Modular Mat Systems With Internal Structural Support Ribs
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Solution Overview
Problem
Existing temporary roadways and equipment support surfaces made of wooden boards or traditional mat systems face challenges such as instability, limited durability, and difficulty in customization and reconfiguration, especially in harsh environments.
Innovation Solution
The development of modular mats with internal structural support ribs and voids that allow for customization into sub-mats, providing increased strength, flexibility, and ease of assembly, while maintaining a reduced weight and enhanced crush resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional mat systems use prefabricated multi-layered mats with boards affixed together, then the mats provide continuous support surface, but the system lacks flexibility for customization and reconfiguration
Solution Approach 1:
The mat is divided into multiple modular sections with standardized connection features. Each section can be independently manufactured, transported, and assembled. The segmentation allows flexible configuration by connecting sections in different patterns while maintaining structural integrity through standardized interconnection mechanisms.
Solution Approach 2:
The mat sections are designed with universal connection features that allow the same component to serve multiple functions: structural support, interconnection with other sections, and potential reconfiguration. The standardized geometry and connection interfaces enable the same mat section to be used in various positions and configurations across different applications.
2Reliability
If wooden boards are placed end to end to form support surfaces, then the roadways can be constructed in remote areas, but the structure lacks stability and durability
Solution Approach 1:
Multiple board elements are merged into integrated mat sections with interconnected structural features. The merging creates a unified structural unit that distributes loads across the entire section rather than relying on individual board stability. Connection features between boards are integrated during manufacturing, providing stable joints without requiring complex field assembly.
Solution Approach 2:
The mat sections are pre-assembled and pre-connected during manufacturing before deployment. Structural reinforcements, connection features, and alignment mechanisms are installed in advance, allowing the sections to be transported as complete units and quickly deployed without requiring complex assembly operations at the installation site.
3Strength
If mats are made with solid construction to increase strength, then crush resistance improves, but the weight of the mats increases
Solution Approach 1:
The mat structure implements varying material density and structural thickness at different locations. High-strength, thick-walled sections are positioned at load-bearing areas such as corners and connection points, while lighter, thinner sections are used in non-critical areas. This local differentiation maintains overall crush resistance while reducing total weight compared to uniform solid construction.
Solution Approach 2:
The mat incorporates composite construction combining materials with different properties: high-strength, rigid materials in structural support elements and lighter materials in non-structural sections. The composite approach allows the mat to achieve required strength levels in critical areas while using lighter materials elsewhere, optimizing the strength-to-weight ratio.
Data Source
AI summary
Mats and methods associated therewith are described. The mats include a main body defined by a plurality of sidewalls and two exterior surface walls opposing each other. The main body includes a pattern of internal walls that define internal voids within the main body. At least one primary structural support rib is arranged within the main body and extends between the two surface walls and from one of the plurality of side walls to another of the plurality of side walls. The at least one primary structural support rib traverses the internal voids defined by the pattern of internal walls.