Multi-Layer Therapeutic Mat with Differential Foam Hardness
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Solution Overview
Problem
Existing therapeutic mats fail to provide sufficient horizontal support and stability during exercises, leading to a risk of injury due to limited frictional force transfer and inadequate pressure distribution, especially for users with limited mobility or performing specific exercises.
Innovation Solution
A multi-layer mat design with a softer upper layer and a more compressible lower layer, utilizing viscoelastic polyurethane foam for the upper layer and polyurethane foam, cork, or rubber for the lower layer, allowing for greater compressibility and improved force transfer, reducing the risk of slipping and enhancing user safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If relatively hard foam material is used to prevent complete compression of the mat, then the mat maintains structural integrity and pressure distribution, but the mat deforms minimally in the load-bearing contact area, limiting horizontal force transmission through friction alone
Solution Approach 1:
The mat is divided into multiple layers with different material properties. The upper layer uses softer foam (20-40 Shore A) that deforms more under load to enable positive engagement and horizontal force transmission, while the lower layer uses harder foam (40-60 Shore A) to maintain structural integrity and prevent complete compression. This segmentation allows each layer to fulfill its specific function without compromise.
Solution Approach 2:
Different regions of the mat have different material characteristics tailored to their specific functions. The upper layer in the load-bearing contact area is designed to be softer and more deformable to maximize horizontal force transmission through positive engagement, while the lower layer maintains higher hardness for overall support. This local differentiation of material properties optimizes both structural integrity and force transmission.
2Force
If softer material is used to increase elastic deformation and positive engagement, then horizontal force transmission improves, but the mat compresses excessively under user weight, compromising pressure distribution
Solution Approach 1:
The mat is divided into multiple layers with different material properties. The upper layer uses softer foam (20-40 Shore A) that deforms more under load to enable positive engagement and horizontal force transmission, while the lower layer uses harder foam (40-60 Shore A) to maintain structural integrity and prevent complete compression. This segmentation allows each layer to fulfill its specific function without compromise.
Solution Approach 2:
The mat combines different foam materials with varying hardness levels in a layered composite structure. The upper layer uses softer polyurethane foam (20-40 Shore A) for deformability and positive engagement, while the lower layer uses harder polyurethane foam (40-60 Shore A) for structural support. This composite construction achieves both adequate elastic deformation for force transmission and sufficient rigidity for pressure distribution.
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 enhanced stability and safety by allowing higher horizontal force transfer, enabling effective movement exercises without the risk of injury, particularly beneficial for older individuals and those with limited mobility, while maintaining optimal pressure distribution and comfort.
Implementation Method 1
The upper layer, which forms the exercise surface, is made of a softer material than the lower layer and can be compressed in the loaded contact area by the weight of the user exercising on the surface. This elastic deformation of the material improves user comfort.
Implementation Method 2
The elastically deformable material also serves to distribute pressure as evenly as possible in the loaded contact area.
Implementation Method 3
The upper layer is made of viscoelastic polyurethane foam and the lower layer is made of polyurethane foam, cork or rubber
Data Source
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AI summary
The invention relates to a mat (01) for therapeutic purposes, wherein the mat (01) can be arranged with its underside (13) on a base, and wherein the mat (01) forms an exercise surface (03) for therapeutic exercises on its upper side (02), and wherein the mat (01) is made of an elastically deformable material, and wherein the elastically deformable material is compressible by the weight of a user located on the exercise surface (03) in the loaded contact area (10), wherein the mat (01) comprises at least two material layers (05, 06) made of two different elastically deformable materials, wherein the lower material layer (06) can be arranged on the base, and wherein the upper material layer (05) forms the exercise surface (03), and wherein the upper material layer (05) is softer than the lower material layer (06).