Environmentally Resistant Mat Core Structure for Heavy Load Support
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Solution Overview
Problem
Conventional wood mats used for temporary roadways and equipment support surfaces deteriorate due to moisture, leading to resource wastage and high maintenance costs, and the availability of large wood beams is limited, necessitating the need for alternative materials that can withstand harsh outdoor conditions and support heavy loads.
Innovation Solution
The development of industrial mats with a core structure made from environmentally resistant non-wood materials such as treated wood, metal, thermoplastic, or thermosetting materials, combined with outer layers, providing sufficient strength, rigidity, and load-bearing capacity to withstand heavy equipment and harsh weather conditions, while allowing for easy disassembly and reuse of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wood mats are used for temporary roadways, then initial cost is reasonable and serviceability is acceptable, but the mats deteriorate due to moisture causing rotting and degradation, leading to short service life and high maintenance costs
Solution Approach 1:
The patent applies composite materials by combining a wood outer layer with a non-wood core structure (metal, plastic, or composite beams). This composite construction allows the mat to benefit from the aesthetic and protective qualities of wood while the internal core provides moisture resistance and structural strength, preventing rotting and degradation in wet environments.
Solution Approach 2:
The patent implements local quality by making different parts of the mat from different materials suited to their specific functions. The outer wood layers provide protection and aesthetic quality, while the internal non-wood core structure provides moisture resistance and structural support. This localized material selection optimizes each component for its specific environmental exposure and functional requirements.
2Strength
If large size wood beams are harvested to make crane mats, then acceptable performance is achieved, but availability of suitable trees is reduced due to weather conditions and environmental factors
Solution Approach 1:
The patent uses composite materials where the core structure is made from non-wood materials such as metal beams, plastic composite beams, or recycled composite materials. This allows the mat to achieve the necessary load-bearing capacity and structural strength without depleting wood resources, as the internal framework provides the primary structural support.
Solution Approach 2:
The patent changes the material parameters of the core structure from organic wood to inorganic or synthetic materials (metal, plastic, composite). This parameter change maintains or enhances structural strength and load-bearing capacity while improving resistance to environmental degradation and eliminating the need to harvest large quantities of timber.
3Duration of action of stationary object
If the core structure is made from non-wood environmentally resistant materials, then service life is extended and resource conservation is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the mat into distinct modular components: outer wood layers and an internal non-wood core structure. This segmentation allows each component to be manufactured separately using optimized processes for that material type, then assembled together. The modular beam structure within the core can also be segmented into individual beams that are independently manufactured and positioned.
Solution Approach 2:
The patent uses composite material construction where pre-manufactured non-wood core components (metal beams, plastic beams, or composite beams) are assembled with wood outer layers. This approach allows specialized manufacturing processes for each material type to be applied independently, reducing overall manufacturing complexity compared to attempting to create a monolithic structure from a single difficult-to-work material.
Data Source
AI summary
A mat having a core that provides strength and rigidity to the mat, and including a structure of a sheet, elongated members, a frame, compartments, or combinations thereof and at least one outer layer associated with the core and made of a sheet, elongated members or combinations thereof. The core and outer layer(s) are integral or are joined together, and the structure of the core is made of one or more environmentally resistant materials to provide an extended service life when encountering rain, snow or other weather conditions that would eventually degrade wood. The mat has a load bearing capacity that is able to withstand a load of at least 500 to 800 psi or even 1000 psi without permanently deforming the core. Bumpers are preferably provided upon sides of the mat to protect them from damage due to transport or installation of the mat.