Ultrasonically welded mat unit and system thereof
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Solution Overview
Problem
Existing entrance mat systems fabricated from vinyl-based materials pose safety concerns due to the release of noxious chemicals during molding and the use of adhesives for bonding layers, which can emit harmful fumes and odors.
Innovation Solution
The development of a mat system using non-vinyl, non-toxic thermoplastic elastomer (TPE) materials, where two layers are ultrasonically welded together without adhesives or mechanical attachments, forming a mat unit with specific rib configurations for effective debris removal from shoes moving in any direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If vinyl-based materials are used for mat fabrication, then the mat can be molded into specific shapes and designs, but noxious and potentially harmful or toxic off gasses are released during the molding process
Solution Approach 1:
The patent changes the material parameter from vinyl-based polymer to thermoplastic elastomer (TPE), which eliminates the release of noxious off gasses during molding while maintaining the ability to form specific shapes and designs through the molding process
Solution Approach 2:
The patent uses TPE as an alternative material that combines the desirable molding characteristics of vinyl with the advantage of not releasing harmful chemicals, effectively creating a safer composite material solution
2Stability of the object's composition
If adhesives are used to join layers together, then the mat can be assembled with multiple layers, but harmful or noxious odors/chemicals are released during adhesive bonding and curing
Solution Approach 1:
The patent replaces the chemical bonding system (adhesives) with an ultrasonic welding system that uses mechanical vibration and heat to join layers together, eliminating the release of harmful adhesive fumes and odors while achieving strong layer bonding
Solution Approach 2:
The ultrasonic welding process utilizes phase transition of the TPE material through localized heating and melting at the bonding interface, allowing layers to fuse together without requiring chemical adhesives
3Shape
If traditional molding processes are used for vinyl materials, then the mat can be formed to desired shape, but the process requires heating to sufficiently mold the material
Solution Approach 1:
The patent employs ultrasonic vibration during the molding process to facilitate shape formation at lower temperatures compared to traditional vinyl molding, reducing thermal exposure while achieving the desired mat geometry
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
This solution eliminates the risk of toxic gas emissions and adhesive-related hazards, providing a safe and effective mat system for commercial and residential use that can remove debris omnidirectionally, ensuring a safer and cleaner entryway while being environmentally friendly.
Implementation Method 1
welding the first and second layers together ultrasonically without any additional material bonding the first and second layers together
Data Source
AI summary
A mat unit includes a plurality of gaps defined by a first layer that are in open communication with gaps defined by a second layer so as to permit debris to fall entirely through both gaps to pass completely through the mat unit. The mat unit is part of an omnidirectional mat cleaning system that includes a first direction of travel above the mat unit extending through a door opening defined by a building structure. A different second direction of travel is above the mat unit extending through the door opening or another door opening defined by the building structure. The mat unit is installed on a floor adjacent the door opening. The mat unit cleans shoes regardless of the direction of travel traveled above the mat unit.