Honeycomb Surface Protection Mat for Liquid Capture and Slip Prevention
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Solution Overview
Problem
Existing surface protection mats fail to effectively and inexpensively capture liquids, prevent slips and falls, and maintain sanitary conditions in high-traffic areas like restrooms, as they often require frequent maintenance, can create tripping hazards, and do not adequately direct fluids to absorbent layers.
Innovation Solution
A multilayered surface protection mat with a semi-rigid top layer and a fluid impervious lower layer, featuring an array of hexagonal funnels to direct liquids onto an absorbent layer, and flexible ribs to prevent movement, made from materials like polypropylene and TPE compounds for enhanced durability and ease of use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional flat mat is used, then it is simple in structure, but it fails to effectively direct liquids to the absorbent layer
Solution Approach 1:
The patent applies curvature by forming the top layer with a honeycomb pattern of hexagonal funnels that direct liquids downward onto the absorbent layer. The curved funnel surfaces effectively channel liquids from the topside to the absorbent material, resolving the contradiction between simple structure and effective liquid capture.
2Ease of operation
If a soft mat is used, then it is comfortable to stand on, but it moves easily causing slip hazards
Solution Approach 1:
The patent uses a flexible top layer made of soft materials like polypropylene or TPE that provides comfort while maintaining structural integrity. The flexible nature allows the mat to conform to foot pressure while the honeycomb structure and peripheral ribs prevent excessive movement, resolving the contradiction between comfort and slip prevention.
Solution Approach 2:
The patent applies different properties to different parts of the mat: the central area has a soft, compliant honeycomb structure for comfort, while the periphery has stiffer ribs for stability and slip prevention. This local differentiation resolves the contradiction between foot comfort and slip hazard reduction.
3Ease of manufacture
If a disposable mat is used, then maintenance is simplified, but cost increases
Solution Approach 1:
The patent divides the mat into functional layers (top layer with honeycomb, absorbent layer, bottom layer) that can be manufactured separately and assembled. This segmentation allows for cost-effective production of disposable mats while maintaining simplicity of maintenance through easy replacement of the entire unit or individual layers.
Solution Approach 2:
The patent explicitly designs the mat as a disposable product using inexpensive materials like polypropylene and TPE. The low cost of materials and simple construction enables economical disposable mats that simplify maintenance through replacement rather than cleaning, resolving the contradiction between maintenance simplicity and material consumption cost.
4Quantity of substance
If a thick mat is used, then it provides better absorbency, but it creates tripping hazards
Solution Approach 1:
The patent uses a flexible top layer that can be made relatively thin while maintaining effectiveness. The honeycomb structure provides sufficient absorbency capacity in a compact form factor, and the flexible nature allows the mat to lie flat on the floor without creating tripping hazards, resolving the contradiction between absorbency and trip safety.
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 effectively captures liquids, prevents slips and falls, maintains sanitary conditions by not requiring touch during maintenance, and is inexpensive and disposable, ensuring a safe and clean surface with reduced maintenance needs.
Implementation Method 1
an array of hexagonal shaped funnels extending through the top layer for directing liquid from the topside downwardly and onto the upper layer of fluid absorbing material
Implementation Method 2
an upper layer of fluid absorbing material
Implementation Method 3
an upper layer of fluid absorbing material
Implementation Method 4
a lower layer of fluid impervious material that resists passage of fluid
Implementation Method 5
flexible ribs to prevent movement
Data Source
AI summary
A surface protection mat, particularly for use in protecting floor surfaces from accidental liquid spills comprises a cartridge unit having an upper layer of moisture absorbing material and a lower moisture barrier, and a top layer of material impervious to liquid. The top layer includes a top side, upon which a person stands, and a bottom side, which includes a chamber for receiving the cartridge and which is set on the floor to be protected. The central portion of the top layer, in part, is formed by a honeycomb structure of specially configured hexagonal shaped cells, which cells funnel liquid downwardly from the top side to the cartridge unit. The cartridge unit is inserted into the chamber and the absorbent upper layer thereof adhered to the top layer. The mat is intended to be disposed of via routine trash collection during maintenance (usually weekly) and replaced by a fresh one.