Knit Spacer Exercise Mat with Thin Foam Cushioning
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Solution Overview
Problem
Conventional exercise mats are bulky, heavy, difficult to transport, and require frequent cleaning and replacement due to quick degradation, while personal mats offer less cushioning and poor grip, making them inconvenient for both personal use and gym settings.
Innovation Solution
A lightweight, machine washable and dryable exercise mat featuring a knit spacer fabric with a traction-enhancing coating, allowing for easy storage, transport, and maintenance, with a compressible design that provides robust cushioning and enhanced grip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional foam exercise mats are used, then cushioning is provided, but the mats become bulky, heavy, and difficult to transport
Solution Approach 1:
The patent uses a thin film foam layer (0.125 to 0.250 inches thick) instead of conventional thick foam pads. This thin foam film provides necessary cushioning while being lightweight and portable, directly resolving the contradiction between cushioning strength and portability weight.
Solution Approach 2:
The patent creates a composite structure combining a non-foam support layer (woven fabric, knit fabric, or nonwoven material) with a thin foam film layer. This composite design provides structural support and durability without the bulk and weight of conventional solid foam mats, while maintaining cushioning performance.
2Strength
If conventional foam exercise mats are used, then cushioning is provided, but the mats require frequent cleaning and replacement due to quick degradation
Solution Approach 1:
The thin foam film (0.125 to 0.250 inches) is more resistant to degradation than conventional thick foam pads. The reduced thickness eliminates internal structural weaknesses that cause foam breakdown, extending the mat's lifespan while maintaining adequate cushioning support.
Solution Approach 2:
The support layer uses porous woven fabrics, knits, or nonwoven materials that allow air circulation and rapid drying after cleaning. This porosity prevents moisture buildup and bacterial growth, reducing degradation and extending durability while facilitating easy maintenance.
3Weight of moving object
If personal exercise mats with reduced foam are used, then portability is improved, but cushioning and grip are reduced
Solution Approach 1:
The composite structure combines a durable support layer (woven fabric, knit, or nonwoven material) with a thin foam film. The support layer provides structural integrity and surface grip, while the foam film provides cushioning, achieving both portability and adequate cushioning performance.
Solution Approach 2:
The thin foam film (0.125 to 0.250 inches) provides sufficient cushioning for exercise activities while keeping the mat lightweight and portable. The foam's cellular structure delivers shock absorption despite its reduced thickness.
4Ease of operation
If woven fabric outer layer is used, then cleaning is easier, but grip and contact friction are reduced
Solution Approach 1:
The woven fabric, knit, or nonwoven support layer uses porous materials that allow rapid drying and easy cleaning. The porous structure prevents moisture accumulation, enabling users to quickly wipe or machine wash the mat without prolonged drying times.
Solution Approach 2:
The composite design combines the smooth, easy-to-clean support layer with the textured foam film surface. The foam's cellular structure provides natural grip and friction for user contact, compensating for the smoothness of the woven fabric support layer while maintaining cleaning ease.
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 enables a portable, easy-to-clean exercise mat that maintains robust cushioning and grip, reducing maintenance needs and extending its lifespan, while being suitable for both personal and gym use.
Implementation Method 1
an intermediate spacer region disposed between the first base region and the second base region and having a plurality of intermediate filaments extending between the first and second base regions in a columnar arrangement and forming a field of columnar filaments for biasing the first base region apart from the second base region
Implementation Method 2
The traction-enhancing coating can be disposed at least one of the first and second base regions
Implementation Method 3
The traction-enhancing coating can be disposed at least one of the first and second base regions
Data Source
AI summary
An exercise mat can include a knit spacer fabric having a first ground fabric spaced apart from a second ground fabric in an uncompressed state. The exercise mat can be configured to be rolled up and compressed for storage and to expand into a planar spaced apart arrangement between the first and second ground fabrics for use. The knit spacer fabric can be formed from a plurality of knit polymeric threads and can include a first wall fabric extending between the first ground fabric and the second ground fabric. The first wall fabric can support the first ground fabric and the second ground fabric in a compressible spaced-apart configuration. The spacer fabric can include a traction-enhancing coating at an outer surface.