Laminated Support Mat Billets with Expansion Pads
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Solution Overview
Problem
Conventional solid sawn timber road panels are costly, scarce, and prone to swelling and buckling due to moisture exposure, leading to undesirable cupping and buckling, and have limited longevity in construction applications.
Innovation Solution
A laminated support mat composed of billets made from individually bonded wood laminations with expansion pads between them, allowing for asymmetrical expansion and preventing cupping and buckling, while using less material and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid sawn timber panels are used to construct road panels, then the panels provide sufficient structural strength, but the panels are prone to swelling and buckling due to moisture exposure
Solution Approach 1:
The solid sawn timber panels are segmented into multiple thinner wood laminations (e.g., five laminations) that are adhesively bonded together to form laminated billets. This segmentation allows each lamination to expand and contract independently, preventing the overall panel from swelling and buckling while maintaining structural strength through the layered composite structure.
Solution Approach 2:
The invention uses composite materials by adhesively bonding multiple wood laminations together to create laminated billets. This composite structure combines the strength of individual laminations with the flexibility to accommodate moisture-induced expansion, eliminating the dimensional instability problems of solid sawn timber while preserving structural integrity.
2Strength
If solid sawn timber panels are used, then the panels can support heavy equipment, but the panels are costly and use scarce material
Solution Approach 1:
The invention segments timber into thinner laminations (e.g., five laminations per billet) that are bonded together, allowing for more efficient use of wood material. This segmentation reduces the amount of timber required compared to using solid sawn timber of equivalent strength, as the laminated structure achieves strength through multiple layers rather than requiring thick, scarce solid timber sections.
Solution Approach 2:
The laminated billet structure creates a composite material that achieves high strength-to-weight ratio, reducing the quantity of timber material needed while maintaining the ability to support heavy construction equipment. The adhesive bonding of multiple laminations creates a efficient use of material that is both strong and lighter than solid sawn timber.
3Strength
If solid sawn timber panels are used, then the panels provide sufficient strength, but the panels have limited longevity due to environmental damage
Solution Approach 1:
By segmenting the timber into thinner laminations bonded together, the invention creates a structure that is more resistant to environmental damage. The laminated structure prevents moisture accumulation and reduces swelling, thereby extending the service life of the panel while maintaining structural strength needed to support heavy equipment.
Solution Approach 2:
The adhesive-bonded lamination structure creates a composite material with improved durability and resistance to moisture-induced degradation. This composite construction extends the service life of the panel by preventing the dimensional instability and structural failure that occur in solid sawn timber when exposed to prolonged moisture and environmental conditions.
4Device complexity
If solid sawn timber panels are used, then the panels can be constructed with simple fastening systems, but the panels exhibit undesirable cupping and buckling
Solution Approach 1:
The segmentation of timber into multiple laminations bonded together inherently prevents cupping and buckling by allowing each lamination to move independently in response to moisture changes. This eliminates the need for complex fastening systems or additional stabilization components, as the laminated structure itself maintains panel flatness and shape stability.
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 laminated support mat effectively prevents cupping and buckling, reduces material usage, and increases design strength, making it more cost-effective and durable for construction applications.
Implementation Method 1
Each billet has an expansion pad disposed between wide faces of adjacent billets. The expansion pad allows for asymmetrical expansion of the billet and prevents cupping and buckling of the support mat.
Data Source
AI summary
A support mat, such as a mat suitable for supporting heavy construction equipment, includes a plurality of billets fastened together, each of the billets being made of a plurality of individual wood laminations adhesively bonded to each other. The billets comprise a plurality of vertically oriented individual wood laminations. The plurality of individual wood laminations has wide faces oriented parallel to a direction of a load applied to the support mat. Each billet has outboard laminations and the wide faces of the outboard laminations of each billet define a wide face of the billet. An expansion pad is disposed between the wide faces of adjacent billets.