Composite Floor Mat with Energy Dissipative Pockets
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Solution Overview
Problem
In commercial gym settings with shared spaces, intense weightlifting activities cause significant vibration and impact noise that is transmitted to adjacent structures, which existing floor mats fail to adequately mitigate due to the heavy weights and intense impacts.
Innovation Solution
A composite floor mat with a durable upper layer, a middle layer of energy dissipative pockets filled with materials like SEREFLEX cushioning, and a bottom layer of microcellular polyurethane that absorbs and distributes impact energy, featuring a network of ribs and a manufacturing process involving a tool with a hinged mold to ensure effective cushioning and noise reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If homogeneous rubber floor mats are used, then the floor mat provides basic cushioning, but the impact noise and vibration transmission to adjacent structures is not adequately mitigated
Solution Approach 1:
The floor mat is divided into multiple functional layers: a top wear layer for durability, a middle layer containing an energy dissipative material in a grid of pockets for impact absorption, and a bottom layer for structural support and additional cushioning. This segmentation allows each layer to specialize in specific functions, with the middle layer's energy dissipative material specifically targeting impact noise reduction through its Bingham fluid properties.
Solution Approach 2:
The floor mat combines multiple materials with different properties: a durable top layer material (such as rubber or polyurethane), an energy dissipative material exhibiting Bingham fluid characteristics in the middle layer, and a supportive bottom layer material. This composite structure leverages the unique properties of each material to achieve both durability and superior impact noise mitigation that homogeneous materials cannot provide.
2Adaptability or versatility
If heavy weights are dropped during weightlifting, then intense exercise regimens can be performed, but significant vibration and impact noise is transmitted to adjacent structures
Solution Approach 1:
The energy dissipative material in the middle layer utilizes its Bingham fluid properties to convert the harmful impact energy from dropped weights into beneficial cushioning effects. The material's yield-stress behavior allows it to remain stable during normal use while dissipating impact energy through controlled deformation, effectively transforming the harmful vibration and noise into manageable energy dissipation.
Solution Approach 2:
The floor mat's middle layer material exhibits parameter changes based on applied stress: it maintains a stable solid-like structure during normal foot traffic but transitions to a more compliant state under heavy impact loads. This stress-dependent parameter change allows the mat to support intense weightlifting activities while effectively mitigating the resulting vibration and impact noise.
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 composite floor mat effectively absorbs and dissipates impact energy from weights and foot traffic, significantly reducing noise transmission through the floor, making it suitable for high-impact gym environments.
Implementation Method 1
The energy dissipative material preferably has the properties of a Bingham fluid and may comprise a synthetic plastic shell filled with semi-processed fluid or gel
Implementation Method 2
The bottom layer, such as a urethane, or more specifically a microcellular polyurethane, is bound to the upper layer and configured to face the floor on which the mat is disposed
Data Source
AI summary
A composite floor mat having an upper layer, a middle layer, and a bottom layer. The upper layer comprises a durable wear surface, the middle layer comprises a plurality of pockets, each filled with an energy dissipative material. The bottom layer is bound to the upper layer and defines a perimeter of the mat and a network of ribs defining the pockets of the middle layer. A mat system comprises a plurality of mat components positioned adjacent one another, including edge mat components, corner mat components, and internal mat components, held together by retaining clips disposed in a channels of the mat components. A process for manufacture of a floor mat assembly, and product produced thereby, are also disclosed.