Fiber-Reinforced Load-Supporting Mat for Heavy-Load Durability
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Solution Overview
Problem
Existing temporary roadway and support surface systems, particularly those using wooden boards or mat-type systems, face challenges in providing a stable and durable surface under harsh environmental conditions and heavy loads, with issues such as material failure at lip structures and limited reinforcement.
Innovation Solution
The incorporation of fiber-reinforcement layers, made from materials like recycled carpet or synthetic fibers, into the mat structure to enhance the mechanical strength and stability, particularly at the lip structures and periphery, through embedding these layers during the manufacturing process using heat and pressure treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional wooden boards or simple mat structures are used, then the structure is simple and easy to manufacture, but the material fails under heavy loads and harsh environmental conditions
Solution Approach 1:
The patent applies composite materials by combining a mat structure made of polymeric material with fiber-reinforcement layers embedded within it. This composite construction provides enhanced strength and resistance to material failure while maintaining a relatively simple overall structure. The fiber-reinforcement layers are integrated during manufacturing to create a unified composite component that leverages the strengths of both materials.
Solution Approach 2:
The fiber-reinforcement layers are strategically positioned at specific locations where stress concentrations occur, such as at the lip structures and periphery of the mat. This local reinforcement approach provides enhanced strength precisely where needed without unnecessarily complicating the entire structure. The reinforcement is concentrated at critical failure points rather than uniformly distributed throughout.
2Reliability
If mat structures without reinforcement are used, then manufacturing is simple and quick, but the mats lack durability under severe weather and heavy equipment loads
Solution Approach 1:
The fiber-reinforcement layers are embedded within the mat structure during the manufacturing process itself, before the mat is deployed for use. This preliminary incorporation of reinforcement ensures durability is built into the structure from the outset rather than added later. The reinforcement is integrated during molding or formation, making the durable mat ready for immediate use without additional assembly steps.
3Adaptability or versatility
If lip structures are added to mats for interconnection, then modular assembly is enabled, but material failure occurs at the lip structures under load
Solution Approach 1:
The fiber-reinforcement layers are specifically positioned to extend into the lip structures at their points of attachment to the main mat body. This local reinforcement at the lip structures provides enhanced strength precisely where the modular interconnections occur and where stress concentrations are most likely to cause failure. The reinforcement is concentrated at these critical junction points rather than uniformly distributed.
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 fiber-reinforcement layers significantly increase the mat's resistance to material failure and provide a more stable and durable support surface, capable of withstanding heavy loads and harsh conditions, while also allowing for modular and customizable configurations.
Implementation Method 1
through embedding these layers during the manufacturing process using heat and pressure treatment
Implementation Method 2
through embedding these layers during the manufacturing process using heat and pressure treatment
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
Mats (100-900) and methods of making the same are described. The mats include a main body (102-902) defined by a plurality of sidewalls and two exterior surface walls (102a,102b) opposing each other, a lip structure (104,106) extending outwardly from the plurality of sidewalls around a portion of a periphery of the main body, and at least one fiber-reinforcement layer (514,606,706,808,810,908,910) arranged between the two exterior surface walls of the mat. The methods include depositing a first deposition layer of material within a mold, positioning at least one fiber-reinforcement layer on the first deposition layer, depositing a second deposition layer of material within the mold over the at least one fiber-reinforcement layer and the first deposition layer, and treating the first deposition layer, the at least one fiber-reinforcement layer, and the second deposition layer to form a mat.