FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
[See section 10, Rule 13]
TITLE OF THE INVENTION
RUG ARTICLE WITH REPLACEABLE LAYERS
APPLICANT:
WELSPUN LIVING LIMITED, an Indian Company, having address at Welspun House, 6th Floor, Kamala City, Senapati Bapat Marg, Lower Parel (W), Mumbai – 400013, Maharashtra, India;
Preamble to the description:
The following specification particularly describes the invention and the manner in which it is to be performed:

TECHNICAL FIELD
[0001] The present disclosure is directed to a rug including a pile layer that is
removable and washable.
BACKGROUND
[0002] Carpets and rugs are some of the most widely used home furnishing products. A carpet or rug is a textile floor covering that typically consists of an upper layer of piles attached to a backing. Carpets or rugs are used for insulating a person's feet from a cold tile or concrete floor, making a room more comfortable as a place to sit on the floor, e.g., when playing with children or as a prayer rug, reducing sound from walking, and adding decoration or color to a room.
[0003] There are several methods available for manufacturing of carpets or rugs, however, for large scale production, a machine tufting method is often used. Typical machine tufted carpets or rugs consist of three parts such as, (i) pile structure tufted on (ii) primary base fabric and a (iii) coating applied on the back side of the carpet or rugs for anti-skid property and dimensional stability. Here, the coating is intended to contact the floor directly. Generally, natural as well as synthetic fibers are used for pile and primary backing. Latex is used for coating. Due to bulky structure, it is very problematic to handle, as well as cleaning of a carpet or rugs during use. Moreover, despite hand scrubbing or professional cleaning, due to bulky structure, rugs and carpets can still retain residue stains or soil marks, odor from food, drink or other liquid, dirt, mold, mildew, allergens, toxins, pet dander, pet or human vomit, urine, or other bodily fluids. There is a possibility of residue of toxic chemicals which may result in hazards to children who crawl, anyone who lies on the rug, or to any person sensitive to allergens, odors and toxins. Further, the design and construction of a rug makes it time-consuming or costly to clean or replace as well as heavy and cumbersome to move. [0004] Certain versions of rug articles are disclosed in U.S. Patent No. 8,309,198, U.S.

Patent No. 4,707,895, and U.S. Patent No. 2920412, and PCT Publication No. WO2021055650. U.S. Patent No. 8,309,198 discloses a rug with a cover and mat portion. PCT Publication No. WO2021055650A1 to Jordan et al. discloses a rug with a cover and mat portion, including edge weights.
SUMMARY
[0005] An embodiment of the present disclosure is a multilayer rug article. The rug article has multiple layers including a base layer with an upper surface and a lower surface opposite the upper surface. The lower surface is configured to lie in contact with a floor and includes an anti-skid coating. The rug article also includes middle layers placed directly above the upper surface of the base layer. The rug article also includes a pile layer with a primary base fabric defining a mating surface on a first side, and pile yarns integrated into the primary base fabric and forming piles that extend upwardly from a second side of the primary base fabric. The rug article also includes a coupling system that permits removable coupling of the pile layer to the upper surface of the base layer or the pile layer and the middle layer to the upper surface of the base layer. In use, the pile layer is completely removable from the base layers to facilitate washing the pile layer at least ten wash cycles or more washing cycle. In another embodiment, the rug article is in combination of three or more layers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The foregoing summary, as well as the following detailed description of
illustrative embodiments of the present application, will be better understood when
read in conjunction with the appended drawings. For the purposes of illustrating the
present application, there is shown in the drawings illustrative embodiments of the
disclosure. It should be understood, however, that the application is not limited to
the precise arrangements and instrumentalities shown.
[0007] Figure 1A is a top view of a rug according to an embodiment of the present
disclosure;

[0008] Figure 1B is schematic side view of the rug shown in Figure 1A, illustrating
the top layer removed from the base layer.
[0009] Figure 2 is a schematic cross-sectional view of the rug taken along line 2- 2
in Figure 1A.
[00010] Figure 3 is a detailed sectional view of a portion of the rug shown in
Figure 2.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[00011] There is a need for rug articles with an ease of use, washable in a home
laundering machine and not monotonous in terms of design. In the present disclosure, the inventors have developed a new solution for replaceable and washable rug articles. Here, a top layer of the rug can be easily removed and replaced whenever it is required for cleaning purposes or aesthetic reason, keeping the bottom or base layers unchanged. Moreover, the bottom layers could have antimicrobial, anti-soil and anti-stain properties and therefore include antimicrobial, anti-soil and anti-stain compositions applied thereto. Hence, the rug articles as described herein are suitable for home-uses (e.g. for products in bath or kitchen uses), commercial uses, the hospitality business, healthcare and restaurants, etc.
[00012] Referring to Figures 1-3, the present disclosure includes a rug 10 having
a base layer 60, a middle layer 80, and a tufted pile layer 160, and a coupling system 90 (Fig. 1B and 2) that removably couples the pile layer 160 and/or middle layer 80 to the base layer 60. The pile layer 160 includes piles, shown as loops, as is typical in a rug. The pile layer 160 is further described below.
[00013] Continuing with Figures 1A and 1B, the rug article 10, in one
version, includes opposed ends 12 and 14 spaced apart along a longitudinal direction 2, and side edges 16 and 18 that extend from the end 12 to end 14 along the longitudinal direction 2. The longitudinal direction 2 can be referred to as the machine direction, e.g. length direction in some instances. The side edges 16 and 18 are spaced apart with respect to each other along a lateral direction 4 (or cross

direction) that is perpendicular to the longitudinal direction 2. The ends 12 and 14 and side edges 16 and 18 collectively define a rug perimeter, which in turn defines a size and shape of the rug article. The article 10 also includes a face 20 and a back 22 opposed to the face 20 along a vertical direction 6 that is perpendicular to the longitudinal and lateral directions 2 and 4, respectively. The rug article 10 has a length L that extends from end 12 to end 14 along the machine direction 2 and a width W that extends along the cross direction 4. As illustrated, the rug article length L is greater than the width W so as to define rectilinear shape. The dimensions of the rug article 10 can be defined during manufacturing to any size. For instance, the rug need not be rectangular but could be circular, oval, or have any shape. The rug article ends 12 and 14 include hems 24a and 24b, respectively. The side edges 16 and 18 can include hems or selvages 26a and 26b, respectively. The rug article 10 can also include one or more optional borders 28 (Figure 1) that extend across the width W or the length L of the rug article 10 for decorative purposes.
[00014] As shown in Figures 1B and 2, the base layer 60 has an upper surface
62 and a lower surface 64 opposite the upper surface 62. The lower surface 64 is
configured to lie in contact with a floor. The lower surface 64 further includes an anti¬
skid coating that extends along a substantial entirety of the lower surface 64. The base
layer 60 may be formed from a nonwoven substrate, a woven fabric, or a knitted fabric.
For example, the base layer may be needle punched nonwoven, thermo-bonded carded
nonwoven, spun-bonded nonwoven, spunless nonwoven, or combinations thereof, e.g.
an SMS or SMMS or variations thereof, a woven fabric or knitted fabric. The base
layer may be comprised of recycled fibers or virgin synthetic fibers (polyester, nylon,
polypropylene fibers) or recovered fibers as needed. Moreover, the base layer could
have anti-stain, anti-microbial compositions applied thereto, that provide for different
degrees of hydrophobicity. This permits the rug to be used in different areas like
households, hospitals or commercial spaces.
[00015] The base layer 60 may also be coated along its lower surface 64. In one

example, but not required, the base layer 60 may be dot coated. However, other anti-skid arrangements could be possible. The anti-skid coating may be a latex coating or thermoplastic rubber (TPR) or polyurethane coating or acrylic coating or simple foam lamination applied to the lower surface 64 of the base layer 60. The coating can be applied to an entirety of the lower surface of the base layer 80. The base layer has a basis weight between about 250 grams per square meter and 400 grams per square meter (whether with or without the coating). However, a broader or narrow range may be used. For example, the base layer can range between 50 grams per square meter and 1600 grams per square meter. In one example, the base layer can range between 300 grams per square meter and 600 grams per square meter. In another example, the base layer can range between 600 grams per square meter and 900 grams per square meter. In another example, the base layer can range between 900 grams per square meter and 1200 grams per square meter. In another example, the base layer can range between 1200 grams per square meter and 1600 grams per square meter. Narrower basis weight ranges are preferable but are not required.
[00016] The middle layer 80 designed to provide additional cushion and support
the article. As illustrated, the middle layer 80 has an upper surface 82 and a lower surface 84 opposite the upper surface 82.The middle layer is positioned so that the lower surface 84 is directly adjacent to the upper surface 62 of the base layer 60. The middle layer 80 may extend along an entirety of the length and width (or other suitable dimension (e.g. for circular rugs and the like)) of the base layer 60. In this manner, the middle layer 80 and the base layer 60 are substantially coterminous with respect to each other. In examples where the pile layer 160 is removable from the middle layer and the base layer, the middle layer can be bonded, either chemically or mechanically, to the base layer 60. In one example, the middle layer 80 may be a nonwoven fabric, a woven fabric, knitted fabric, a foam layer, or combination thereof. In one example, the middle layer 80 is a needle-punched nonwoven fabric. In another example, the middle layer 80 is a spun bond nonwoven fabric. In another example, the middle layer 80 is a woven fabric. In another example, the middle layer 80 is a knitted fabric.

In another example, the middle layer 80 is memory foam. For middle layer 80 made of nonwoven fabrics, the fibers may be polymeric, either virgin polymer or recycled or recovered polymers. For woven and knitted middle layers, the yarns may also be virgin or recycled or recovered polymeric fibers. For middle layer 80 made of memory foam, is the foam is polymeric foam, either virgin or recycled or recovered. While one middle layer 80 is shown for clarity, an embodiment of the present disclosure includes multiple middle layers.
[00017] The pile layer 160 forms the exposed surface of the rug 10 and includes
piles 162. The pile layer 160 as shown in a tufted pile construction and includes a primary base fabric 30 and a pile component 40 forming the piles. A light coating (not numbered) may be applied to the lower surface of the primary base fabric to aid in affixing the piles 162 in place. Preferably, the pile layer is tufted however other pile fabrics may be used, similar to the terry constructions. The pile component includes a first set of piles formed from yarns that form pile loops. A “pile” as used herein include a pile loop or a cut pile. As illustrated, the pile fabrics includes pile loops. However, the pile fabrics can include cut piles as well.
[00018] Continuing with Figure 1A-3, the pile layer 160 includes a primary
base fabric 30 and a pile component 40 along a face 20 of the article 10. The top layer or pile layer 160 includes an upper side 32 and a lower side 34 spaced from the upper side along the vertical direction 6. The lower side 34 defines a mating surface that is configured for placement against the upper surface of the middle layer 80 as further described below. The pile component 40 can project upwardly away from the upper side 32 of the primary base fabric 30 in the vertical direction 6, as is typical in tufted constructions. More specifically, pile yarns are integrated into the primary base fabric and form piles that extend upwardly from an upper side of the primary base fabric 30.
[00019] The primary base fabric 30 may be any substrate layer that is used to
support the piles. In one example, the primary base fabric 30 may be a woven fabric, knitted, non-woven or other suitable textile substrate configured for tufted

constructions. The primary base fabric may be formed from primary base fabric yarns. The primary base fabric yarns may include natural fibers and/or continuous filament yarns. The natural fibers in the primary base fabric yarns can be cotton, flax, bamboo, hemp, wool, or other natural fibers with improved moisture absorbency and retention properties. In one example, the natural fibers are cotton fibers.
[00020] The primary base fabric yarns may have a count between about 895
denier ( 6 Ne) to about 90 denier (60 Ne). In one example, the primary base fabric yarns may have a count between 536 denier (10 Ne) to about 107 denier (50 Ne), and preferably between about 536 denier (10 Ne) to about 180 denier (30 Ne). In another example, the primary base fabric yarns may have a count between 536 denier (10 Ne) to about 224 denier (24 Ne). In one example, the primary base fabric yarns have a count of about 335 denier (16 Ne). In another example, the primary base fabric yarns have a count of about 268 denier (20 Ne). In another example, the primary base fabric yarns have a count of about 224 denier (24 Ne). While a cotton count is used to denote the linear density of the primary base fabric yarns, the primary base fabric yarns when continuous filament may, of course, have equivalent denier. The primary base fabric could be made by natural fibers or synthetic fibers or recovered fibers. Furthermore, the primary base fabric yarns, when spun or twisted, can have between about 150 and 350 turns/meter of twist, preferably between about 200 to about 300 turns/meter of twist. In addition, the primary base fabric yarns can be plied yarns. In one example the primary base fabric yarns is a 2-ply yarn. In another example, the primary base fabric yarns are 3-ply yarns. In another example, the pile primary base fabric yarns are 4-ply yarns.
[00021] As illustrated in Figures 1A-3, the pile component 40 can extend
across a majority of the rug article face 20. Specifically, the pile component 40 extends from one end to the other end along the machine direction 2. The pile component 40 also extends from one hem 26a at side edge 16 to the opposing hem 26b at side edge 18 along the cross direction. The pile component40 therefore

defines a substantial portion of the face 20 of the rug article 10.
[00022] Turning to Figure 3, the pile component 40 includes a plurality of
piles 162 that extend away from the primary base fabric 30. The plurality of piles 162 are formed by a set of pile yarns 164. The plurality of piles 162 further define a base located at the primary base fabric 30, a pile end spaced apart from the base along a respective pile loop 162, and a pile height H1 (not shown) that extends from the base to the pile end. The pile height H1 may vary as needed based on design needs. The piles could be loop or cut in appearance.
[00023] The pile yarns 164 define the piles that extend upwardly from the
primary base fabric. The pile yarns 164 may include natural fibers, synthetic staple fiber and/or continuous filament yarns or suitable combination thereof. The natural fibers in the pile yarns 164 can be cotton, flax, bamboo, hemp, wool, or other natural fibers with improved moisture absorbency and retention properties. In one example, the natural fibers are cotton fibers. Furthermore, the pile yarn can be a ring spun yarn, an open-end yarn, a rotor spun yarn, or the Hygrocotton ® brand yarn. The pile yarns 164 may have a count between about 895 denier (6 Ne) to about 90 denier (60 Ne). In one example, the pile yarns 164 may have a count between 536 denier (10 Ne) to about 107 denier (50 Ne), and preferably between about 536 denier (10 Ne) to about 180 denier (30 Ne). In another example, the pile yarns 164 may have a count between 536 denier (10 Ne) to about 224 denier (24 Ne). In one example, the pile yarns 164 have a count of about 335 denier (16 Ne). In another example, the pile yarns 164 have a count of about 268 denier (20 Ne). In another example, the pile yarns 164 have a count of about 224 denier (24 Ne). While a cotton count is used to denote the linear density of the pile yarns, the pile yarns when continuous filament may, of course, have equivalent denier, as further described below. Furthermore, the pile yarns 164 can have between about 150 and 350 turns/meter of twist, preferably between about 200 to about 300 turns/meter of twist. In addition, the pile yarns 164 can be plied yarns. In one example the pile yarn is a 2-ply yarn. In another example, the pile yarns 164 are 3-ply yarns. In another example, the pile

yarns 164 are 4-ply yarns. In another example, the pile yarns1 64 are 6-ply yarns. In
another example, the pile yarns 164 are 8-ply yarns. In another example, the pile
yarns 164 are 10-ply yarns. In another example, the pile yarns 164 are 12-ply yarns.
[00024] The pile yarns 164 may also be formed from continuous filament
yarns. The continuous filament yarns may include PA (Nylon) filaments, PET
filaments, PLA filaments, PP filaments, or other filaments. The yarns may be made
from recycled polymers, such as recycled nylon fibers and recycled PET fibers.
Continuous filament pile yarns may have a count between about 75 denier to about
1600 denier. In another example, the continuous filament thermoplastic yarns have a
count between about 75 denier to about 900. In another example, the continuous
filament thermoplastic yarns have a count between about 170 denier to about 530. In
another example, the continuous filament thermoplastic yarns have a count between
about 200 denier to about 400 denier. In another example, the continuous filament
thermoplastic yarns have a count between about 220 denier to about 330 denier. In
another example, the continuous filament yarns have a count of about 220 denier. In
another example, the continuous filament yarn has a count of about 270 denier. In
another example, the continuous filament yarn has a count of about 330 denier.
[00025] The pile layer, including the primary base fabric and pile component,
may have a basis weight between 20 grams per square meter (GSM) and 2400 grams per square meter. In one example, the basis weight is between 260 grams per square meter and 700 grams per square meter. In another example, the basis weight is between 400 grams per square meter and 600 grams per square meter. In another example, the basis weight is between 400 grams per square meter and 900 grams per square meter. In another example, the basis weight is between 400 grams per square meter and 900 grams per square meter. In another example, the basis weight is between 900 grams per square meter and 1400 grams per square meter. In another example, the basis weight is between 1100 grams per square meter and 1400 grams per square meter. In another example, the basis weight is between 1400 grams per square meter and 2400 grams per square meter.

[00026] As described above, the pile layer 160 includes a coating along its
mating surface that is designed to aid in fixation of the piles or tufts to the primary base
fabric. The coating here may be latex or another adhesive system. In the present
disclosure, the amount of coating applied the primary base fabric can range between
30 grams per square meter to 600 grams per square meter. In one example, the coating
weight is between 30 grams per square meter and 100 grams per square meter. In
another example, the coating weight is between 100 grams per square meter and 200
grams per square meter. In another example, the coating weight is between 200 grams
per square meter and 300 grams per square meter. In another example, the coating
weight is between 300 grams per square meter and 400 grams per square meter. In
another example, the coating weight is between 400 grams per square meter and 500
grams per square meter. In another example, the coating weight is between 500 grams
per square meter and 600 grams per square meter. In preferred example, the coating
weight is between 30 grams per square meter and 300 grams per square meter.
[00027] The rug as described herein is configured so that the pile layer 160 can
be easily removed. Thus, a coupling system 90 is used to permit removable coupling of the top layer, which may include the pile layer alone or the pile layer and the middle layer, to the base layer. This allows the top layer to be completely removable from the base layer in order to facilitate washing the top layer via at least one wash cycle. The coupling system 90 can be any mechanical fastening system that extends along at least an outer perimeter of the base layer and an outer perimeter of the top layer. In one example, the coupling system is a snap-fit coupler. In one example, the coupling system is a hook and loop coupler. In one example, the coupling system include elastic bands. In one example, the coupling system includes at least two pockets to receive at least two portions of a perimeter of the base layer or the top layer.
[00028] In use, a user can remove the top layer by decoupling the top layer from
the base layers. The top layer can then be replaced with a new top layer, with a different design or color way, or washed as needed via at least one wash cycle. In some embodiments, the pile layer is dimensionally stable after at least 10 washes, or even

after at least 15 washes, or even after at least 20 washes, or even after at least 30 washes, or even after at least 40 washes, or even after at least 60 washes, or even after at least 80 washes, or even after at least 100 washes.
[00029] Embodiments of the present disclosure also include rug articles
including various electronically enabled smart components. In one example, the rug article may include one or more sensors that are configured to detect a present of liquid or moisture in the rug article. The sensors may be flexible sensors that area integrated into the rug article, such as in one or more of the base layer, the middle layer, and/or the pile layer. The flexible sensor is configured to obtain sensor data that is indicative of liquid in the textile material that is in contact with the at least one flexible sensor. The flexible sensor includes a conductive element, the entirety of which is integrated into the desired layer of the rug article. In one example, the conductive element is a conductive yarn that may include conductive fibers. In another example, the conductive fibers may be stainless steel fibers. The conductive element may include conductive inks. In practice, the rug article may also include an interface element that is electrically connected to the at least one flexible sensor. Here, the interface element is configured to forward the sensor data provided by the at least one flexible sensor to a computing device via a communication link.
[00030] In such an example, the computing device, which may be any typical
computing device, includes a processor, memory, and input module and output
modules. The processor can execute a software application, that, in response to
receiving sensor data from the rug article (or multiple rug articles) can: a) determine if
the sensor data indicates that a criterion is met for one or more rug articles, b) based on
the determination that the criterion is met for the one or more of the rug articles,
determine if a respective the flexible sensors is in contact with liquid, and optionally c)
identify a pattern among occurrences where the criterion is met. In this case, the pattern
includes a predicted time that at least one flexible sensor is likely to be in contact with
liquid.
[00031] The sensors and software application as described above may made

according to disclosure of U.S. Patent No. 10,866,202, entitled Textile Articles and Systems for Liquid Detection, the entire disclosure of which is incorporated by reference into the present application.
[00032] Additionally, the rug article may be configured as an interactive textile
rug article. Such an interactive rug article may include one or more design objects or motifs integrated into the pile layer, either printed or formed in the pile structure as a design.
[00033] In such an embodiment, the rug article may interface with one or more
computing devices. The computing devices may be any computing device with a processor, memory, inputs, and outputs. Certain inputs may include cameras that can capture the design motif or object of the rug article within a viewing angle or field of the camera. The computing devices may include an augmented reality program configured to be stored in a memory of the computing device and executable by the processor of the computing device. The augmented reality program includes at least one content level. When the augmented reality program is executed by the processor, it can compile a design object depiction that is based on the one or more design object identifiers included in the design object.
[00034] In addition, the augmented reality program is configured to progress
through an augmented content level with the first augmented content level configured to display on the computing device 1) the design object depiction and at least a portion of the rug article, 2) one or more first augmentation elements each of which include content that is related to the design object and the rug article, and 3) at least one first input element configured to control the design object depiction and the one or more first augmentation elements. In use, engagement of the first augmentation elements and the at least one first input element cause progression through the first augmented content level.
[00035] The interactive design and computing devices described above may be
made in accordance with disclosure of U.S. Patent No. 9,524,589, entitled “Interactive Textile Article and Augmented Reality System,” the entire disclosure of which is

incorporated by reference into the present application.
[00036] Another embodiment of the present disclosure is a method of making a
rug article. The method includes forming a base layer. In this example, the base layer has an upper surface and a lower surface opposite the upper surface with the lower surface configured to lie in contact with a floor. The lower surface further includes an anti-skid coating. The method may also include forming a top layer. The top layer may have a basis weight between 260 grams per square meter and 2400 grams per square meter. The top layer may have a pile layer and a middle layer as described above. The pile layer has a primary base fabric defining a mating surface on a first side, and pile yarns integrated into the primary base fabric and forming piles that extend upwardly from a second side of the primary base fabric. The pile yarns include virgin, recycled and recovered nylon fibers, polyester fibers, polypropylene fibers, natural fibers, or any combination thereof. The top layer wherein the top layer is machine washable. The method may include affixing a coupling system to either or both base layer and the top layer so that the top layer is removably coupled to the base layer. The method also include incorporation one of more flexible sensors in the rug article and or implementing one or more augmented reality programs.

We Claim:
1. A rug, comprising:
a base layer having an upper surface and a lower surface opposite the upper surface, the lower surface configured to lie in contact with a floor, the lower surface further including anti-skid coating;
a middle layer having an upper surface and a lower surface opposite the upper surface, the lower surface of the middle layer is directly above of the upper surface of the base layer;
a pile layer having a primary base fabric having a first side defining a mating surface, and a second side having pile yarns integrated into the primary base fabric and forming piles that extend upwardly from the primary base fabric, wherein the primary base fabric is directly above the upper surface of the middle layer; and
a coupling system that permits removable coupling of 1) the pile layer to the upper surface of the middle layer, or 2) the pile layer and the middle layer to the upper surface of the base layer, such that, at least the pile layer is completely removable from the base layer in order to facilitate washing the pile layer at least ten wash cycles.
2. The rug according to claim 1, further comprising two or more additional layers.
3. The rug according to claim 1, wherein the pile layer has a basis weight between 200 grams per square meter to 2400 grams per square meter.
4. The rug according to claim 1, wherein the pile yarns may include virgin, recovered and recycled fibers in staple or filament form or in combination thereof.
5. The rug according to claim 1, wherein the pile yarns include any one of nylon fibers, polyester fibers, polypropylene fibers, regenerated fiber, natural fibers, or any combination thereof.

6. The rug according to claim 1, wherein the middle layer is any one or any combination of a woven fabric, a knitted fabric, a nonwoven fabric, or memory foam.
7. The rug according to claim 1, wherein the primary base fabric is any one or any combination of a woven fabric, a knitted fabric, and a nonwoven fabric.
8. The rug according to claim 1, wherein the base layer has a basis weight between about 50 grams per square meter to 1600 grams per square meter.
9. The rug according to claim 1, wherein the anti-skid coating is made of any one of latex or polyurethane, acrylic or thermoplastic resin.
10. The rug according to claim 1, wherein the coupling system is a snap-fit coupler.
11. The rug according to claim 1, wherein the coupling system is a hook and loop coupler.
12. The rug according to claim 1, wherein the coupling system includes elastic bands.
13. The rug according to claim 1, wherein the coupling system includes at least two pockets to receive at least two portions of a perimeter of the base layer or the top layer.
14. The rug according to claim 1, wherein the coupling system extends along at least a portion of an outer perimeter of the base layer and an outer perimeter of a top layer that includes either or both of the pile layer and the middle layer.
15. A method of manufacturing a rug, comprising:
forming a base layer, the base layer having an upper surface and a lower surface opposite the upper surface, the lower surface configured to lie in contact with a floor, the lower surface further including anti-skid coating that extends along a substantial entirety of the lower surface; and
Forming a middle layer configured to be placed directly above the upper surface of the base layer;
forming a pile layer having a primary base fabric, having a first side

defining a mating surface, and a second side having pile yarns integrated into the primary base fabric and forming piles that extend upwardly from the primary base fabric, wherein the pile yarns include virgin, recovered and recycled nylon fibers, polyester fibers, polypropylene fibers, natural fibers, or any combination thereof; and
Affixing a coupling system to one or more of the base layer, the middle layer and the pile layer so that at least the pile layer is movably coupled to the base layer.