Cushioned bath mat

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Solution Overview

Problem

Existing bath mats lack a combination of effective moisture absorption, quick drying, and durable, washable design with aesthetic appeal, particularly in bathroom settings.

Innovation Solution

A cushioned mat design featuring a nonslip base, a viscoelastic polyurethane foam intermediate layer, and a braided or tufted surface layer with an absorbent textile material, where the foam core is encased in a plush sleeve and secured to a textile layer using gluing, sewing, or flame bonding, allowing for moisture absorption and ornamental designs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If a bath mat uses an absorbent textile material layer with foam material, then moisture absorption and quick drying are improved, but the mat lacks durability and washability

Engineering Contradiction:

Improvemoisture absorption capacityVSAvoiddurability and washability

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The mat is divided into distinct functional layers: a nonslip base material layer, an intermediate foam material layer, and a textile material layer. This segmentation allows each layer to be optimized for its specific function while maintaining overall durability through proper layer integration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mat combines different materials with complementary properties: nonslip base material for grip, viscoelastic foam material for cushioning and moisture management, and absorbent textile material for moisture absorption. The composite structure enables the mat to achieve both high moisture absorption and durability through the synergistic combination of materials.

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If the mat uses a cushioned foam material layer, then comfort and quick drying are improved, but the mat may lack aesthetic appeal and durable surface design

Engineering Contradiction:

ImprovecomfortVSAvoidaesthetic appeal and surface design

Core Design Contradiction:

Ease of operationVSShape

Solution Approach 1:

The textile material layer is tufted or braided to create localized aesthetic patterns and surface designs while maintaining the overall cushioned comfort provided by the foam layer. This allows different regions of the mat surface to have varied aesthetic qualities without compromising the underlying comfort function.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The textile material layer is integrated with the foam material layer through tufting or braiding techniques, where the textile elements are nested within or attached to the foam structure. This nesting approach combines the aesthetic and functional properties of both materials into a unified design.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Quantity of substance

If the mat uses multiple layers (textile and foam), then moisture absorption and comfort are improved, but the manufacturing complexity increases

Engineering Contradiction:

Improvemoisture absorption capacityVSAvoidmanufacturing complexity

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The foam material layer serves multiple functions simultaneously: it provides cushioning comfort, acts as a moisture barrier, and serves as the substrate for attaching the textile layer through tufting or braiding. This self-service approach reduces manufacturing complexity by eliminating the need for separate components for each function.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The attachment method combines the textile layer and foam layer into a single integrated structure through tufting or braiding, where the same process that secures the textile also creates the aesthetic surface design. This merging of attachment and design functions simplifies manufacturing compared to separate attachment and finishing steps.

Inventive Principle:

Principle #5Merging (Combining)

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 mat provides a luxurious, absorbent, and quick-drying surface while maintaining durability and hygiene, with the ability to absorb moisture instantly and dry quickly, offering a comfortable and attractive solution for bathroom use.

Implementation Method 1

a layer of an absorbent, quick-drying textile material, a layer of a viscoelastic polyurethane foam material having an open cell structure

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Implementation Method 2

a nonslip base material

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS11389024B2Cushioned bath mat

Publication Date: 2022.07.19 MINDSINSYNC INC

AI summary

The invention pertains to a cushioned mat, in particular bath mat, including a non-slip base material, a cushion layer secured to the non-slip base material, a surface layer arrangement secured to a surface of the cushion layer opposite to the non-slip base material. The surface layer arrangement includes a textile material layer and a flexible cable including a cushioned core and an outer sleeve formed form textile material, the flexible cable being braided with or tufted to the textile material layer. In embodiments the flexible cable is braided or woven to form ornamental patterns.