Method for fabricating an anti-fatigue mat employing multiple durometer layers

Abstract

A method is disclosed for fabricating an anti-fatigue mat that employs a layer of resilient gel material that exhibits a first durometer. The method employs a frame assembly that receives a flexible support sheet. The frame assembly includes an aperture that receives a layer of heated liquid gel which cools to form the layer of resilient gel material exhibiting the first durometer. In one embodiment, a barrier layer exhibiting a second durometer is situated on the gel layer that exhibits the first durometer. In one embodiment, the barrier layer prevents the flow of oils from the gel layer to a flexible base sheet disposed on the barrier layer. In another embodiment, the flexible base sheet may exhibit a second durometer. In either embodiment, the layers exhibiting the first and second durometer cooperate to influence the feel of the mat to the user.

1 . A method of fabricating an anti-fatigue mat, comprising:
 providing a first flexible sheet;   forming a resilient gel layer on the first flexible sheet, the resilient gel layer exhibiting a first predetermined durometer; and   applying a barrier layer to the resilient gel layer, the barrier layer exhibiting a second predetermined durometer.   
     
     
         2 . The method of  claim 1 , wherein the second predetermined durometer of the barrier layer is greater than the first predetermined durometer of the resilient gel layer. 
     
     
         3 . The method of  claim 1 , wherein the first predetermined durometer of the resilient gel layer is greater than the second predetermined durometer of the barrier layer. 
     
     
         4 . The method of  claim 1 , wherein the barrier layer adheres to the resilient gel layer. 
     
     
         5 . The method of  claim 1 , further comprising positioning a second flexible sheet on the barrier layer. 
     
     
         6 . The method of  claim 4 , further comprising positioning a second flexible sheet on the barrier layer, such that the barrier layer adhered to the resilient gel layer may move with respect to the second flexible sheet. 
     
     
         7 . The method of  claim 1 , wherein the barrier layer comprises foam exhibiting the second predetermined durometer. 
     
     
         8 . The method of  claim 5 , wherein the second flexible sheet includes an integral non-slip surface. 
     
     
         9 . The method of  claim 5 , further comprising attaching a non-slip layer to the second flexible sheet. 
     
     
         10 . A method of fabricating an anti-fatigue mat, comprising:
 providing a first flexible sheet;   forming a resilient gel layer on the first flexible sheet, the resilient gel layer exhibiting a first predetermined durometer;   applying a barrier layer on the resilient gel layer; and   positioning a second flexible sheet on the barrier layer, the second flexible sheet exhibiting a second predetermined durometer.   
     
     
         11 . The method of  claim 10 , wherein the first predetermined durometer of the resilient gel layer is less than the second predetermined durometer of the second flexible sheet. 
     
     
         12 . The method of  claim 10 , wherein the first predetermined durometer of the resilient gel layer is greater than the second predetermined durometer of the second flexible sheet. 
     
     
         13 . The method of  claim 10 , wherein the barrier layer adheres to the resilient gel layer, such that the barrier layer adhered to the resilient gel layer may move with respect to the second flexible sheet. 
     
     
         14 . The method of  claim 10 , wherein the second flexible layer comprises foam exhibiting the second predetermined durometer. 
     
     
         15 . The method of  claim 10 , wherein the second flexible sheet includes an integral non-slip surface. 
     
     
         16 . The method of  claim 10 , further comprising attaching a non-slip layer to the second flexible sheet.