Mat Construction with Environmentally Resistant Skin
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional wood mats used for temporary roadways and equipment support surfaces deteriorate due to moisture, leading to premature degradation and the need for frequent replacement, as the wood core cannot be easily repaired.
Innovation Solution
A durable mat system featuring a core construction of elongated components made from wood, engineered wood, thermosetting plastic, or metal, encapsulated with a crumb rubber-polyurethane matrix for environmental and abrasion resistance, providing a stable and long-lasting surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wood mats are used for temporary roadways, then initial cost is reasonable and basic functionality is provided, but the wood core deteriorates over time due to moisture causing rotting and degradation
Solution Approach 1:
The patent applies composite materials by combining a wood core construction with an encapsulation layer made of polyurethane and crumb rubber particles. This composite structure provides the benefits of both materials: the wood core provides structural strength and rigidity, while the polyurethane-rubber encapsulation provides environmental resistance to moisture, abrasion, and impact, thereby extending the service life of the mat without sacrificing basic functionality.
2Reliability
If the wood core is protected from moisture, then environmental resistance is improved, but the core cannot be easily repaired when damaged
Solution Approach 1:
The patent segments the mat into two distinct functional layers: an inner wood core construction that provides structural strength and rigidity, and an outer encapsulation layer made of polyurethane and crumb rubber that provides environmental protection. This segmentation allows the protective function to be separated from the structural function, enabling the core to be replaced or repaired independently if needed, while the encapsulation provides continuous environmental resistance.
3Reliability
If a durable encapsulation is added to protect the core, then environmental resistance and abrasion resistance are improved, but the complexity of mat construction increases
Solution Approach 1:
The patent merges multiple protective functions into a single encapsulation layer that combines polyurethane matrix material with crumb rubber particles. This unified encapsulation simultaneously provides environmental resistance, abrasion resistance, and impact resistance, eliminating the need for separate protective layers for each function and thereby reducing overall construction complexity while maintaining comprehensive protection.
4Ease of operation
If the mat is designed for easy installation and removal, then ease of operation is improved, but structural integrity under heavy loads may be compromised
Solution Approach 1:
The patent employs a modular mat design where the encapsulated core construction can be dynamically assembled and disassembled as needed. The mat sections are designed to be easily connected and disconnected for rapid installation and removal, while the internal wood core structure with its cross-laminated plies and metal fasteners maintains high structural integrity to support heavy loads when deployed. The dynamic capability is achieved without compromising static strength.
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 encapsulated mat system offers improved resistance to moisture, abrasion, and impact, extending the service life of the mats while maintaining structural integrity and ease of installation and removal, even under heavy loads and adverse weather conditions.
Implementation Method 1
an encapsulation of a durable skin comprising crumb rubber particles embedded in a polyurethane matrix that surrounds and encapsulates the entire core construction
Implementation Method 2
the skin having a thickness sufficient to provide environmental resistance for the core construction to which it is applied while also providing abrasion resistance to the mat
Data Source
AI summary
An industrial mat that has a core construction that provides strength and rigidity to the mat, with the core construction being formed of a support structure that includes one or more elongated components or a plurality of elongated members of wood, engineered wood, a thermosetting plastic material or a metal. The mat includes an encapsulation of a durable skin that includes crumb rubber particles embedded in a polyurethane matrix that surrounds and encapsulates the entire core construction. The skin has a thickness sufficient to provide environmental resistance to the core construction to which it is applied while also providing abrasion resistance to the mat.