Foam mat and method for manufacturing a foam mat
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Solution Overview
Problem
Existing foam mats made from virgin foam have inconsistent densities, making them unsuitable for carpet padding or cushions, and closed-cell foam is not washable or dryable in household appliances within reasonable time.
Innovation Solution
A method of forming a foam mat by milling foam into particles of specific sizes, mixing with glue, applying heat and compression to achieve a desired density, and bonding the particles with a fabric layer to create a cushion with configurable density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If closed-cell foam is used for mats, then comfort and cushioning are improved, but drying time in household appliances increases considerably
Solution Approach 1:
The patent changes the physical structure parameter of the foam from closed-cell to open-cell configuration. This parameter change allows water to circulate through the foam matrix during washing and drying, dramatically reducing drying time while maintaining acceptable cushioning properties through optimized density and particle composition.
Solution Approach 2:
The patent employs open-cell foam with a porous structure that permits water penetration and rapid evaporation. The interconnected pores allow moisture to escape during drying cycles, solving the contradiction between comfort and drying time by enabling fast drying while retaining cushioning capabilities.
2Manufacturing precision
If sheets of virgin foam with consistent density are used, then manufacturing precision is improved, but adaptability for different applications (carpet padding, mat cushions) deteriorates
Solution Approach 1:
The patent segments the foam into individual particles or small pieces rather than using intact sheets. This segmentation allows the same foam material to be reconfigured into different density levels and product forms, enabling both manufacturing precision through controlled particle processing and adaptability for various applications through adjustable compression and blending ratios.
Solution Approach 2:
The patent applies parameter changes by controlling the compression, density, and composition ratios of foam particles during processing. By adjusting these parameters, the same raw foam material can be transformed into products with different final densities suitable for carpet padding, mat cushions, or other applications, thereby achieving both consistency and versatility.
3Loss of substance
If rebonded foam is used for carpet padding, then material utilization is improved, but manufacturing precision and consistent density deteriorate
Solution Approach 1:
The patent recovers and reuses foam trimmings and offcuts that would otherwise be discarded or downcycled. By incorporating these recovered materials into new products through controlled processing, the patent achieves high material utilization while maintaining manufacturing precision through standardized particle preparation and compression procedures.
Solution Approach 2:
The patent uses parameter changes in the form of controlled compression, heating, and density adjustment during the rebonding process. These parameter controls ensure that recovered foam particles are transformed into consistent, high-quality products with predictable density, resolving the contradiction between material recovery and manufacturing precision.
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 method allows for the creation of foam mats with consistent and configurable densities, improving their suitability for various applications and ensuring they can be washed and dried in household appliances within standard times.
Implementation Method 1
applying heat and compression to the plurality of foam particles mixed with glue to form a body of foam having a second density
Implementation Method 2
applying heat and compression to the plurality of foam particles mixed with glue to form a body of foam having a second density
Implementation Method 3
mixing the plurality of particles with glue
Implementation Method 4
open-cell foam does dry as quickly as open-cell foam
Implementation Method 5
open-cell foam
Data Source
AI summary
Foam edge waste may be shredded or ground into foam particles rather than discarding them. The particles may be mixed with an adhesive and subject to high temperature and high pressure to form into new foam bodies with configurable densities. Utilizing discarded foam sections this way reduces the waste of foam, reduces environmental pollution caused by foam waste combustion, offers more environmental protection and saves resources. The resulting foam articles have reduced water retention and provide superior comfort by making a foam with consistent properties from inconsistent materials.