Abstract: An anti-fatigue mat is disclosed including a foam member and a gel member that each exhibit a different durometer. The foam member includes a support surface that supports the gel member atop the foam member. The foam member includes a foam ramp that extends outwardly downward from the gel member to a bottom surface of the foam member. A flexible cover layer is situated above the gel member and extends over the foam ramp so that the foam member and the flexible cover layer together encapsulatively seal the gel member therein. The flexible cover layer includes an indentation region situated substantially adjacent a gel/foam interface between the gel member and the foam member and further situated a predetermined distance from the peripheral edge of the mat in one embodiment. The bottom surface of the mat may include a non-slip surface to stabilize the mat on the particular surface that the mat covers.

Abstract: 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.

Abstract: An anti-fatigue mat provides a “dual mode” feature wherein the anti-fatigue mat includes a resilient cushioning member that may be removed to enable cleaning of the remainder of the mat and/or the resilient cushioning member. The anti-fatigue mat includes a wear element having a wear surface on which a user may stand. The resilient cushioning member is situated adjacent the wear element in a receiver that is attached to the wear element. The receiver receives the resilient cushioning member via an aperture through which the resilient cushioning member may be installed and removed. The receiver may include multiple apertures to facilitate installation and removal of the resilient cushioning member. The anti-fatigue mat also provides a “dual friction” feature wherein the interior surface of the wear element may exhibit high friction with respect to the resilient cushioning member, and the receiver exhibits sufficiently high friction to reduce slippage on a floor.

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.

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.

Abstract: A method of fabricating an anti-fatigue mat employs a pre-formed gel cushioning member that includes opposed major surfaces. One of the opposed major surfaces of the gel cushioning member is heated and liquefied. A flexible support sheet is applied and bonded to the liquefied surface of the gel cushioning member. The remaining opposed surface of the gel cushioning member is then heated and liquefied. A flexible base sheet is applied and bonded to this liquefied surface of the gel cushioning member. The method may move one of the opposed surfaces of the gel cushioning member adjacent a heat source to liquefy a portion of the gel cushioning member passing by the heat source. A flexible sheet is dispensed or applied to the liquefied portion of the gel cushioning member as the liquefied portion passes by a flexible sheet dispenser.