Patent attributes
An anti-fatigue mat is made by placing a top surface layer member upside down on a mold surface having a contiguous raised portion that defines the perimeter of the anti-fatigue mat. The raised portion surrounds a region into which a major portion of the surface layer sits, resulting in a depression formed relative to the height of the raised portion in the area surrounded by the raised portion. A frame member fit around the raised portion and holds the top surface layer member in place. A gel material is dispensed onto the back side, which is facing upward in the mold, of the top surface layer member. A substrate material is then dispensed onto the gel material and a press head is lowered onto the mold to apply pressure and heat. After the press head is removed, the rough mat can be removed and trimmed to form an anti-fatigue mat. The composition of the gel and substrate materials are carefully selected to achieve the desired bonding of the layers as well as the desired resilience and compressibility of the mat to provide the anti-fatigue effect.
