Industrial Mat with Impact Bumpers and Segmented Core
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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 short service life and the need for frequent replacement, as the wood core cannot be repaired without replacing the entire mat.
Innovation Solution
A reusable mat system with a durable core structure made of environmentally resistant materials, such as steel, thermosetting resin, or elastomeric materials, combined with removable upper and lower layers and impact-absorbing bumpers, allowing for extended service life and improved resistance to abuse and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wood core is used in mat construction, then initial cost is reasonable and mat provides useful service, but mat deteriorates over time due to moisture causing gradual rotting and degradation
Solution Approach 1:
The mat is divided into three replaceable segments: upper layer, support core, and lower layer. The support core is made of environmentally resistant materials (steel, thermoset resin, or elastomeric) that do not deteriorate from moisture, while the upper and lower layers can be replaced if damaged. This segmentation allows the durable core to protect against moisture while enabling replacement of surface layers that may be affected by wear or damage.
Solution Approach 2:
The mat uses composite construction combining different materials with complementary properties: the support core uses environmentally resistant materials (steel, thermoset resin, or elastomeric) that resist moisture and degradation, while the upper and lower layers can be made of various materials including wood, plastic, or elastomeric materials. This composite approach allows each layer to be optimized for its specific function and replacement cycle.
2Ease of repair
If conventional wood mat construction is used, then mat provides temporary roadway surface, but mat cannot be repaired without replacing entire mat when core deteriorates
Solution Approach 1:
The mat is divided into three replaceable segments: upper layer, support core, and lower layer. The support core is made of environmentally resistant materials (steel, thermoset resin, or elastomeric) that do not deteriorate from moisture, while the upper and lower layers can be replaced if damaged. This segmentation allows the durable core to protect against moisture while enabling replacement of surface layers that may be affected by wear or damage.
Solution Approach 2:
The design allows selective replacement of only the upper and lower layers when they become damaged or worn, while the support core is retained and reused. This partial replacement approach recovers the valuable core structure and only discards the surface layers that have reached the end of their service life, significantly reducing material waste compared to replacing the entire mat.
3Reliability
If bumpers are added to protect core from damage, then resistance to abuse and damage is improved, but device complexity increases
Solution Approach 1:
The bumpers are integrated with the support core structure, combining the protective function with the existing structural framework. The bumpers are positioned at strategic locations on the core and work together with the layered construction to provide comprehensive protection against impact and abuse during transport and installation, while maintaining a unified structural appearance.
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 system provides a stable, long-lasting solution with enhanced resistance to moisture and damage, enabling it to withstand heavy loads and harsh environmental conditions without permanent deformation, thus extending its service life and reducing maintenance costs.
Implementation Method 1
bumpers provided upon the longitudinal sides of the core, the front and rear end sides of the core, or upon both the longitudinal and front and rear end sides of the core to protect the core from damage due to transport or installation of the mat. The bumpers are made of wood, or of a plastic or elastomeric material and have a shape that absorbs impact and shock forces.
Data Source
AI summary
An industrial mat that has a support core configured and arranged to support other components of the mat; and upper and lower layers that provide upper and lower surfaces of the mat, with the layers protecting the support core. Bumpers are provided upon the longitudinal sides of the core, the front and rear end sides of the core, or upon all sides to protect the core from damage due to transport or installation of the mat. The bumpers are typically made of wood, or of a plastic or elastomeric material and have a shape that absorbs impact and shock forces. The mat also includes lifting elements of D-shaped rings, O-shaped rings, chains, or cables attached to the upper or lower layer or the support core, with the lifting elements configured and dimensioned to provide certified overhead lifting of the mat for installation and reclamation thereof.