Cushioned Absorbent Mat with Barrier Layer for Quick Drying
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Solution Overview
Problem
Conventional mats are uncomfortable, prone to moisture retention, and quick degradation, making them unhygienic and short-lived, especially in wet environments like bathrooms.
Innovation Solution
A mat design featuring a compressible open-celled polyurethane foam core laminated with a moisture-absorbent woven textile layer and a non-slip spandex base, where the textile layer is made of microfibers with a specific density and pile height, and a barrier layer to prevent moisture from reaching the foam, ensuring quick drying and enhanced comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the mat is made thicker to provide more comfort, then comfort is improved, but the mat becomes heavier and more difficult to dry
Solution Approach 1:
The mat combines multiple materials with different properties: a foam layer for comfort and cushioning, a textile layer for moisture absorption, and a rubberized base for slip resistance. This composite structure provides comfort without requiring excessive thickness, thereby reducing weight while maintaining functionality.
2Quantity of substance
If the mat is made more absorbent to handle moisture, then moisture absorbency is improved, but the mat retains moisture longer and dries slower
Solution Approach 1:
The mat is divided into distinct functional layers: the textile layer absorbs moisture from contact with feet, while the foam layer provides cushioning. A barrier layer prevents moisture penetration into the foam, allowing the absorbent layer to be separated from the cushioning layer. This segmentation enables the mat to absorb moisture effectively while preventing moisture retention in the cushioning layer, thus reducing overall drying time.
3Productivity
If the mat is made with a barrier layer to prevent moisture retention, then drying speed is improved, but comfort is reduced
Solution Approach 1:
The barrier layer is strategically positioned only where needed - between the textile layer and foam layer at the interfaces where moisture penetration would occur. The foam layer itself remains uncompressed and maintains its cushioning properties in areas not directly exposed to moisture. This localized application of the barrier layer preserves the comfort properties of the foam while still preventing moisture retention and enabling quick drying.
4Ease of manufacture
If the mat uses conventional materials to reduce cost, then manufacturing cost is reduced, but the mat degrades quickly and becomes unhygienic
Solution Approach 1:
The invention extracts and removes the problematic element - the direct contact between moisture and the foam cushioning layer - by introducing a barrier layer. This prevents the foam from absorbing moisture and becoming a breeding ground for bacteria and odors. The textile layer continues to provide absorbency while the barrier protects the foam, extending the mat's hygienic lifespan without significantly increasing manufacturing complexity or cost.
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 provides a comfortable, slip-resistant, and absorbent mat that dries quickly, reducing the risk of odor and deterioration, thus extending its lifespan and maintaining hygiene.
Implementation Method 1
a layer of compressible material
Implementation Method 2
the compressible material used has a memory in as much that if the state of the layer is changed, such as by weight or pressure being applied to the same then, when the means which causes the change is removed, the material at least partially returns to its original state
Implementation Method 3
the fabric or textile material layer has good moisture absorbency characteristics
Implementation Method 4
a barrier layer provided intermediate the fabric or textile layer and the compressible material layer, act to restrict or prevent the moisture passing into the compressible material layer
Implementation Method 5
a base onto which the compressible material layer is located... provides increased slip resistance for the mat on the base
Data Source
Figure 1~2
Figure 3~4
AI summary
A cushioned, absorbent article such as a mat including a layer of absorbent (8), quick-drying woven textile material, a layer of viscoelastic polyurethane foam material (4) having an open cell structure, the layer of foam material (4) being glued and sewed to the layer of woven textile material (8) to form a textile and foam assembly and typically a rubberized base material (2), glued to a foam material side of the textile and foam assembly.