Extruded, polymeric underlayment pads
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Solution Overview
Problem
Conventional pads used for absorbing and diverting energy and substances often fail to effectively absorb impacts without shifting or racking, and they may not be suitable for conforming to irregular surfaces or providing adequate drainage and insulation.
Innovation Solution
A pad design featuring a substrate with parallel ridges on both sides, where the upper ridges terminate in alternating bevels and the lower ridges are triangular, allowing for deflection and impact absorption, and includes complementary slots and ridges for uniform height, periodic breaks for drainage, and can be made from extruded polyolefin composite materials with post-consumer tire particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional pads are used for absorbing impacts, then impact absorption is achieved, but the pads shift or rack under load
Solution Approach 1:
The pad is divided into multiple discrete ridges rather than a continuous structure. Each ridge acts as an independent load-bearing element, preventing the entire pad from shifting or racking when force is applied. The segmented ridge structure allows localized deformation while maintaining overall pad stability.
Solution Approach 2:
The ridges are positioned at specific locations and orientations to provide targeted impact absorption in different directions. The alternating bevels on upper ridges and triangular profiles on lower ridges create localized deformation zones that absorb impact energy while the overall ridge pattern maintains pad stability.
2Strength
If the pad is made thicker to achieve comparable impact attenuation, then impact absorption improves, but the pad becomes less compliant for irregular surfaces
Solution Approach 1:
Instead of increasing pad thickness in the vertical dimension, the invention uses a patterned ridge structure that distributes impact forces across multiple ridges. This dimensional approach allows the pad to maintain thinness while achieving comparable impact attenuation through the collective action of multiple ridges, preserving compliance for irregular surfaces.
Solution Approach 2:
The pad combines a flexible substrate material with a ridge structure that provides mechanical strength. This composite approach allows the base material to remain compliant for conforming to irregular surfaces while the ridge pattern provides the necessary impact attenuation without requiring increased thickness.
3Ease of manufacture
If the pad structure is simplified for ease of manufacture, then manufacturing cost decreases, but drainage and insulation capabilities are reduced
Solution Approach 1:
The ridge structure serves multiple functions simultaneously: it provides impact absorption through its geometric profile, creates drainage channels through the spaces between ridges, and provides insulation by trapping air pockets within the ridge pattern. This multi-functional design achieves complex functionality without requiring separate components, maintaining manufacturing simplicity.
Solution Approach 2:
The ridge pattern creates a porous structure with channels and voids that facilitate drainage while the ridges themselves provide insulation. This porous architecture is formed through a single extrusion process, combining drainage and insulation capabilities with impact absorption without complicating manufacturing.
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 pad achieves impact attenuation comparable to thicker conventional pads, is compliant for irregular surfaces, and provides effective drainage and insulation, making it suitable for various applications including sports surfaces and flooring.
Implementation Method 1
the substrate under the first plurality of ridges can deflect to absorb a load applied to one or more of the first plurality of parallel ridges
Implementation Method 2
At least one of the first plurality of parallel ridges and second plurality of parallel ridges can include periodic breaks allowing water to traverse the ridges
Data Source
AI summary
One aspect of the invention provides an extruded, polymeric underlayment pad including: a substrate; a first plurality of at least four intersecting ridges extending perpendicularly from a first side of the substrate; and a second plurality of at least four intersecting ridges extending from a second side of the extruded polymeric substrate.