Cover with pull-through prevention arrangement
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Solution Overview
Problem
Existing marine floor mats face issues with fastener pull-through and tearing during detachment, leading to damage and complicating easy removal.
Innovation Solution
A marine floor mat design featuring dual-density foam layers and snap or quick-release couplers that prevent fastener pull-through and facilitate easy detachment without damaging the mat or the marine surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fasteners are used to secure the marine floor mat, then the mat attachment is secure, but the fasteners may pull through the mat layers causing damage during removal
Solution Approach 1:
The patent changes the physical parameters of the foam material by using dual-density construction - a softer top layer (7.5-9.5 lbs/ft³) and a denser bottom layer (8-12.9 lbs/ft³). This parameter change allows the fasteners to be securely held in the dense bottom layer while the softer top layer provides a cushioning effect that prevents fastener pull-through damage during removal, thus maintaining both attachment security and mat integrity.
Solution Approach 2:
The patent employs composite materials by combining two different foam densities in a layered structure. The composite construction integrates the advantages of both materials: the softer foam provides comfort and fastener cushioning, while the denser foam provides structural support and fastener anchoring. This composite approach resolves the contradiction between secure attachment and damage prevention during removal.
2Ease of manufacture
If traditional single-density foam is used, then manufacturing is simple, but the mat either allows fastener pull-through or is difficult to remove
Solution Approach 1:
The patent modifies the density parameter of the foam material by creating a gradient structure with two distinct density zones. This parameter change enables the mat to be easily removable while preventing fastener pull-through, as the softer top layer allows for easier fastener extraction while the denser bottom layer maintains structural integrity. The manufacturing process remains relatively simple by using standard foam bonding techniques.
3Reliability
If fastener density is increased to prevent pull-through, then attachment security improves, but the mat becomes more complex and harder to remove
Solution Approach 1:
The patent applies local quality by varying the foam density at different locations through the mat thickness - softer foam at the top surface where fasteners enter, and denser foam at the bottom where fasteners are anchored. This localized material property variation provides secure attachment without requiring increased fastener density, thus maintaining simple mat structure and ease of removal while improving attachment reliability.
Data Source
AI summary
A marine floor mat arrangement includes first and second foam layers having densities of between about 7.5 lbs/ft3 and about 9.5 lbs/ft3, and between about 8 lbs/ft3 and 12.9 lbs/ft3, respectively, wherein the second density is greater than the first density, and a plurality of snap couplers each including a first portion including a body portion extending entirely through the first and second layers and a flanged portion extending outwardly from the body portion where the flanged portion abuts an exposed outer surface of the first layer, and a second portion releasably connected with the first portion of the snap coupler, where the second portion of the snap coupler is attached to the surface of a marine vehicle.