Carpet mat
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Solution Overview
Problem
Traditional anti-slip pads for carpets have weak hooking forces, are prone to deformation and detachment, and can cause hand pricking, failing to effectively prevent carpet slippage and ensuring user safety.
Innovation Solution
Heat-treating protruding monofilaments on the hook layer to create small bumps that provide a strong hooking force and friction, ensuring firm attachment to the carpet surface while preventing detachment and hand pricking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If protruding monofilaments are used on the anti-slip pad to hook with the carpet, then the hooking force is improved, but the monofilaments are prone to deformation, falling off, and pricking hands after long-term use
Solution Approach 1:
The patent applies heat treatment to the protruding monofilaments, changing their physical state from rigid to softened, allowing them to form rounded bumps that maintain hooking capability while eliminating sharp edges that cause hand pricking. This parameter change resolves the contradiction between achieving sufficient hooking force and ensuring user safety.
Solution Approach 2:
The monofilaments undergo heat treatment during manufacturing to pre-form rounded bumps before the product is put into use. This preliminary action prevents deformation and falling off during long-term use, as the rounded structure is already established and more stable than sharp monofilaments.
2Object-affected harmful factors
If the protruding monofilaments are made thinner to reduce hand pricking, then the safety is improved, but the hooking force decreases
Solution Approach 1:
Heat treatment changes the physical parameters of the monofilaments by softening them and forming rounded bumps. This allows the use of thinner monofilaments that won't prick hands while maintaining adequate hooking force through the rounded bump structure that can still penetrate carpet fibers effectively.
3Strength
If the protruding monofilaments are made longer to increase hooking force, then the bonding strength is improved, but the risk of hand pricking increases
Solution Approach 1:
Heat treatment transforms long sharp monofilaments into rounded bumps with reduced effective length. The rounding process maintains the hooking capability by preserving the bump's ability to penetrate carpet fibers while eliminating the sharp edges that cause hand pricking, thus resolving the contradiction between bonding strength and safety.
4Ease of operation
If traditional anti-slip fabric is used beneath the carpet, then the anti-slip function is provided, but the fabric is light, thin, easy to wrinkle, and not wear-resistant
Solution Approach 1:
The patent creates a composite structure by bonding the heat-treated hook layer to a foam backing material. This composite construction combines the hooking capability of the monofilaments with the durability, thickness, and wrinkle resistance of the foam material, resolving the contradiction between providing anti-slip function and ensuring wear resistance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The heat-treated monofilaments achieve a high bonding force and friction, preventing carpet displacement and reducing monofilament detachment, enhancing safety and usability.
Implementation Method 1
The protruding monofilaments on the hook layer are heat-treated to make their top ends melted/softened into the small bumps
Implementation Method 2
the top ends of the protruding monofilaments are melted/softened into the small bumps
Implementation Method 3
can firmly hook with various carpets above and provide a large friction force, thereby playing a locking role on the carpet above
Data Source
Figure 1~2
Figure 3
AI summary
A carpet pad includes a top hook layer and a bottom anti-slip layer. An upper surface of the hook layer is provided with protruding monofilaments in a bent shape. Top ends of the protruding monofilaments are provided with bumps formed by melting/softening and then cooling the protruding monofilaments. The protruding monofilaments on the hook layer are heat-treated to make their top ends melted/softened into the small bumps. The heat-treated protruding monofilaments have a certain degree of curvature and inclination, and thus can firmly hook with various carpets above and provide a large friction force, in particular in a vertical direction. The length and density of the protruding monofilaments are reasonably designed to make the protruding monofilaments well hook and lock with the carpet above. In addition, the protruding monofilaments touch soft, and the bumps are not prickly.