Fusion-Welded Modular Mat Structure for Heavy-Load Interlocking
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Solution Overview
Problem
Traditional modular mat systems suffer from structural weaknesses under heavy loads, stress risers at connection points, and cumbersome assembly/disassembly, leading to cracking and inefficiency in installation and removal.
Innovation Solution
A modular mat system with layers joined by fusion welding, featuring cellular structures and offset bands for enhanced strength, and traction elements for improved grip, allowing for quick assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If mechanical connectors (bolts or multiple piece cams) are used to link modular mats together, then the mats can be assembled and disassembled, but stress risers occur at connection points causing structural weakness and cracking under heavy loads
Solution Approach 1:
The patent merges the connector components into a single integrated piece cam mechanism that locks mats together without creating stress risers. The unified design eliminates the need for multiple separate mechanical connectors, distributing loads more evenly across the connection point while maintaining assembly and disassembly capability.
Solution Approach 2:
The patent replaces traditional mechanical bolt connections with a cam-based locking mechanism that uses rotational motion to secure mats together. This substitution eliminates the need for threaded fasteners and multiple connector pieces, reducing stress concentration points while preserving the ability to quickly assemble and disassemble the mat system.
2Area of stationary object
If a large number of mats with mechanical connectors are used to cover large areas, then the mats can be connected side-by-side, but the installation and removal process becomes tedious and time consuming
Solution Approach 1:
The patent segments the connector design into modular components that can be quickly engaged and disengaged. The cam mechanism is divided into movable and fixed portions that interact through simple geometric shapes, allowing rapid connection of multiple mats without requiring complex alignment or multiple fastening steps, thus reducing installation time for large coverage areas.
3Strength
If flanges are made as solid pieces to provide structural support, then the mats have adequate strength, but the flanges decrease structural strength when attached to opposing mats under load due to bending and flexing
Solution Approach 1:
The patent employs a thinner, more flexible flange design that can bend and flex under load without compromising overall structural integrity. The flange is engineered with appropriate thickness and material properties to provide sufficient support while maintaining the flexibility needed to accommodate natural mat movement and loading conditions, preventing stress concentration and potential failure.
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 system maintains structural integrity under high loads, is durable for industrial applications, and facilitates efficient installation and removal, with enhanced grip and reduced stress risers.
Implementation Method 1
A modular mat system with first layer that is joined to a second layer by fusion welding, hot welding, hand welding, seam welding, heat pressing, or other methods know to those having skill in the art.
Implementation Method 2
Each layer has a central core with a first cellular structure formed from ribs extending from the interior surface
Implementation Method 3
The exterior surface of at least one layer comprises a plurality of traction elements raised from the exterior surface to allow the mat system to grip the surface on which it is laid or to allow vehicles to grip the mat system.
Data Source
AI summary
A module mat system with first layer that is joined to a second layer by fusion welding, hot welding, hand welding, seam welding, heat pressing, or other methods know to those having skill in the art. Each layer has a central core with a first cellular structure formed from ribs extending from the interior surface. The cross section of the ribs in the central core of the first layer matches the cross section of the ribs in the central core of the second layer such that when fusion welded together the ribs of the central core of the first layer weld to the ribs of the central core of the second layer.