ANTI-FATIGUE MAT

Abstract

An anti-fatigue wellness mat is described. The anti-fatigue wellness mat can include a frame, a first fabric attached to the frame, and a granular substance underneath the first fabric. Related apparatus, systems, techniques and articles are also described.

Claims

1. A mat comprising: a frame; a first fabric attached to the frame; and a granular substance underneath the first fabric.

2. The mat of claim 1, further comprising a sheet underneath the frame, the sheet attached to a bottom of the frame.

3. The mat of claim 2, further comprising a foam padding attached to the sheet, the foam padding facing the granular substance.

4. The mat of claim 1, wherein the frame is made of one or more of wood, metal, plastic, and foam.

5. The mat of claim 1, wherein the first fabric is stretchable.

6. The mat of claim 1, wherein the granular substance is sand.

7. The mat of claim 1, wherein the granular substance is stored in demarcated sections.

8. The mat of claim 1, wherein the granular substance is held on a second fabric.

9. The mat of claim 8, wherein the second fabric is stretchable.

10. The mat of claim 9, wherein the granular substance is covered by the second fabric that touches the foam padding attached to the sheet.

11. A method comprising: temporarily attaching a frame with an expanded polystyrene foam; attaching a fabric to the frame; inserting a granular substance on the fabric; removing the expanded polystyrene foam from the frame; covering the sand with a foam padding attached to a plate; and attaching another fabric to the frame at a side opposite to the plate to form a mat.

12. The method of claim 11, wherein a sheet of the fabric is attached to a portion of the fabric to enclose the sand, the sheet of the fabric touching the foam padding.

13. The method of claim 11, wherein the plate is made of one or more of metal, wood, plastic, fabric, foam, fiberglass, graphite, and carbon graphite.

14. The method of claim 13, wherein the frame is made of one or more of wood, metal, plastic, and foam.

15. The method of claim 11, wherein: the fabric is a cloth; and the other fabric is a stretchable microfiber comprising one or more of spandex, neoprene, and elastane.

16. The method of claim 11, wherein the granular substance comprises at least one of rice, salt, coffee beans, corn flakes, fertilizer, nuts, coal, and ball bearings.

17. The method of claim 11, wherein the foam padding and the plate are attached to the frame at a location where the expanded polystyrene foam was temporarily fitted to the frame.

18. The method of claim 11, wherein three partition walls are inserted into the expanded polystyrene foam.

Description

DESCRIPTION OF DRAWINGS

[0009] FIG. 1 illustrates two mats being used by a user in accordance with the subject matter of the present disclosure;

[0010] FIG. 2 illustrates a process of constructing the mat, which is covered with a first fabric in accordance with the subject matter of the present disclosure;

[0011] FIG. 3 illustrates partition walls placed within a marked-up portion of expanded polystyrene foam in accordance with the subject matter of the present disclosure;

[0012] FIG. 4 illustrates a frame below which the expanded polystyrene foam with partition walls is temporarily fitted in accordance with the subject matter of the present disclosure;

[0013] FIG. 5 illustrates a second fabric being attached on the frame in accordance with the subject matter of the present disclosure;

[0014] FIG. 6 illustrates the second fabric attached along the entire frame in accordance with the subject matter of the present disclosure;

[0015] FIG. 7 illustrates partitions filled with sand and formed by the partition walls in accordance with the subject matter of the present disclosure;

[0016] FIG. 8 illustrates the partitions filled with sand being enclosed by the attached second fabric in accordance with the subject matter of the present disclosure;

[0017] FIG. 9 illustrates a sheet, on which a foam padding is attached in accordance with the subject matter of the present disclosure;

[0018] FIG. 10 illustrates a bottom portion of the sheet in accordance with the subject matter of the present disclosure; and

[0019] FIG. 11 illustrates the first fabric attached to the frame to form the top surface of the mat in accordance with the subject matter of the present disclosure.

[0020] Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

[0021] FIG. 1 illustrates two mats 102 being used by a user 104. The mat 102 can also be referred to as an anti-fatigue mat. The two mats 102 are designed for the two feet—left foot and right foot—of a user 104. Each mat 102 can be substantially larger than an average adult human foot so that individuals with feet of all sizes can use the mat 102. This can advantageously enable manufacturing a single size of the mat 102, thereby minimizing manufacturing cost. In alternate implementations, however, mats 102 can be made in different sizes. For example, the different sizes of the mats 102 can proportionally correspond to different sizes of feet. In such examples, the ratio of the area of a mat with a particular mat size to the area of a foot with a particular foot size, specific to which that mat is manufactured, can remain constant. Each mat can have the shape of a human foot. In alternate implementations, each mat can have any shape, such as a square, rectangle, circle, triangle, a polygon with any number of sides, or any other shape. The term mat as used herein can also be referred to as a device, an apparatus, or the like.

[0022] The mat 102 can include a frame 106 and a first fabric 108 that overlays sand. First fabric 108 can be a stretchable fabric, such as spandex, neoprene, elastane, and/or the like. The stretchable fabric can be stretched in any direction, and can also be referred to as a four-way stretch fabric. In some implementations, the stretchable fabric can be made of polyesters, polyamides (e.g., nylon, KEVLAR, NOMEX, trogamide), and/or polypropylene. Although first fabric 108 is described as a stretchable fabric, in alternate implementations any other fabric can be used, such as cotton fabric, synthetic rubber material or any other synthetic material. While sand is described, in other implementations any other granular substance can be used, such as rice, salt, coffee beans, corn flakes, fertilizer, nuts, coal, ball bearings, and/or any other granular material.

[0023] The process for constructing the mat 102 for the right foot is shown by FIG. 2. The structural details of various components used during the construction of the mat 102 are detailed in FIGS. 3-11. The construction and inner structural details of the mat 102 for the left foot are similar to that for the right foot.

[0024] FIG. 2 illustrates a process 200 of constructing the mat 102. The process 200 can include steps 202, 204, 206, 208, 210, 212, and 214, a description of which follows. At step 202, expanded polystyrene foam 220 can be marked with an inner circumference of the frame 106, and partition walls 222, 224 and 226 can be inserted and affixed on the marked portion of expanded polystyrene foam 220. The marking on expanded polystyrene foam 220 can be performed by placing the frame 106 on expanded polystyrene foam 220, and then marking by using a marker, such as a permanent marker, to outline the inner circumference of the frame 106.

[0025] Expanded polystyrene foam 220 can then be temporarily fitted, at 203, on to frame 106. The temporary fitting can be performed by hand. In alternate implementations, any other mechanism for temporary fitting can be implemented, such as an automatic machine fitting.

[0026] A second fabric 228 can be attached, at step 204, on frame 106 on which expanded polystyrene foam 220 has been temporarily fitted at 203. The method of attaching the second fabric 228 with the frame 106 can be gluing. While gluing is described, in alternate implementations any other method of attaching the second fabric 228 with the frame 106 can be used, such as stitching, inserting nails or staples, mechanically locking, and/or any other attachment mechanism. The attaching of second fabric 228 to frame 106 can be completed at step 206.

[0027] In one implementation, second fabric 228 can be made of a same or similar material as first fabric 108. For example, first fabric 108 can be a stretchable fabric, such as spandex, neoprene, elastane, and/or the like. The stretchable fabric can be stretched in any direction, and can also be referred to as a four-way stretch fabric. In some implementations, the stretchable fabric can be made of polyesters, polyamides (e.g., nylon, KEVLAR, NOMEX, trogamide), and/or polypropylene. Although first fabric 108 is described as a stretchable fabric, in alternate implementations any other fabric can be used, such as cotton fabric, synthetic rubber material or any other synthetic material, all of which may or may not have stretchable properties. In another implementation, second fabric 228 can be made of a different material than first fabric 108.

[0028] Sand 230 can be inserted, at step 208, on top of the second fabric 228. The insertion can be accomplished by pouring. A measured amount of sand 230 can be inserted for each mat 102 to ensure a uniform experience for users for each mat 102. In alternate implementations, amounts of sand 230 inserted into each section of each mat 102 can be customized based on preferences of a user so as to offer a unique customized made-to-order experience.

[0029] A sheet 231 of second fabric 228 can be used to optionally cover, at step 210, the sand. Sheet 231 can then be attached to second fabric 228 in the end product at step 208. Sheet 231 of second fabric 228 can be smooth to enable an easy dispersion of the sand, thereby preventing accumulation of the sand at particular locations. The mechanism of attaching sheet 231 to second fabric 228 in the end product of step 208 can be gluing. While sheet 231 is described as being glued to second fabric 228, in other implementations any other attachment mechanism can be used such as stitching, inserting nails or staples, mechanically locking, and/or any other attachment mechanism.

[0030] A sheet 232, on which a foam padding 234 is attached, is attached at step 212 to frame 106. Sheet 232 can be made of metal, in which case sheet 232 can be referred to as a metallic sheet. Further, although sheet 232 is described as metallic, in alternate implementations, sheet 232 can be made of any other material such as wood, plastic, fabric, foam, fiberglass, graphite, carbon graphite or any other like material. In implementations where sheet 231 of second fabric 228 is not used to optionally cover, at step 210, sand 230, foam padding 234 can directly touch sand 230. Foam padding 234 can be smooth so as to enable an easy dispersion of sand 230, thereby preventing accumulation of sand 230 at particular locations. The mechanism for attaching the frame to sheet 232 can be by inserting/screwing nails. In alternate implementations, such attachment mechanism can be gluing, stitching, stapling, mechanically locking, and/or any other attachment mechanism. The mechanism for attaching foam padding 234 to sheet 232 can be gluing. While foam padding 234 is described as being glued to sheet 232, in other implementations any other attachment mechanism can be used such as stitching, inserting nails or staples, mechanically locking, and/or any other attachment mechanism.

[0031] In another implementation, however, step 210 may not occur, and sheet 232 with foam padding 234 may be directly attached onto the end product at step 208. While this implementation that does not have the step 210 can advantageously reduce the amount of material being used, the implementation that has the step 210 can advantageously present a better leak-proof design to prevent leakage of sand 230.

[0032] After step 212, expanded polystyrene foam 220 and partition walls 222, 224 and 226 affixed thereto can be removed from the side other than the side where sheet 232 has been attached to frame 106. First fabric 108 can be attached, at step 214, onto frame 106 at the side other than the side where sheet 232 is attached to frame 106 to obtain mat 102. First fabric 108 can be attached onto frame 106 by gluing. While first fabric 108 is described as being glued to frame 106, in other implementations any other attachment mechanism can be used such as stitching, inserting nails or staples, mechanically locking, and/or any other attachment mechanism. In one implementation, the second fabric 228 can be made of a same or similar material as first fabric 108. In another implementation, second fabric 228 can be made of a different material than first fabric 108.

[0033] FIG. 3 illustrates partition walls 222, 224, and 226 placed within the marked-up (at step 202) portion of expanded polystyrene foam 220. Partition walls 222, 224, and 226 can be inserted into and affixed to the marked-up portion of expanded polystyrene foam 220. The expanded polystyrene foam can be closed-cell extruded polystyrene foam. While an expanded polystyrene foam is described, in alternate implementations other materials can instead be used such as wood, plastic, metal or any other solid material. In alternative implementations, partition walls 222, 224 and 226 can be made of plastic, wood, metal or any other solid material.

[0034] FIG. 4 illustrates frame 106, below which expanded polystyrene foam 220 with partition walls 222, 224 and 226 is temporarily fitted at step 203. Frame 106 can be made of wood. Even though wood is described, in other implementations frame 106 can be made of other materials, such as metal, plastic, foam or any other like material. The inner walls of frame 106 can be curved inward at the bottom, which prevents sand 230 from being accumulated close to those walls.

[0035] FIG. 5 illustrates second fabric 228 being attached, at step 204, on frame 106. Second fabric 228 is attached, at step 206, along the entire frame 106, as shown in FIG. 6. In various implementations, second fabric 228 can be a woven fabric, a non-woven fabric, a knitted fabric, a netting fabric, and/or a technical fabric. Second fabric 228 can be separate pieces of fabric that are attached in each separate corresponding section of the multiple sections formed by partition walls 222, 224, and 226. In an alternate implementation, second fabric 228 can be a single piece of fabric that is attached to frame 106. Second fabric 228 can be anti-bacterial, water-proof, odor-repelling, and/or odor-resistant.

[0036] FIG. 6 illustrates second fabric 228 attached, at step 206, along the entire frame 106.

[0037] FIG. 7 illustrates sand 230 filled, at step 208, in the partitions formed by partition walls 222, 224, and 226 of FIG. 6. While sand is described, in other implementations any other granular substance can be used. Partition walls 222, 224, and 226 can ascertain that sand 230 is proportionately distributed in sections demarcated by those partition walls 222, 224, and 226. This prevents sand 230 from accumulating in excess at undesirable locations.

[0038] FIG. 8 illustrates the partitions of FIG. 9 filled with sand being enclosed by sheet 231 of second fabric 228, which can be attached, at step 210, to second fabric 228 visible in FIG. 7.

[0039] FIG. 9 illustrates a sheet 232, on which a foam padding 234 is attached. Sheet 232 can be made of one or more of the following metals: aluminum or cast aluminum. Sheet 232 can be made of metal, in which case sheet 232 can be referred to as a metallic sheet. Further, although sheet 232 is described as metallic, in alternate implementations, sheet 232 can be made of any other material such as wood, plastic, fabric, foam, fiberglass, graphite, carbon graphite or any other like material. Foam padding 234 can be made of ethylene-vinyl acetate (EVA), which can also be referred to as poly ethylene-vinyl acetate (PEVA). In alternate implementations, foam padding 234 can be made of memory foam, gel foam or any other material with foam like qualities.

[0040] FIG. 10 illustrates a bottom portion of sheet 232. The bottom portion of sheet 232 can touch the ground when a user steps on mat 102 placed on the ground. In another implementation, another foam padding (not shown) can be attached to the bottom surface of the sheet 232 in order to prevent: (a) friction and thus wear-tear of mat 102 and/or the surface of the ground, and (b) discomfort to the user as caused by rubbing between the surface of sheet 232 and the ground surface. This other foam padding (not shown) can be attached to the bottom surface of sheet 232 by gluing, stitching, inserting nails, mechanically locking, and/or any other attachment mechanism.

[0041] FIG. 11 illustrates first fabric 108 attached, at step 214, to frame 106 of FIG. 10 to form mat 102. First fabric 108 can be a stretchable fabric, such as spandex, neoprene, elastane, and/or the like. The stretchable fabric can be stretched in any direction, and can also be referred to as a four-way stretch fabric. In some implementations, the stretchable fabric can be made of polyesters, polyamides (e.g., nylon, KEVLAR, NOMEX, trogamide), and/or polypropylene. Although first fabric 108 is described as a stretchable fabric, in alternate implementations any other fabric can be used, such as cotton fabric, synthetic rubber material or any other synthetic material. First fabric can be anti-bacterial, water-proof, odor-repelling, and/or odor-resistant.

[0042] Although a few variations have been described in detail above, other modifications can be possible. For example, the logic flows depicted in the accompanying figures and described herein do not require the particular order shown, or sequential order, to achieve desirable results. Other embodiments may be within the scope of the following claims.