Compliant Roller Mat Washer for Three-Dimensional Vehicle Mats
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Solution Overview
Problem
Current methods for cleaning three-dimensional or contoured vehicle mats are time-consuming and labor-intensive, as they require manual removal and scrubbing, which is inefficient for mats with complex shapes.
Innovation Solution
An automatic mat washer system featuring compliant rollers that deform to accommodate the mat's shape, combined with rotating brushes that scrub both surfaces simultaneously, and a deflector to alter the mat's angle and direct it to a holding pan for easy retrieval.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual cleaning methods are used for three-dimensional vehicle mats, then the cleaning process can be performed with simple equipment, but the cleaning process becomes time-consuming and labor-intensive
Solution Approach 1:
The cleaning system is divided into separate functional modules: compliant rollers for mat advancement, rotating brushes for scrubbing, deflectors for routing, and a holding pan for collection. Each module performs a specific function, allowing the system to process three-dimensional mats efficiently without requiring overly complex integrated mechanisms.
Solution Approach 2:
The compliant rollers automatically grab and advance the mat through the cleaning system without manual intervention. The rotating brushes autonomously scrub the mat surfaces as they pass, and the deflectors automatically route the mat to the holding pan, creating a self-service cleaning process that eliminates labor-intensive manual scrubbing.
2Adaptability or versatility
If compliant rollers are used to accommodate the contoured shape of the mat, then the mat can be grabbed and advanced effectively, but the roller structure becomes more complex
Solution Approach 1:
The compliant rollers utilize flexible roller surfaces that can deform to match the contoured shape of three-dimensional vehicle mats. This flexibility allows the rollers to effectively grab and advance mats with complex geometries, including curved transitions and angled walls, without requiring complex adjustable mechanisms or multiple specialized rollers.
3Productivity
If brushes rotate at greater RPM than compliant rollers to exert tension for scrubbing action, then cleaning effectiveness is improved, but the risk of mat bunching downstream increases
Solution Approach 1:
Deflectors are positioned downstream of the brushes to act as intermediaries that gently guide and flatten the mat as it exits the high-speed brush zone. These deflectors prevent the mat from bunching by redistributing the tension created by the fast-rotating brushes, ensuring smooth mat transport to the holding pan while maintaining effective cleaning performance.
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 system enables quick and thorough cleaning of complex vehicle mats by automatically advancing and scrubbing the mat, preventing bunching and ensuring complete surface cleaning, while depositing the mat in a holding pan for easy access.
Implementation Method 1
the one or more compliant rollers can deform a distance radially toward an axis of rotation when contacting the mat to accommodate the contoured three dimensional shape of the mat
Implementation Method 2
The one or more brushes can rotate at a greater RPM than the compliant rollers to exert a tension on a first portion of the vehicle mat between the brushes and the compliant rollers
Data Source
AI summary
An apparatus for cleaning a semi-rigid, three-dimensional vehicle mat can include a first set of compliant rollers spaced from one another and a second set of compliant rollers spaced from one another that cooperatively grab and advance the mat toward one or more brushes that scrub debris from above and/or below the mat. One or more of the compliant rollers can deform a distance radially toward an axis of rotation when contacting the mat to accommodate the contours of the mat and still grab the mat for advancing. The apparatus can include a holding pan that supports the mat so it is accessible through a second opening below the brushes and a first opening of a frame that supports the rollers and brushes. A deflector can be included to reroute the mat downstream of the brushes along a pathway toward the pan. A related method of use also is provided.