a lower bonding surface (20) and an upper wearing surface (22) having a transparent polyurethane coating (24). The upper wearing surface (22) may have a decorative pattern (26 & 28) as illustrated in Figures 2 and 3 wherein the pattern is a natural cork pattern. As illustrated in Figures 4 and 5 the pattern can be human designed (30 & 32).
Still referring to Figure 1, there further included a middle bonding laminate (34) adapted to bond the top layer to the bottom layer.
The laminated cork rug of my invention is sufficiently pliable so that it may be rolled without resulting in de-lamination or cracking of any laminate.
Referring to Figure 6, my invention is shown in a cut-away format with the upper surfaces of the laminates exposed. The bottom laminate (12) comprises anti-fatigue rubber the composition of which is well known in the art. Generally the thickness of the bottom laminate is about 7 mm although this may vary to suit varies environmental conditions of use. Rubber is recommended for commercial or industrial use because of its durable wear. Alternatively, the bottom laminate comprises anti-fatigue vinyl foam the composition of which is also well known in the art. The thickness of the vinyl form is also of about 7 mm depending upon environmental conditions use. Vinyl foam is recommended for residential use because it gives the rug a softer feel. Both the rubber and vinyl bottom laminates are selected for their anti-slip characteristics and their ability to enhance the stability of the construction of the rug. The rubber used is synthetic rubber such as styrene-butadiene rubber (BSR) or nitrile rubber. The rubber laminate has a textured bottom surface (16) for anti-slip resistance.
Referring to Figure 7, the top laminate of cork may be is comprised of a single sheet of cork (40). In another embodiment of the invention, the top laminate of cork may be comprised of a plurality cork strips (42). In yet another embodiment of the invention the top laminate of cork may be comprised of rectangular cork tiles (44) joined together by joining means. Patterns can be applied to the cork surface. Typically a human-designed pattenrn as illustrated in Figures 4 & 5 is applied using a mosaic of a plurality of individual cork tiles of various shapes (46) as illustrated in Figure 8.
Referring to Figure 9, cork strips are available in a variety of sizes to create the desired visual effect.
Referring to Figure 10, cork tiles are also available in a variety of sizes to create the desired visual effect.
When tiles are used as illustrated in Figure 10 with the effect shown in Figure 7, Item 44, the tiles are joined by joining means comprising a first bead of contact cement placed on a first edge of a first rectangular cork tile of and a second bead of contact cement placed on a second adjoining edge of a second rectangular cork tile. When the tiles are joined a seam is formed between them. The seam is covered by a strip of thin fiberglass tape and then the strip of thin fiberglass tape is sealed with a coat of sealant.
Referring to Figure 1 and Figure 6, the middle bonding laminate (34) comprises bonding material adapted to provide structural strength to the rug and having anti-puncture characteristics. In a preferred embodiment of the invention, the bonding material comprises reinforcement fiberglass tissue. In another embodiment of the invention the bonding material comprises reinforcement fiberglass roving. Adhesive material is placed on the top (60) and the bottom (62) surfaces of the bonding material. In one embodiment of the invention the adhesive material is contact cement. In the preferred embodiment, the contact cement is environmentally benign having a water base. In another embodiment of the invention where a rubber latex bottom laminate is used, the appropriate bonding material is latex-based cement.
Referring to Figure 11 and Figure 12, my rag (10) includes a peripheral edge (66) that is reinforced by edging (68). In one embodiment of the invention the edging is carpet serging (70). In another embodiment of the invention the edging is a strip of cork (72).
A method of manufacturing a laminated anti-fatigue area rng comprising a bottom laminate of anti-fatigue material having an upper bonding surface and a lower contact surface having anti-slip properties for stability; a top laminate of cork having a lower bonding surface and an upper wearing surface coated with a polyurethane coating; a middle bonding laminate adapted to bond the top layer to the bottom layer;
and, a peripheral edge; comprises the steps of:
a. forming the bottom laminate having a predetermined size from anti-fatigue material;
b. forming the top laminate having said predetermined size;
c. applying the middle bonding laminate to the lower bonding surface of the top laminate using an adhesive;
d. placing the upper bonding surface of the top laminate into contact with the middle bonding laminate;
e. trimming the peripheral edge so that it is clean; and, f. fixing edging to the peripheral edge.
The method further comprises the step of providing a decorative pattein within the upper wearing surface of the top laminate.
Although the description above contains much specificity, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Thus the scope of the invention should be determined by the appended claims and their legal equivalents.
Claims (24)
1. A laminated anti-fatigue area rug comprising:
a. a bottom laminate of anti-fatigue material having and upper bonding surface and a lower contact surface having anti-slip properties for stability;
b. a top laminate of cork having a lower bonding surface and an upper wearing surface having a polyurethane coating, wherein said upper wearing surface comprises a decorative pattern; and, c. a middle bonding laminate adapted to bond said top layer to said bottom layer; and, d. wherein said laminated rug is sufficiently pliable that it can be rolled without resulting in de-lamination or cracking of any laminate.
a. a bottom laminate of anti-fatigue material having and upper bonding surface and a lower contact surface having anti-slip properties for stability;
b. a top laminate of cork having a lower bonding surface and an upper wearing surface having a polyurethane coating, wherein said upper wearing surface comprises a decorative pattern; and, c. a middle bonding laminate adapted to bond said top layer to said bottom layer; and, d. wherein said laminated rug is sufficiently pliable that it can be rolled without resulting in de-lamination or cracking of any laminate.
2. The rug of claim 1 wherein the bottom laminate comprises rubber.
3. The rug of claim 1 wherein the bottom laminate comprises vinyl foam.
4. The rug of claim 2 wherein said rubber is synthetic rubber.
5. The rug of claim 4 wherein said synthetic rubber is styrene-butadiene rubber.
6. The rug of claim 4 wherein the synthetic rubber is nitrile rubber.
7. The rug of claim 4 wherein the rubber has a textured bottom surface for anti-slip resistance.
8. The rug of claim 1 wherein said top laminate of cork is comprised of a single sheet of cork.
9. The rug of claim 8 wherein the top laminate of cork is comprised of a plurality of rectangular cork tiles joined together by joining means.
10. The rug of claim 1 wherein said decorative pattern is a natural cork pattern.
11. The rug of claim 1 wherein the decorative pattern is human-designed comprising a mosaic of a plurality of individual cork tiles.
12. The rug of claim 9 wherein said joining means comprises a first bead of contact cement placed on a first edge of a first rectangular cork tile of said plurality of tiles and a second bead of contact cement placed on a second adjoining edge of a second rectangular cork tile of said plurality of tiles, so that when said first and second tiles are joined a seam is formed between them, and wherein said seem is covered by a strip of thin fiberglass tape, and further wherein said strip of thin fiberglass tape is sealed with a coat of sealant.
13. The rug of claim 1 wherein said middle bonding laminate comprises bonding material adapted to provide structural strength to the rug and having anti-puncture characteristics.
14. The rug of claim 13 wherein said bonding material comprises reinforcement fiberglass tissue.
15. The rug of claim 11 wherein the bonding material comprises reinforcement fiberglass roving.
16. The rag of claim 11 wherein the bond material further comprises adhesive material.
17. The rag of claim 16 wherein said adhesive material is contact cement.
18. The rug of claim 16 wherein the upper bonding layer of said bottom laminate of anti-fatigue material is bonded to the middle bonding laminate by the adhesive material.
19. The rug of claim 18 wherein the adhesive material is water-based.
20. The rug of claim 1 wherein said laminated anti-fatigue area rug further comprises a peripheral edge, said peripheral edge reinforced by edging.
21. The rug of claim 20 wherein said edging is carpet serging.
22. The rug of claim 21 wherein the edging is a strip of cork.
23. A method of manufacturing a laminated anti-fatigue area rug comprising a bottom laminate of anti-fatigue material having and upper bonding surface and a lower contact surface having anti-slip properties for stability; a top laminate of cork having a lower bonding surface and an upper wearing surface; a middle bonding laminate adapted to bond said top layer to said bottom layer; and, a peripheral edge; wherein said method comprises the steps of:
a. forming said bottom laminate having a predetermined size from anti-fatigue material;
b. forming said top laminate having said predetermined size;
c. applying said middle bonding laminate to said lower bonding surface of the top laminate using an adhesive;
d. placing said upper bonding surface of the top laminate into contact with the middle bonding laminate;
e. trimming said peripheral edge so that it is clean;
f. fixing edging to the peripheral edge.
a. forming said bottom laminate having a predetermined size from anti-fatigue material;
b. forming said top laminate having said predetermined size;
c. applying said middle bonding laminate to said lower bonding surface of the top laminate using an adhesive;
d. placing said upper bonding surface of the top laminate into contact with the middle bonding laminate;
e. trimming said peripheral edge so that it is clean;
f. fixing edging to the peripheral edge.
24. The method of claim 23 further comprising the step of providing a decorative pattern within the upper wearing surface of the top laminate.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2579536 CA2579536A1 (en) | 2007-02-26 | 2007-02-26 | A laminated anti-fatigue area rug and method of manufacture |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2579536 CA2579536A1 (en) | 2007-02-26 | 2007-02-26 | A laminated anti-fatigue area rug and method of manufacture |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2579536A1 true CA2579536A1 (en) | 2008-08-26 |
Family
ID=39718239
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2579536 Abandoned CA2579536A1 (en) | 2007-02-26 | 2007-02-26 | A laminated anti-fatigue area rug and method of manufacture |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2579536A1 (en) |
-
2007
- 2007-02-26 CA CA 2579536 patent/CA2579536A1/en not_active Abandoned
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| FZDE | Dead |
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