Slip-Resistant Mat Backing With Moisture Drainage Channels
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Solution Overview
Problem
Existing slip-resistant mats are ineffective on smooth floors with residual moisture, prone to movement under heavy loads, and have manufacturing limitations that reduce surface area contact and increase the risk of slippage and injury.
Innovation Solution
A slip-resistant mat design featuring a backing with a repeating pattern of projections and channels that maximizes surface area contact with the floor, allowing moisture to be dispersed and increasing friction, while being lightweight and easy to move, without the need for permanent fastening, using a CNC machined mold system to efficiently produce the mat with precise channel patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional grippers or cleats are used on mat backing, then movement on carpeted floors is reduced, but slip resistance on smooth floors with moisture deteriorates
Solution Approach 1:
The mat backing is segmented into a pattern of raised projections and channels, where the channels create discrete contact points (projections) with the floor surface. This segmentation allows the mat to maintain stability through multiple contact points while reducing the continuous surface area that could trap moisture, thereby improving slip resistance on smooth floors.
Solution Approach 2:
The mat backing features localized raised projections that concentrate contact with the floor at specific points rather than across the entire surface. This local quality enhancement at the projection contact points provides stable grip, while the channel areas between projections remain open to drain moisture, resolving the contradiction between stability and slip resistance.
2Stability of the object's composition
If the number of grippers is increased to reduce mat movement, then stability improves, but manufacturing complexity and cost increase
Solution Approach 1:
The invention merges the functions of multiple discrete grippers into a continuous pattern of raised projections formed by extruding material through a screen. This combining approach achieves the stability of multiple contact points without the manufacturing complexity of individually attaching numerous gripper components, simplifying production while maintaining performance.
3Stability of the object's composition
If metal screen open area is increased to create more grippers, then mat stability improves, but screen resilience deteriorates
Solution Approach 1:
The invention changes the parameters of the screen structure by using a specific open area range (10-30%) and corresponding mesh sizes (8-16 mesh) that balance gripper formation capability with screen structural integrity. This parameter optimization allows sufficient projection formation for stability while maintaining screen resilience for manufacturing durability.
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 mat provides superior slip-resistance and stability on various surfaces, including those with moisture, reduces wear and tear, and enhances user comfort without adding weight or installation complexity, while maintaining ease of relocation.
Implementation Method 1
moisture trapped between the mat and the floor is dispersed away from the projections and into the channels
Implementation Method 2
a repeating pattern of projections and channels extending over a substantial portion of the backing of the mat such that the projections in combination form a lower surface of the mat which contacts the floor
Data Source
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AI summary
A system and method for making a slip resistant mat (10) can include assembling parts with predetermined geometries to form a mold (38) that can be used for making slip resistant mats (10) that have channels (22) to account for moisture between the mat and the floor. The unique geometries of the parts which form the mold (38) can be manufactured efficiently and with reduced costs. The mold (38) of this invention can be used to make slip resistant mats (10) with channels (22) that can both dissipate water and offer a high degree of mat to floor surface contact.