Dual-Denier Textile Backing for Slip-Resistant Floor Mats
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Solution Overview
Problem
Existing automotive floor mats lack sufficient slip resistance when placed over carpets, leading to potential sliding and increased wear, which can compromise safety and require costly carpet replacements.
Innovation Solution
A lightweight textile structure with a non-woven backing comprising fibers of two different deniers, where the secondary backing is treated to create a surface with staggered fiber lengths, enhancing frictional resistance by creating mechanical engagement with the carpet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a molded polymer mat or traditional rubber mat with molded protrusions is used, then slip resistance is improved, but weight increases
Solution Approach 1:
The patent employs a composite backing structure combining two distinct fiber types: (1) a first plurality of fibers with denier of 2-40 providing flexibility and surface area, and (2) a second plurality of fibers with denier of 30-500 providing structural integrity and mechanical engagement. This composite fiber assembly delivers enhanced slip resistance through combined mechanical interlocking while maintaining lightweight properties, avoiding the need for heavy molded polymer or solid rubber constructions.
2Reliability
If molded protrusions are added to rubber backing, then lateral movement resistance is improved, but device complexity increases
Solution Approach 1:
The patent achieves lateral movement resistance by changing the fundamental parameter of fiber denier within the backing layer. By incorporating fibers ranging from 2-500 denier in two distinct groups, the structure creates varied mechanical engagement capabilities without requiring complex molded protrusion geometries. The fiber assembly itself provides the necessary mechanical interlocking through its inherent structural diversity.
3Weight of moving object
If fiber denier is reduced to decrease weight, then weight is improved, but mechanical engagement capability worsens
Solution Approach 1:
The patent segments the fiber population into two distinct functional groups: fine fibers (2-40 denier) that contribute to lightweight construction and surface area, and coarse fibers (30-500 denier) that provide mechanical engagement capability. This segmentation allows each fiber type to optimize its specific function while working synergistically, achieving both weight reduction and maintained mechanical interlocking performance.
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 textile structure significantly increases the coefficient of friction, reducing the likelihood of the mat sliding and thereby extending carpet lifespan and enhancing safety by preventing lateral movement.
Implementation Method 1
provide increased (frictional) resistance to lateral movement when overlying and contacting another individual floor covering, such as a larger area carpet or other textile
Data Source
AI summary
A textile structure is provided which comprises a backing of at least a first plurality of fibers and a second plurality of fibers, wherein the first plurality of fibers have a first fiber denier and the second plurality of fibers have a second fiber denier different than the first fiber denier. A method of providing a slip resistant covering to overlie a floor pan carpet of a motor vehicle is provided comprising overlying the carpet with an accessory mat having an underlying backing comprising at least a first plurality of fibers and a second plurality of fibers, wherein the first plurality of fibers have a first fiber denier and the second plurality of fibers have a second fiber denier different than the first fiber denier, and wherein the underlying backing of the accessory mat is configured to be in direct contact with the floor pan carpet.