Interlocking Modular Mat with Sponge Insert for Fatigue Reduction
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Solution Overview
Problem
Conventional modular floor mats tend to be rigid, leading to increased fatigue during long periods of standing, despite providing lateral support and comfort, as they lack a softer feel while maintaining interconnectivity and structural integrity.
Innovation Solution
An interlocking modular mat design featuring a sponge insert within a cavity formed by the mat body's top portion and peripheral structures, which extends beyond the bottom of the connectors, providing a cushioned feel without compromising the mat's ability to interlock with adjacent mats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional modular floor mats are made rigid to provide lateral support and structural integrity, then the mat can maintain its shape and interconnect reliably, but the mat increases fatigue during long periods of standing
Solution Approach 1:
The mat is divided into two functional segments: a rigid structural portion (mat body with connectors) that maintains shape and interconnectivity, and a separate compliant portion (sponge insert) that provides cushioning. This segmentation allows each part to optimize its specific function without compromise.
Solution Approach 2:
The mat combines two materials with contrasting properties: a rigid material (such as polyvinyl chloride or thermoplastic polyurethane) for the mat body and connectors, and a compliant material (sponge) for the insert. This composite structure integrates both strength and comfort functions in a single system.
2Object-affected harmful factors
If the mat is made softer to reduce fatigue, then comfort improves, but the mat loses lateral support and structural integrity
Solution Approach 1:
The mat is divided into two functional segments: a rigid structural portion (mat body with connectors) that maintains shape and interconnectivity, and a separate compliant portion (sponge insert) that provides cushioning. This segmentation allows each part to optimize its specific function without compromise.
Solution Approach 2:
Different regions of the mat have different mechanical properties: the mat body and connectors are rigid to provide lateral support, while the sponge insert is compliant to provide cushioning. Each region is optimized for its specific function.
3Object-affected harmful factors
If a sponge insert is added to provide cushioning, then comfort and fatigue reduction improve, but the device complexity increases
Solution Approach 1:
The sponge insert is nested within the mat body, fitting into a cavity formed by the rigid structure. This nesting approach integrates the compliant element within the existing rigid framework, adding comfort functionality while utilizing the space already defined by the mat's structural geometry.
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 sponge insert enhances comfort and reduces fatigue by acting as the primary support surface while maintaining the structural integrity and interlocking capabilities of the modular mat system.
Implementation Method 1
the sponge insert provides a cushioned feel without compromising the mat's ability to interlock with adjacent mats
Data Source
AI summary
An interlocking modular mat having four sides has female connectors on two sides and male connectors on the other two sides so that the modular mat can interlock with an adjacent mat and its connectors. The modular mat is configured with a plurality of structures surrounding a periphery of a top portion of the mat. The plurality of structures in combination with an underside of the top portion of the mat form a cavity. A sponge insert is configured to fit in the cavity and have a height such that a portion of the sponge insert extends from a bottom side the mat body. With the sponge insert extending beyond the bottom side of the mat body, the sponge insert bottom face generally become the supporting bottom of the modular mat to provide a more cushioned feel for a mat user.