Integral Floor Mat Production for Custom Shapes Without Added Connectors
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Solution Overview
Problem
Existing floor coverings, such as carpet tiles and mats, require labor-intensive joining processes to form desired shapes and sizes, leading to potential tripping hazards and increased costs, while custom-made mats are impractical and expensive.
Innovation Solution
Production of integrally formed mats from multiple tiles with built-in water retention and scraping elements, allowing for seamless division into desired shapes and sizes without additional connecting means, using flexible, watertight rubber-like plastic material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple small mat units are joined together to form a mat of desired size and shape, then the mat can cover specific floor areas, but the joining process becomes labor intensive and creates tripping hazards
Solution Approach 1:
The mat is segmented into multiple tile units that can be independently manufactured and then easily assembled. Each tile has a grid pattern with lateral supports that enable simple interlocking without complex joining mechanisms, resolving the contradiction between customization and assembly complexity
Solution Approach 2:
Multiple tiles are merged into a unified mat structure through the grid pattern system where lateral supports of adjacent tiles interlock. This merging provides structural integrity and custom shapes without requiring labor-intensive joining processes or additional components
2Reliability
If carpet tiles are used for wall-to-wall coverage, then lateral support is provided to prevent slippage, but the tiles cannot be used as self-contained floor mats or rugs
Solution Approach 1:
The tile design with grid pattern and lateral supports serves multiple functions: it provides wall-to-wall carpeting coverage and simultaneously functions as self-contained floor mats or rugs. The lateral supports ensure stability in both applications, allowing the same tile structure to be used for different floor covering purposes
3Ease of manufacture
If standard size and shape mats are used, then production is simplified, but unique shaped floor areas cannot be satisfactorily covered
Solution Approach 1:
The mat is segmented into multiple identical or varied tile units that can be arranged in different configurations. This segmentation allows standard tiles to be manufactured simply while enabling custom shapes and sizes through different tile arrangements to cover unique floor areas
4Adaptability or versatility
If joint mechanisms are used to connect mat units, then multiple tiles can be assembled, but the joints may fail creating tripping hazards and require additional labor for repair
Solution Approach 1:
Adjacent tiles are merged through interlocking lateral supports that form a unified structure without requiring separate joint mechanisms. This merging eliminates potential joint failure points while maintaining the capability to assemble multiple tiles into custom mat configurations
Solution Approach 2:
The traditional joint mechanism is extracted and replaced by the lateral support structure that is integral to each tile. This extraction eliminates the separate joint component that could fail, while the lateral supports continue to provide the necessary connection function between tiles
Data Source
AI summary
A mat of one or more tiles of desired shape is provided. The mat is produced from a production mat manufactured as an integral unit with multiple tiles connected together according to various embodiments of this invention. The production mat may be divided into one or more mats of desired shape and size by severing the production mat between adjacent tiles. As such, the production mat may be cut into discrete mats, each having one or more tiles according to this invention. The entirety of the production mat is used as one or more mats according to aspects of this invention thereby avoiding waste and/or recycling of any portion of the production mat while utilizing each of the tiles in the production mat as part of the resulting mat(s). This avoids the need for any supplemental or auxiliary connecting means for joining two adjacent tiles to form a mat.