Modular mat system
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Solution Overview
Problem
Conventional floor mats require specific constructions for different purposes and often necessitate costly and time-consuming installation and replacement, leading to high maintenance and replacement costs, especially in high-traffic environments where wear and tear are significant.
Innovation Solution
A modular mat system comprising interlocking tiles with different durometer hardness levels, color indicators for wear, and interchangeable inserts, allowing for easy assembly and replacement of individual components to form a variety of shapes and designs, with a drainage system to prevent water accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional floor mats are made as single-purpose constructions, then they perform well for their specific function, but they require costly and time-consuming replacement when worn or when needs change
Solution Approach 1:
The floor mat is divided into multiple interchangeable inserts (e.g., ribbed insert for drainage, smooth insert for slip resistance, logo insert for branding) that can be independently replaced. Each insert fits into a recessed area within the mat body, allowing worn or damaged inserts to be swapped without replacing the entire mat structure.
Solution Approach 2:
Different inserts are made from materials with varying durometer hardness levels (e.g., softer inserts for comfort and grip, harder inserts for durability and logo retention). This allows selection of appropriate material properties for specific functional zones without compromising overall mat performance.
2Reliability
If floor mats are designed for specific purposes with specialized constructions, then they meet functional requirements, but they require inventory from multiple suppliers and increase warehousing costs
Solution Approach 1:
A single mat body structure accommodates multiple types of inserts for different functions (drainage, slip resistance, branding, comfort). The standardized recessed areas and insertion mechanisms allow one mat platform to serve multiple purposes by simply changing the insert configuration, eliminating the need for separate specialized mats from different suppliers.
3Reliability
If entire mat structures are replaced when worn, then functional performance is restored, but downtime and replacement costs are high
Solution Approach 1:
The mat is segmented into a permanent mat body and replaceable inserts. When inserts show wear or damage, only those specific inserts need to be removed and replaced, not the entire mat structure. This dramatically reduces replacement time and material waste.
Solution Approach 2:
Worn inserts can be removed and replaced with new or refurbished inserts while the mat body remains in use. The removed inserts can be recovered, refurbished, and reused, reducing overall material consumption and replacement costs.
4Ease of operation
If floor mats are placed on flat floors without recesses, then installation is simple, but the mats slide when horizontal pressure is applied
Solution Approach 1:
The mat body includes localized recessed areas specifically positioned to receive inserts. These recesses create mechanical interlocking features that prevent sliding while maintaining overall installation simplicity. The recesses are strategically placed at corners or edges where stability is most needed.
Data Source
AI summary
The present disclosure relates to a modular mat system. More particularly, the disclosure is directed to a modular mat system with that may be built out using common pieces of mats. Specifically, a modular mat system with a mat piece with a top plate with inserts, a bottom plate with a plurality of tabs and recesses operative to engage with further mat pieces to build a mat system is discussed. The modular mat system is operative to remove water and other detritus from shoes of a user or other such platform moving across the mat system and feed it to a perimeter drain below the system.