Interlocking polymeric matting article
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Solution Overview
Problem
Existing polymeric matting articles lack a secure and efficient mechanism for folding and securing themselves in a compact position, which limits their versatility and application in packaging and building construction.
Innovation Solution
A polymeric matting article with a web of extruded polymer monofilaments that are heat welded at junctions to form a matrix with interlocking formations, allowing it to be folded and secured using elongated ribs and channels or clam shell configurations with interlocking domes, enabling secure folding and versatile use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If polymeric matting articles are made without interlocking formations, then the structure is simpler and easier to manufacture, but the ability to fold and secure in a compact position is lost
Solution Approach 1:
The matting article is divided into multiple panels that can be folded relative to each other. Each panel maintains the beneficial matting properties while the segmentation enables folding and compact storage when combined with interlocking formations
Solution Approach 2:
The interlocking formations integrate the folding mechanism and securing function directly into the matting article structure itself, rather than adding separate components. The ribs and channels are formed as part of the matting panels, combining structural support with interlocking capability
2Ease of operation
If interlocking formations are added to enable folding, then the folding and securing capability is improved, but the manufacturing complexity increases
Solution Approach 1:
The interlocking formations (ribs and channels) are integrated into the matting panel structure during the same manufacturing process, eliminating the need for separate assembly steps. This merging of functions reduces manufacturing complexity despite adding interlocking capability
Solution Approach 2:
The matting article utilizes the thermal properties of the polymer material to enable heat welding of the interlocking formations. By controlling temperature parameters during manufacturing, the ribs and channels are permanently bonded to the panels, ensuring reliable interlocking while maintaining ease of operation
3Reliability
If the matting article is made from heat-weldable polymer monofilaments, then the interlocking formations can be securely attached, but the material selection is limited to specific polymer types
Solution Approach 1:
The invention specifies polymers with melting points in a particular range (80°C to 160°C) that enable heat welding. By controlling the thermal parameters and using extrusion processes, a wide variety of polymer types can be used as long as they fall within this temperature range, maintaining both reliability and material versatility
Solution Approach 2:
The matting article can be constructed from composite polymer structures or blends that maintain the required thermal properties for heat welding. This allows incorporation of different polymer characteristics (flexibility, strength, color) while maintaining the heat-weldable interlocking capability
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 solution allows for a lightweight, resilient, and adaptable matting article that can be used in both packaging and building construction, providing cushioning, drainage, air circulation, and sound damping while maintaining structural integrity.
Implementation Method 1
the polymer monofilaments being heat welded at junctions to form a matrix of tangled monofilament
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A polymeric matting article includes a web of extruded polymer monofilaments, the polymer monofilaments being heat welded at junctions to form a matrix of tangled monofilament; and at least one pair of interlocking formations; wherein the web is configured to be foldable onto itself and secured in a folded position by engaging the interlocking formations.