Modular Floor Mat System with Hidden Connectors for Tool-Free Assembly
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Solution Overview
Problem
Existing anti-fatigue mats are limited in size and require tools for assembly, and their connectors can be visible or felt, which hinders ease of use and deployment.
Innovation Solution
A modular floor mat system comprising mat components with elongate channels and sockets, connected by a strap and posts that provide resistance to separation, allowing for tool-free assembly and hidden connectors, enabling the creation of large-area mats with superior resistance to separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If anti-fatigue mats are made as single large pieces, then they provide continuous comfort coverage, but they become difficult to manufacture, package, ship and deploy
Solution Approach 1:
The mat is divided into multiple modular components that can be separately manufactured, packaged and shipped. Each component contains connection features (channels and sockets) that enable tool-free assembly of multiple components into a large-area mat system, resolving the contradiction between providing large continuous coverage and ease of deployment.
2Ease of operation
If connectors are used to join mat components, then assembly is enabled, but connectors become visible or felt by the user
Solution Approach 1:
The connector elements (posts and straps) are nested within recesses and channels formed in the mat components themselves. The posts fit into sockets that are recessed into the mat surface, and the straps are received within channels, so that when assembled, the connectors are hidden within the mat structure and not visible or felt by users standing on the mat.
3Ease of operation
If mat components are joined with simple connectors, then assembly is easy, but resistance to separation is insufficient
Solution Approach 1:
The connection system merges multiple connection mechanisms into a single integrated connector: posts provide vertical engagement and tensile resistance, while straps provide lateral engagement and shear resistance. This combination of multiple connection types in one connector maintains ease of assembly while significantly improving resistance to separation forces.
Solution Approach 2:
The connector uses composite construction with posts and straps made from different materials optimized for different functions - posts for tensile loading and straps for shear loading. This composite approach allows each element to be optimized for its specific loading condition, improving overall connection strength while maintaining simple assembly.
4Strength
If the strap connector contacts the floor, then it provides structural support, but it may mar the floor surface
Solution Approach 1:
The strap connector is positioned in a vertical dimension above the floor surface by receiving it within a channel that has its roof elevated from the mat's lower surface. This vertical displacement removes the strap from contact with the floor, preventing marring while maintaining the strap's structural support function within the channel.
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
Enables the assembly of large-area anti-fatigue mats without tools, with hidden connectors that resist both tensile and shear forces, providing a comfortable and durable solution for reducing user fatigue.
Implementation Method 1
The posts of the connector have shafts with a first diameter, and free ends with a larger, second diameter. The free ends of the posts therefore engage the sidewalls of the sockets with an interference fit.
Implementation Method 2
In one embodiment, the free ends of the posts are barbed, such that the force necessary to withdraw them from the sockets is greater than the force necessary to insert them.
Data Source
AI summary
Multiple components of a floor mat system may each be formed of a resilient material such as foamed polyurethane. First and second channels are formed in the respective lower surfaces of first and second mat components, so as to inwardly extend from lateral boundaries thereof. The roofs of the channels are spaced above the general lower surfaces of the mat components. A first socket is formed to upwardly extend from the roof of the first channel, and a second socket is formed to upwardly extend from the roof of a second channel. A connector is used to join the mat components. Posts of the connector are received in the sockets, while a strap joining the posts is received within the first and second channels.