Simulated Terrain Mat Using Woven Fabric and Latex Adhesion
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Solution Overview
Problem
Existing mats for simulating natural terrain in indoor displays suffer from shedding of turf material, tearing due to paper backing, inability to form realistic shapes, and issues with water absorption leading to color bleeding, especially when used on carpets or tablecloths.
Innovation Solution
A mat constructed with a water impervious resinous material, such as polyvinyl chloride, coated with a water-based latex emulsion and adhered with terrain-simulating particles, which can be sealed and shaped using a heat gun to form hills and valleys, and modified with water to create features like roads and lakes, allowing for realistic terrain simulation without the limitations of paper-backed mats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If paper backing is used for the mat, then the mat can be easily manufactured and applied, but the mat tends to tear upon repeated usage and cannot be rolled for storage
Solution Approach 1:
The patent changes the fundamental parameter of the backing material from paper to a woven fabric substrate. This material substitution provides both the necessary strength for repeated usage and the flexibility to be rolled for storage, while maintaining ease of manufacture through standard textile and coating processes
Solution Approach 2:
The patent creates a composite structure combining a woven fabric substrate with multiple functional layers including adhesive layers and terrain-simulating material. This composite construction provides superior strength, durability, and rollability compared to paper backing, while maintaining manufacturability through layered assembly
2Adaptability or versatility
If flocking or synthetic material is applied to paper backing, then the mat can simulate natural terrain, but the turf simulating material sheds especially when rolled for storage
Solution Approach 1:
The patent changes the substrate parameter from paper to woven fabric, which provides superior mechanical interlocking and adhesion properties. This prevents the terrain-simulating material from shedding during rolling and unrolling operations while maintaining realistic terrain appearance
Solution Approach 2:
The woven fabric substrate acts as a flexible, durable base that maintains structural integrity during rolling and unrolling. This flexible structure prevents the terrain material from detaching while allowing the mat to be stored in a compact rolled state
3Ease of manufacture
If paper backing is used, then the mat can be easily manufactured, but the mat wrinkles upon repeated use
Solution Approach 1:
The patent changes the backing material parameter from paper to woven fabric, which provides superior dimensional stability and wrinkle resistance. The woven structure maintains surface flatness and composition stability through repeated use while remaining manufacturable through standard textile processes
4Adaptability or versatility
If the mat is used on carpets or tablecloths, then the mat can be displayed in various locations, but the color bleeds through when the mat becomes wet
Solution Approach 1:
The patent changes the backing material from paper to woven fabric, which provides superior water resistance. This prevents color bleeding through the mat when wet, while maintaining the ability to display on various surfaces including carpets and tablecloths
5Ease of manufacture
If the mat cannot be formed into different shapes, then the manufacturing process is simple, but realistic terrain features such as hills and valleys cannot be simulated
Solution Approach 1:
The woven fabric substrate provides inherent flexibility that allows the mat to be heated and shaped into various terrain forms. This flexible structure enables creation of hills, valleys, and other realistic features while maintaining relatively simple manufacturing processes
6Ease of operation
If the mat is rolled for storage, then the mat can be compactly stored, but the turf material sheds and the paper backing may tear
Solution Approach 1:
The patent changes the backing material from paper to woven fabric, which provides superior tensile strength and flexibility. This allows the mat to be rolled for compact storage while preventing both material shedding and structural tearing during the rolling and unrolling operations
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 provides a durable, flexible, and realistic simulation of natural terrain that can be easily shaped and reused without shedding or tearing, and can be safely used on various surfaces without color bleeding, offering enhanced versatility and longevity.
Implementation Method 1
a layer of terrain simulating particles are adhered utilizing a water base latex emulsion
Implementation Method 2
The shape of the mat can be altered utilizing a heat gun to form hills and valleys
Implementation Method 3
The particles are sprayed with a sealant to further 'fix' them to the surface
Data Source
AI summary
A mat for simulating natural terrain for use in an indoors display is the subject of this invention. The mat comprises a sheet of water impervious resinous material, a water base latex emulsion coating applied to the resinous material and a quantity of terrain simulating particles which are adhered to the sheet by the dried coating. The particles are fixed to the sheet by a sealant which is sprayed on the particles after the coating has dried. The particles may comprise flocking, ground foam rubber or rigid solid pieces. The invention also encompasses a method of preparing a simulated natural terrain utilizing the mat as afore described. This method includes outlining desired terrain features, applying water to the outlined area, scraping the substrate to remove particles from the outlined area and then coloring the area. Additional terrain features can be incorporated into the mat by scraping the mat to expose the underlying substrate in the shape of a design in the roadway such as a centerline, crosswalk or the like. Still further terrain simulating features may by utilizing a heat source to raise the temperature of the substrate and then shaping it into hills and valleys.