Injection Molded Carpet Mat with Plastic Migration Prevention
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Solution Overview
Problem
Conventional vehicle floor mats face issues with carpet detachment from backing material, limited flexibility, high production costs, and adhesive degradation over time, due to the use of laminated and injection-molded methods.
Innovation Solution
An injection molded carpet mat with a web of carpet integrally formed with a flexible mat, using vertically oriented molds and vacuum retention to prevent plastic migration into the carpet, and a mold design with peripheral ribs and protrusion teeth to secure the carpet in place during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional lamination method is used to attach carpeting to backing material, then the carpeting can be easily attached, but the carpeting becomes detached during normal use especially at peripheral edges
Solution Approach 1:
The patent merges the carpeting attachment process with the backing material formation process by injection molding the carpeting directly into the backing material in a single integrated operation, eliminating the separate lamination step and creating a unified structure where the carpeting is permanently embedded in the backing material
Solution Approach 2:
The patent applies preliminary action by pre-positioning the carpeting in the mold cavity before injection molding, ensuring proper alignment and securing the carpeting edges to the mold walls beforehand, which prevents detachment during subsequent processing and use
2Manufacturing precision
If injection molding method is used to produce carrier material with undercut, then cutting tolerances are absorbed and reinforced border is available, but the carpet edges become insufficiently flexible and production cost increases due to slide systems
Solution Approach 1:
The patent applies local quality by providing reinforcement only at the peripheral edges of the carpeting through the molded carrier material, while the central area maintains full flexibility, achieving both edge stability and overall carpet flexibility without requiring slide systems
Solution Approach 2:
The patent uses preliminary action by forming the carrier material with integrated edge reinforcement and carpet securing features directly in the mold before carpet installation, creating built-in structures that absorb cutting tolerances and secure carpet edges without requiring additional slide mechanisms
3Strength
If chemical adhesives or heat are used to fasten decorative material to carrier material, then the material can be secured, but the adhesive power decreases over time and with extended use
Solution Approach 1:
The patent merges the material attachment function into the structural carrier material itself by injection molding the decorative material directly into the carrier material, creating a permanent mechanical bond that eliminates the need for separate adhesives and ensures long-lasting attachment
Solution Approach 2:
The patent replaces expensive, time-limited adhesives with a permanent molded structure that provides indefinite attachment durability, effectively eliminating the adhesive lifespan limitation by using the carrier material itself as the permanent bonding mechanism
4Device complexity
If injection molding is used to produce carpet mat, then integration of carpet and backing is achieved, but the flowing resin migrates into the carpeting and the heat thins or degrades the carpeting
Solution Approach 1:
The patent applies preliminary action by pre-positioning the carpeting in the mold cavity and securing its edges to the mold walls before resin injection, creating a protective framework that prevents resin migration into the carpet fibers during the molding process
Solution Approach 2:
The patent uses skipping by rapidly injecting the resin and immediately cooling it to solidify, reducing the time the resin remains in a migratory state and minimizing thermal exposure to the carpeting, thereby preventing both migration and thermal degradation
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 solution enhances flexibility, reduces production costs, and extends the lifespan of the mat by preventing plastic migration into the carpet, ensuring a durable and cost-effective product with improved edge retention.
Implementation Method 1
providing the cavity with a surface having at least one vacuum opening bordered by a peripheral retaining barrier, applying vacuum to the cavity, inserting a sheet of carpet into the mold recess of the cavity and against the surface so that the carpet is held in the mold recess by the vacuum
Data Source
AI summary
An injection molded carpet mat includes a flexible base having an upper surface defining a carpet recess, and an opposite lower surface. A carpet sheet is secured in the carpet recess by being integrally formed with the base, and having a napped top surface, a bottom surface and a peripheral edge. The lower base surface having a plurality of spaced ribs supporting the carpet bottom surface adjacent the peripheral edge and defining a track on the lower base surface corresponding to the peripheral edge of the carpet sheet.