A multi-layer exercise mat including a first layer including an outer surface and an opposing inner surface, the opposing inner surface of the first layer including a first array of three-dimensional features integral with the first layer; and a second layer including an outer surface and an opposing inner surface, the opposing inner surface of the second layer including a second array of three-dimensional features integral with the second layer. The first and second arrays of three-dimensional features are configured to grip each other to removably secure the inner surface of the first layer to the inner surface of the second layer.

A cushion includes a cover and a cushioning element having a top surface heat-fused to the cover. The cushioning element comprises an elastomeric material having a plurality of voids formed therein. At least 60% of a bottom surface of the cushioning element is exposed such that when the cushion is disposed over a surface at least 60% of the bottom surface of the cushioning element is in direct contact with the surface. Methods of forming the cushion include disposing a cover adjacent a mold, conforming the cover to a selected shape of the mold, injecting molten elastomeric material into the mold, bonding the molten elastomeric material to the cover, solidifying the molten elastomeric material to form the cushioning element, and separating the mold from the cover. The cushioning element maintains the cover in the selected shape.

Clean, safe and efficient methods, systems, and processes for utilizing thermolysis methods to processes to convert various carpet, rug, polymeric materials and other waste sources, such as solid waste, tires, manure, auto shredder residue, glass and carbon fiber composite materials, municipal solid wastes, medical wastes, waste wood and the like into a Clean Fuel Gas and Char source are disclosed. The invention processes the carpet, rug, polymeric material to effectively shred and/or grind the waste source, such as post-consumer carpet remnants and waste, and then process using thermolysis methods to destroy and/or separate halogen and other dangerous components to provide a Clean Fuel Gas and Char source. Additional waste sources, such as solid waste, tires, manure, auto shredder residue, glass and carbon fiber composite materials, municipal solid wastes, medical wastes, waste wood and the like, are suitable for the processing of the invention disclosed.

Method and apparatus for fabricating an anti-fatigue mat are disclosed. In one embodiment an anti-fatigue mat includes a foam member and a gel member, wherein each member exhibits a different durometer. The foam member includes a gel receiver that is configured with a geometry shaped to receive the gel member. A top fabric is situated on the top of the mat above the gel member and the foam member. A non-slip surface is provided on the bottom of the anti-fatigue mat. The gel member may be sealed within the mat by the foam member and the top fabric.

A method for producing an injection molded and anti-skid mat providing a lower mold half and an enclosing upper mold half, the mold halves defining therebetween an interior cavity which is a negative of the mat to be produced. A cavity defining surface is configured in the bottom mold half with locations for preplacement of a plurality of underside adhering portions. A flowable plasticized/rubberized material is communicated through a channel in at least one of the mold halves in order to fill the interior cavity, the material setting and cooling prior to removing the upper mold half and the formed mat.

Disclosed herein are expanded thermoplastic polyurethane beads polymerized from an isocyanate, an isocyanate-reactive compound having a molecular weight between 500 and 10 000 g/mol and a chain extender, wherein customary adjuvants may be additionally present, and the thermoplastic polyurethane has a hard phase fraction ranging from 0.1 to 0.95 and the hard phase fraction is defined by:

[00001]$\mathrm{Hard}.Math..Math.\mathrm{phase}.Math..Math.\mathrm{fraction}=\frac{\underset{x=1}{\overset{k}{.Math.}}.Math.\left(\left(\frac{m_{\mathrm{KVx}}}{M_{{\mathrm{KV}}_x}}\right).Math.M_{\mathrm{Iso}}+m_{\mathrm{KVx}}\right)}{m_{\mathrm{ges}}}$

where M.sub.KVx represents a molar mass of chain extender x in g/mol, m.sub.KVx represents a mass of chain extender x in g, M.sub.Ixo represents a molar mass of isocyanate in g/mol, m.sub.ges represents a total mass of all starting materials without adjuvants, and k represents a number of chain extenders. Also disclosed herein are processes for producing expanded thermoplastic polyurethanes and processes for producing molded parts therefrom.

The invention relates to a method for manufacturing a pellet, comprising a) providing residual rubber powder from a rubber disintegration process; b) providing a pelletizing system, including a pelletizer and a cooling device; c) feeding the residual rubber powder as at least part of a feed material, into a pelletizer; d) providing the rubber powder in an amount between 50% and 100%; e) applying a pressure to the residual rubber for a predetermined process duration; f) releasing the pelletized rubber and cooling the pelletized rubber at a cooling rate dependent on the operational temperature of the pelletizer.

A mat unit includes a plurality of gaps defined by a first layer that are in open communication with gaps defined by a second layer so as to permit debris to fall entirely through both gaps to pass completely through the mat unit. The mat unit is part of an omnidirectional mat cleaning system that includes a first direction of travel above the mat unit extending through a door opening defined by a building structure. A different second direction of travel is above the mat unit extending through the door opening or another door opening defined by the building structure. The mat unit is installed on a floor adjacent the door opening. The mat unit cleans shoes regardless of the direction of travel traveled above the mat unit.

A method for making a slip resistant mat can include assembling parts with predetermined geometries to form a mold that can be used for making slip resistant mats that have channels to account for moisture between the mat and the floor. The unique geometries of the parts which form the mold can be manufactured efficiently and with reduced costs. The mold of this invention can be used to make slip resistant mats with channels that can both dissipate water and offer a high degree of mat to floor surface contact.

A mat unit includes a plurality of gaps defined by a first layer that are in open communication with gaps defined by a second layer so as to permit debris to fall entirely through both gaps to pass completely through the mat unit. The mat unit is part of an omnidirectional mat cleaning system that includes a first direction of travel above the mat unit extending through a door opening defined by a building structure. A different second direction of travel is above the mat unit extending through the door opening or another door opening defined by the building structure. The mat unit is installed on a floor adjacent the door opening. The mat unit cleans shoes regardless of the direction of travel traveled above the mat unit.