Interlocking Road Surface Panels for Rapid Small-Scale Installation

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Solution Overview

Problem

Existing cast-in-place and precast road surface systems are labor-intensive and economically inefficient, especially on a small scale, and generate significant waste.

Innovation Solution

A preconstructed road surface panel system featuring interlocking panels with trapezoidal or parallelogram cross sections, male-female components, and pegs for stability, allowing for easy installation and use of varying materials and thicknesses to accommodate different loads and applications, with optional shear members for reinforcement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If cast in place road surface systems are used, then road surfaces can be created, but installation is labor intensive and not economical on small scale

Engineering Contradiction:

Improveinstallation efficiencyVSAvoidinstallation speed

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The road surface is divided into multiple precast panels that can be manufactured separately and assembled on-site. Each panel is a discrete unit with standardized dimensions and interlocking features, allowing rapid installation without formwork or extensive on-site construction activities.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Panels are precast with interlocking features, reinforcement, and surface finishes before delivery to the installation site. This preliminary preparation of critical components significantly reduces on-site labor requirements and installation time.

Inventive Principle:

Principle #10Preliminary action

2Ease of operation

If precast road surface systems are used, then installation is simplified, but they are not economical on small scale and create waste

Engineering Contradiction:

Improveinstallation simplicityVSAvoidmaterial waste

Core Design Contradiction:

Ease of operationVSLoss of substance

Solution Approach 1:

The panel system offers customizable parameters including various lengths, widths, thicknesses, and material compositions to match specific project requirements. This flexibility allows precise fitting for small-scale applications, minimizing off-cuts and material waste while maintaining installation simplicity.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If traditional road surface systems are used, then road surfaces can be constructed, but they generate significant waste in the long term

Engineering Contradiction:

Improveconstruction feasibilityVSAvoidwaste generation

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The interlocking panel design allows for easy disassembly and reuse of panels when road repairs or replacements are needed. Panels can be recovered from one location and installed in another, significantly reducing long-term material waste compared to traditional cast-in-place systems that must be broken up and discarded.

Inventive Principle:

Principle #34Discarding and recovering

Data Source

PatentUS12410563B2Road surface panels systems

Publication Date: 2025.09.09 CHEPETS IGOR

AI summary

1. A panel system is provided that includes: a first and second panel each having a top side providing a road surface and a bottom side opposite the top side, where the bottom side contacts a ground surface, and a plurality of lateral sides. At least one of the plurality of the lateral sides of the first and second panels include a feature that interlock adjacent lateral sides of the first and second panels against vertical movement relative to each other.