Encapsulated Wood Mat for Moisture Resistance
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Solution Overview
Problem
Conventional wood mats used for temporary roadways and equipment support surfaces deteriorate due to moisture, leading to a need for improved resistance to wood deterioration and abuse to extend their service life.
Innovation Solution
A reusable mat system with a core construction of various materials, such as wood or engineered wood, encapsulated in a thermoplastic, thermosetting, or elastomeric material to provide environmental and abrasion resistance, and featuring a load-bearing capacity to withstand significant loads without deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wood mats are used for temporary roadways, then initial cost is reasonable and basic structural support is provided, but the wood core deteriorates over time due to moisture causing rotting and degradation
Solution Approach 1:
The patent applies composite materials by combining a wood core construction with an encapsulation layer of thermoplastic, thermosetting, or elastomeric material. This composite structure allows the wood to provide structural support while the synthetic encapsulation layer protects against moisture deterioration, thereby extending service life without sacrificing the load-bearing capabilities of the wood core.
Solution Approach 2:
The patent uses an encapsulation shell made of thermoplastic, thermosetting, or elastomeric material that surrounds and protects the wood core. This flexible protective shell acts as a barrier against moisture and environmental factors, preventing the wood from rotting and degrading while maintaining the overall structural integrity of the mat.
2Strength
If wood mats are used to provide structural support, then load-bearing capacity is achieved, but the mats are vulnerable to abuse and damage that reduces their durability
Solution Approach 1:
The composite construction combines the high strength-to-weight ratio of wood with the durability and abuse resistance of synthetic materials. The wood core maintains load-bearing capacity while the encapsulation layer provides protection against physical damage, abrasion, and environmental exposure, thereby improving overall durability without compromising strength.
Solution Approach 2:
The encapsulation layer serves as a protective cushion that shields the wood core from abuse and damage before such damage can occur. This pre-protective layer absorbs impacts, resists abrasion, and prevents direct exposure to harmful environmental factors, thereby extending the mat's service life while maintaining its load-bearing capabilities.
3Duration of action of stationary object
If the wood core is replaced to extend service life, then structural integrity can be maintained, but essentially an entirely new mat must be made increasing complexity and cost
Solution Approach 1:
The composite construction with an encapsulated wood core allows the protective layer to be replaced or repaired independently of the wood core. This modular approach simplifies maintenance, as only the encapsulation layer needs to be addressed when showing wear, while the intact wood core can be reused, thereby reducing overall replacement complexity and cost.
Solution Approach 2:
The mat is segmented into two functional components: the wood core for structural support and the encapsulation layer for protection. This segmentation allows independent treatment of each component, enabling replacement or repair of only the encapsulation layer when needed, rather than replacing the entire mat, thus reducing complexity and cost.
Data Source
AI summary
An industrial mat that includes a core construction that provides strength and rigidity to the mat, with the core construction including various layers or plies of components at least some of which are typically made of wood or engineered wood; and a durable skin that surrounds and encapsulates at least the wood components of the mat or the entire core construction. The skin has a thickness sufficient to provide environmental resistance to the wood components or to the core construction to which it is applied. The skin also provides abrasion resistance to the boards and mat.