Detachable carpet mat
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Solution Overview
Problem
Traditional carpet mats are cumbersome to manufacture, expensive, and lack versatility, with designs like Velcro causing damage and discomfort due to high separation forces, and existing detachable solutions are inconvenient and prone to wear.
Innovation Solution
A detachable carpet mat design featuring a surface layer with raised monofilaments that form hooks after heat treatment, allowing easy detachment and reattachment without damaging the surface, using an adhesive anti-slip layer for secure bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If Velcro is used to connect the surface and liner of the carpet mat, then the connection force is strong, but a large separation force is required causing damage to the carpet mat and reducing comfort
Solution Approach 1:
The patent divides the connection system into two segments: raised monofilaments on the surface layer that form hooks, and corresponding loops on the liner layer. This segmentation allows the surface layer to be separated and reattached multiple times without requiring large separation forces, resolving the contradiction between strong connection and easy disassembly.
Solution Approach 2:
The patent changes the physical state of the monofilaments through heat treatment, transforming them from straight to curved configurations that form hooks. This parameter change enables the hooks to engage with loops on the liner, providing strong connection while allowing gentle separation, thus resolving the contradiction between connection strength and disassembly ease.
2Stability of the object's composition
If traditional bonding methods are used to attach anti-slip material to the carpet mat back, then the structure is stable, but the mat cannot be washed in a machine without separation or breakage
Solution Approach 1:
The patent segments the carpet mat into a permanent liner layer with anti-slip properties and a removable surface layer. The surface layer can be detached and washed separately in a machine, while the liner remains stable on the floor. This segmentation resolves the contradiction between structural stability and washability.
3Ease of manufacture
If the carpet mat is designed as a single integrated structure, then the manufacturing is simple, but it lacks versatility and cannot be replaced seasonally
Solution Approach 1:
The patent divides the carpet mat into separable components: a permanent liner layer and interchangeable surface layers. This segmentation enables users to replace surface layers seasonally or as needed, providing versatility while keeping the liner layer simple to manufacture. The hook-loop connection system facilitates easy assembly and disassembly.
Solution Approach 2:
The liner layer serves multiple functions: providing anti-slip stability, serving as a base for multiple surface layers, and enabling seasonal replacement. This multi-functionality resolves the contradiction between manufacturing simplicity and adaptability, as the universal liner can work with various surface layer designs.
4Strength
If hooks are distributed on the upper surface of the adhesive anti-slip layer, then the connection is strong, but the mat thickness increases and the surface feels uncomfortable
Solution Approach 1:
Instead of placing hooks on the upper surface of the anti-slip layer, the patent inverts the approach by placing raised monofilaments (that form hooks) on the lower surface of the surface layer, facing the anti-slip layer. This inversion allows strong connection while keeping the mat thickness minimal and the upper surface comfortable for users.
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 design provides secure, comfortable, and durable attachment without surface damage, enabling easy replacement and maintenance, with improved bonding capacity and reduced wear, and allows for thinner mats with enhanced user experience.
Implementation Method 1
after heat treatment, top ends of the raised monofilaments melt/soften, forming small lumps
Implementation Method 2
top ends of the raised monofilaments melt/soften
Implementation Method 3
the hooks may be hooked to gaps of various adhesive anti-slip layers below and form a locking effect
Data Source
AI summary
A detachable carpet mat, where raised monofilaments and fleeces are bent through a high temperature to form a hooking-connecting effect with a first water-repellent anti-slip layer placed below the monofilaments and the fleeces, resulting in better bonding capacity, greater friction force and better firmness. Melted and solidified through the high temperature, the monofilaments and fibers of a hooking layer are not prone to falling off; the monofilaments of the hooking layer have a certain curvature and surfaces of small bumps of piles are passivated so as to prevent users from accidentally hurting their hands, and at the same time, enhance the locking effect with the first water-repellent anti-slip layer below.