Foam Mat Connecting Means with Rotatable Circular Segments
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Solution Overview
Problem
Existing mat systems for sports require precise orientation and alignment of individual mats, which is challenging due to tolerances in the arrangement of undercut recesses, making it difficult to construct stable and flexible mat arrangements, especially in applications like school sports and martial arts.
Innovation Solution
The mat system employs connecting means with two circular segment regions joined by a short bridge, allowing for rotatable engagement within corresponding recesses, with a specific spacing range that enables tolerance compensation, and uses elastic materials like foam with a Shore hardness of 5 to 50 Shore A to facilitate flexibility and loadability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional connecting means with rigid geometric shapes are used, then manufacturing precision can be maintained, but tolerance compensation capability deteriorates
Solution Approach 1:
The connecting means employs circular segment shapes instead of traditional rigid geometric forms. The circular segments can rotate within corresponding recesses, enabling the system to accommodate orienting tolerances and misalignments while maintaining secure connections between mats.
Solution Approach 2:
The connecting means is designed to be rotatable within the recesses rather than fixed in a single orientation. This dynamic capability allows the system to adapt to varying tolerances in mat placement and recess positioning, transforming a static connection into an adaptable joint.
2Stability of the object's composition
If connecting means with large joining bridges are used, then structural stability is improved, but rotatability and tolerance compensation capability deteriorate
Solution Approach 1:
The connecting means is divided into two distinct circular segment regions connected by a joining bridge. This segmentation allows each circular segment to rotate independently within its corresponding recess, maintaining stability while enabling tolerance compensation through rotational movement.
Solution Approach 2:
The design optimizes the ratio between the joining bridge dimensions and the circular segment radii. By controlling this geometric parameter, the system achieves an optimal balance where the joining bridge provides sufficient structural stability while remaining small enough to permit effective rotation and tolerance compensation.
3Adaptability or versatility
If elastic materials with high flexibility are used, then tolerance compensation is improved, but load-bearing capacity deteriorates
Solution Approach 1:
The connecting means is constructed from elastic materials such as foam with specific Shore hardness ranges (5-50 Shore A). This material selection provides an optimal composite property balance, delivering sufficient flexibility for rotation and tolerance compensation while maintaining adequate load-bearing capacity to support mat structures and withstand usage loads.
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
This configuration effectively compensates for large tolerances, allowing for easy assembly and disassembly of mats while providing adequate load-bearing capacity and flexibility, ensuring a stable and adaptable sports mat system.
Implementation Method 1
The individual mats (1) and the connecting means (10) should basically have certain elasticity
Implementation Method 2
a cushion layer (5) of chemically cross-linked polyethylene of bulk density of 60 kg/m3
Implementation Method 3
the respective circular segment regions of the connecting means can rotate within the likewise circular segment undercut recesses and thus equal out considerable tolerances
Data Source
Figure 1~4
Figure 5
Figure 6~8
AI summary
The invention concerns a mat system comprising a plurality of individual mats (1,1', 1''), each with a top side (2), a bottom side (3) running parallel with it, and at least one rectilinear side edge (7). The rectilinear side edges (7) of the individual mats (1,1', 1'') each have at least one undercut recess (6, 6'), corresponding to connecting means(10, 10', 10'', 12)which have a shape enabling,by engagement of each one of their halves in an undercut recess(6, 6'), a connecting of two mats (1,1', 1'') along their rectilinear side edges (7).The individual mats (1,1', 1'') and the connecting means(10, 10', 10'', 12) each comprise at least one layer of foam material. In order to equal out even large tolerances in the orienting of the individual mats to each other and those inthe arrangement of the undercut recesses in the individual mats, it is proposed that the connecting means(10, 10', 10'', 12) each comprise two interconnected circular segment regions(11, 11', 13, 13') with a radius R, R', wherein for the spacing A (A, A', A'', A''') of the centre points (M, M') of the circular segment regions (11, 11', 13, 13')the following relation applies: (I) 0.8 ∗ (R + R') < A < 1.3 ∗ (R + R').