Exercise Mat 3D Texture Vacuum Embossing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing exercise mats provide inadequate support, are slippery, and are difficult to transport due to their weight and thickness.
Innovation Solution
An exercise mat with a three-dimensional surface texture, comprising a polyurethane malleable layer, a thermoplastic elastomer layer with embossed texture, and a rubber layer, which provides improved grip, support, and ease of rolling, made using a vacuum embossing machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the mat is made thicker to provide adequate support, then support and cushioning are improved, but weight and difficulty to roll-up increase
Solution Approach 1:
The patent changes the material parameters by using thermoplastic elastomer with specific durometer ranges (40-70 Shore A) and creating a three-dimensional texture with controlled depth (0.5-5mm). This allows the mat to provide adequate support with reduced thickness compared to traditional solid foam mats, thereby reducing weight while maintaining cushioning properties.
Solution Approach 2:
The mat combines thermoplastic elastomer material with a three-dimensional textured surface structure, creating a composite construction that achieves both support and weight reduction. The layered approach with textured surface integrates structural integrity with material efficiency.
2Ease of operation
If the mat surface is made smooth for comfort, then comfort is improved, but grip and stability deteriorate
Solution Approach 1:
The patent applies local quality by creating a three-dimensional textured surface where different regions have varying heights and patterns. This localized variation provides grip in contact areas while maintaining comfort in pressure-bearing regions, resolving the contradiction between smooth comfort and textured grip.
Solution Approach 2:
The invention transitions from a two-dimensional smooth surface to a three-dimensional textured surface with height variations. This dimensional change allows the mat to provide both comfort (through cushioning peaks) and grip (through valleys and texture patterns) simultaneously.
3Weight of moving object
If the mat is made lighter for easy transport, then ease of transport is improved, but support and cushioning deteriorate
Solution Approach 1:
The patent optimizes material parameters by selecting thermoplastic elastomer with specific density and durometer properties, and by controlling the three-dimensional texture depth and pattern. These parameter changes enable weight reduction while maintaining adequate support through efficient material distribution.
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 offers enhanced grip, tactile feedback, and stability while maintaining cushioning, reducing weight and size when rolled, and improving moisture management.
Implementation Method 1
heating and vacuuming the second layer to conform the upper surface to a predetermined three-dimensional surface texture
Implementation Method 2
heating and vacuuming the second layer to conform the upper surface
Implementation Method 3
a first malleable layer formed from a polyurethane material
Implementation Method 4
The second layer may be formed from a thermoplastic elastomer material and may have the three-dimensional surface texture formed on an upper surface thereof
Data Source
AI summary
Examples of an exercise mat having a three-dimensional surface texture and methods for making same are disclosed. The exercise mat may have a first malleable layer formed from a polyurethane material with an elastic fabric material attached to a lower surface thereof. A second layer may be attached to the elastic fabric material of the first layer. The second layer may be formed from a thermoplastic elastomer material and may have the three-dimensional surface texture formed on an upper surface thereof to which the first layer conforms. The exercise mat may also include a third rubber layer attached to the second layer.