Impact Absorbing Safety Matting System with Elastomeric Sub-surface Structure
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Solution Overview
Problem
Conventional impact attenuating structures, such as matting systems and padding in footwear, face issues like loss of cushioning and stability over time, surface deformation leading to fatigue and injury, and inadequate protection against bottoming out, especially in thinner and smaller applications.
Innovation Solution
A continuous array of elastomeric subsurface structures with geometric shapes, such as cylindrical columns with varying thickness and draft angles, providing a stable surface layer that absorbs impact and maintains cushioning by differentiating compressibility zones to prevent sudden deformation and bottoming out.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional foam or rubber materials are used for impact attenuation, then cushioning is provided, but the materials get harder as force increases and bottom out, reducing protection when most needed
Solution Approach 1:
The patent divides the impact attenuating structure into multiple discrete cells arranged in an array. Each cell independently absorbs impact energy through controlled deformation, preventing the entire structure from bottoming out. The segmentation allows progressive collapse of individual cells while maintaining overall structural integrity and consistent cushioning performance across varying impact forces.
Solution Approach 2:
The patent varies the geometry of individual cells within the array, creating zones with different compressibility characteristics. Some cells have thicker walls or different shapes to provide progressive resistance to compression. This local variation in cell properties ensures that as some cells compress, others maintain cushioning capability, preventing sudden hardening and bottoming out.
2Loss of energy
If foam materials are used for cushioning, then impact absorption is provided, but the materials do not return rapidly to former height and shape, leading to compaction and loss of cushioning over time
Solution Approach 1:
The patent employs elastomeric cells that dynamically respond to applied loads by deforming and then rapidly rebounding to their original shape. The elastomeric material properties enable the cells to absorb impact energy during compression and then quickly recover, preventing permanent compaction. This dynamic behavior maintains cushioning performance over extended periods and through repeated use.
3Ease of operation
If anti-fatigue matting provides cushioning, then standing comfort is improved, but excessive softness creates instability requiring muscular activity that accelerates fatigue
Solution Approach 1:
The patent carefully controls the geometric parameters of the cells, including wall thickness, cell size, and arrangement density, to achieve optimal balance between cushioning and stability. The cells provide sufficient compliance for comfort while maintaining structural rigidity to prevent excessive surface deformation. This parameter optimization ensures the surface remains stable enough to support posture without requiring compensatory muscular activity.
4Force
If conventional mats are compressed, then impact absorption occurs, but surface area around the foot deforms creating uneven surfaces that lead to foot entrapment and additional fatigue
Solution Approach 1:
The patent segments the impact absorption function into discrete, contained cells that deform independently. When compressed, each cell collapses in a controlled manner within its boundaries, preventing lateral surface deformation. This segmentation contains the deformation locally, maintaining surface integrity and preventing foot entrapment while still absorbing impact forces effectively.
Solution Approach 2:
The patent designs cells with specific geometric characteristics, including reinforced walls and controlled collapse zones, to manage deformation locally. The cell structure allows vertical compression for impact absorption while resisting lateral expansion that would cause surface unevenness. This localized deformation control prevents foot entrapment and maintains a stable walking surface.
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 offers improved stability and impact attenuation with minimal surface deformation, reducing fatigue and injury risks while maintaining comfort and performance in thinner applications, including anti-fatigue mats and athletic footwear.
Implementation Method 1
Impact Absorbing Safety Matting System with Elastomeric Sub-surface Structure
Implementation Method 2
elastomeric subsurface structures with geometric shapes, such as cylindrical columns with varying thickness and draft angles, providing a stable surface layer that absorbs impact
Implementation Method 3
conventional matting systems use closed-cell foam or vulcanized rubber chips bound together to provide a cushioning and shock absorbing structure
Implementation Method 4
for attenuating applied force and absorbing impact energy
Data Source
AI summary
A cushioning and impact absorbing pad system with a surface layer of thickness t, and an elastomeric sub-surface structure of height h. The sub-surface structure comprises an array of elastomeric columns wherein each column has a frustoconical column wall surrounding a central void. The cross-sectional thickness of the column wall increases from the first end to the enclosed second end by a percentage within a range of greater than 125% and less than 140%. Column walls are tapered with draft angles in the range of greater than 6 degrees and less than 10 degrees.