Impact absorbing safety matting and padding system with elastomeric sub-surface structure
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Solution Overview
Problem
Conventional impact attenuating systems, such as matting and padding, suffer from reduced cushioning capability under increased force, bottoming out issues, and instability, leading to fatigue and injury, particularly in applications requiring thinner and more durable solutions like anti-fatigue mats and athletic footwear.
Innovation Solution
A continuous array of geometrically shaped elastomeric subsurface structures with a frustoconical column design, featuring a collapsible first zone and a less compressible second zone, provides stable and effective impact attenuation and cushioning, minimizing surface deformation and preventing 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 under light loads, but the material gets harder under increased force and bottoms out, reducing cushioning capability when most needed
Solution Approach 1:
The matting system is segmented into a two-layer structure: a top layer of compressible foam material for initial cushioning, and a bottom layer of deformable elastomeric cells for sustained impact attenuation. This segmentation allows each layer to handle different stages of force application, preventing bottoming out while maintaining cushioning capability across varying force levels.
Solution Approach 2:
The invention combines two different materials with complementary properties: foam material (good for light-load cushioning) and elastomeric cell structure (good for high-load impact attenuation). This composite structure allows the system to maintain cushioning capability across the full range of applied forces, as each material contributes its strengths at different force levels.
2Strength
If compressible foam material is used, then initial cushioning is provided, but the material does not return rapidly to former height and shape, leading to permanent compression and loss of cushioning effect over time
Solution Approach 1:
The matting system divides the cushioning function between two layers: the foam top layer provides initial compression and energy absorption, while the elastomeric cell bottom layer provides rapid recovery and structural support. This segmentation ensures that the overall system maintains its cushioning effect over time, as the elastomeric layer prevents permanent compression of the foam.
Solution Approach 2:
The invention changes the physical parameters of the bottom layer by using elastomeric material with specific durometer hardness (40-70 Shore A) and a cellular structure with specific geometry (cylindrical, frustoconical, or polyhedral shapes). These parameter changes enable the bottom layer to deform elastically and recover rapidly, preventing the permanent compression that would otherwise occur in foam-only structures.
3Ease of operation
If anti-fatigue matting provides excessive cushioning and instability, then postural adjustments are encouraged for blood flow, but excessive muscular activity is required to maintain balance, accelerating fatigue
Solution Approach 1:
The invention optimizes the physical parameters of both layers to achieve the right balance: the foam layer density and thickness are selected to provide gentle compression for blood flow, while the elastomeric cell layer stiffness (controlled by durometer and cell geometry) provides sufficient stability. This parameter optimization ensures that the matting promotes health benefits without requiring excessive muscular effort to maintain balance.
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 enhanced stability and impact protection while maintaining a relatively stable surface, reducing fatigue and injury by effectively absorbing impact and maintaining resilience even under prolonged use, suitable for thinner applications without compromising performance.
Implementation Method 1
impact absorbing safety matting and padding system with elastomeric sub-surface structure
Implementation Method 2
deformable structures for attenuating applied force and absorbing impact energy
Data Source
Figure 1~4
Figure 5A~6B
Figure 7~8
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 frustoconical column walls have a zone that is a more compressible, relatively collapsible zone in a region at an end of the column opposite the surface layer and a tone that is a relatively less compressible zone in a region at the end of the column abutting the surface layer. Column walls are tapered with draft angles in the range of greater than 6 degrees and less that 10 degrees.