Laminated Mat Core Layer Strength via Board Abutment
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Solution Overview
Problem
Conventional wood mats used for temporary roadways and equipment support surfaces deteriorate due to moisture, leading to short service life and inability to replace the core without making a new mat, necessitating improved strength, durability, and reusable components.
Innovation Solution
A laminated mat system with a core layer made of chemically treated softwood or plastic, encapsulated in a three-layer structure with hardwood or plastic top and base layers, featuring interlocking boards for enhanced strength and ease of assembly/disassembly, and using materials like recycled plastic and elastomeric materials for increased durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If conventional wood mats are used for temporary roadways, then initial cost is reasonable, but service life is short due to moisture deterioration and rotting
Solution Approach 1:
The mat is divided into three separable layers: top layer, core layer, and base layer. This segmentation allows the core layer to be reused while replacing only the deteriorated top and base layers, extending overall service life and reducing waste from complete mat replacement.
Solution Approach 2:
The mat combines different materials in each layer - hardwood or plastic for top and base layers providing durability and moisture resistance, and softwood or plastic for the core layer providing structural support. This composite structure optimizes both strength and resistance to environmental deterioration.
2Ease of manufacture
If the core layer is made of wood, then initial manufacturing is simple, but the core deteriorates over time causing the entire mat to be discarded
Solution Approach 1:
The core layer is designed as a separate, replaceable component between the top and base layers. When the core deteriorates, it can be removed and replaced without discarding the entire mat, enabling repair rather than complete replacement.
Solution Approach 2:
The design allows the core layer to be recovered and reused after replacement. The durable top and base layers are retained while only the deteriorated core is discarded and replaced, maximizing material utilization and reducing waste.
3Ease of operation
If boards are spaced apart in layers, then assembly is simple, but strength and stability of the mat structure is reduced
Solution Approach 1:
The three layers are combined and secured together to form an integrated mat structure. This merging of layers provides mutual support and distributes loads across the entire mat, significantly enhancing structural strength and stability compared to simple spaced boards.
Solution Approach 2:
The layered composite structure with different materials in each layer provides both simplicity in assembly and enhanced strength. The combination of hardwood, softwood, and/or plastic layers creates a synergistic effect that improves overall structural performance.
4Ease of repair
If the entire mat is discarded when the core deteriorates, then replacement is simple, but material waste increases and cost increases
Solution Approach 1:
The mat is segmented into replaceable layers, allowing selective replacement of only the deteriorated core layer while retaining the durable top and base layers. This reduces material waste and extends the overall service life of the mat structure.
Solution Approach 2:
The design enables recovery and reuse of the top and base layers when the core deteriorates. Only the core layer is discarded and replaced, minimizing material waste and reducing the frequency of complete mat replacement.
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 solution provides improved resistance to impact, abrasion, and environmental degradation, extending the service life of the mats, allowing for replacement of top and base layers while reusing the core, and reducing maintenance and transportation issues.
Implementation Method 1
The rectangular core layer comprising a plurality of parallel boards of substantially equal length that are made of chemically treated softwood, encapsulated softwood, or of plastic or elastomeric materials
Data Source
AI summary
A laminated mat for use as the temporary surface at a construction site or roadway leading thereto. This mat includes at least three layers of boards in a top layer, at least one core layer and a base layer. Preferably, each layer is rectangular. The top and base layers each include a plurality of parallel boards of substantially equal length that are made of oak or other hardwoods, or of plastic or elastomeric materials. The core layer includes a plurality of parallel boards of substantially equal length that are made of chemically treated softwood, encapsulated softwood, or of plastic or elastomeric materials, with the boards arranged to be perpendicular to the boards of the top layer, and configured so that adjacent boards in the core layer engage, contact and abut each other to minimize or eliminate space between adjacent boards to improve the strength of the core layer.