Overlapping Modular Mat Structure for Faster Ground Cover Deployment

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Solution Overview

Problem

Conventional mat systems for temporary roadways and equipment support surfaces in remote locations are labor-intensive to install and remove, prone to rotting due to water and contaminant infiltration, and require frequent repairs and replacements, leading to environmental issues.

Innovation Solution

A modular ground cover system comprising a mat with interconnected web members and fortifying members, made from a rigid polymeric material, designed to be easily assembled and disassembled, with a hollow structure to reduce weight and enhance flexibility, and featuring lip stiffeners for additional support and flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional mat systems are used, then load-bearing capacity is provided, but installation and removal require significant time and labor

Engineering Contradiction:

Improveinstallation and removal speedVSAvoidtime required for installation and removal

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The mat system is divided into multiple individual mats that can be independently handled, installed, and removed. Each mat is a self-contained unit with interlocking features, allowing rapid deployment without requiring complex assembly procedures. The segmentation enables parallel installation of multiple mats simultaneously, significantly improving productivity while reducing total installation time.

Inventive Principle:

Principle #1Segmentation

2Reliability

If conventional wooden mats are used, then structural support is provided, but rotting occurs due to water and contaminant infiltration

Engineering Contradiction:

Improvestructural integrityVSAvoidwater and contaminant infiltration

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The mat construction incorporates a flexible membrane or shell layer that encapsulates the structural components, creating a barrier against water and contaminant infiltration. This flexible shell prevents moisture from reaching the internal structure, eliminating rotting issues while maintaining the mat's structural integrity and load-bearing capacity over extended periods.

Inventive Principle:

Principle #30Flexible shells and thin films

3Strength

If multiple layers of mats are used, then load-bearing capacity is enhanced, but device complexity increases

Engineering Contradiction:

Improveload-bearing capacityVSAvoidnumber of layers required

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The mat design merges multiple functional elements into a single integrated structure. By combining structural support components, interlocking mechanisms, and protective barriers into one unified mat unit, the system achieves enhanced load-bearing capacity without requiring multiple separate layers. This consolidation reduces device complexity while maintaining or improving strength characteristics.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12291826B2Overlapping modular mat system including mat components having fortifying members

Publication Date: 2025.05.06 NPK ACCESS SOLUTIONS LLC

AI summary

A mat comprising a first side and a second side opposite the first side is disclosed. The mat has a body with a thickness defined between the first side and the second side and a width defined between a first edge and a second edge. A plurality of fortifying members can be positioned between the first side and the second side extend within the body substantially vertically with respect to the width. A lip can extend from the body of the mat and have a first rib having a first rib thickness. A first channel portion can have a first channel thickness whereby the first rib thickness is greater than the first channel thickness.