Modular Overlapping Mats With Support Ribs for Heavy-Load Terrain
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Solution Overview
Problem
Existing temporary roadways and support surfaces constructed from wooden boards or traditional mat systems lack durability, flexibility, and ease of customization, particularly in harsh environments, and do not efficiently accommodate varying loads and terrain conditions.
Innovation Solution
The development of modular mats with a main body defined by sidewalls and exterior surface walls, featuring internal voids and structural support ribs that allow for division into sub-mats, providing increased strength, flexibility, and customization options through the use of primary and secondary structural support ribs, and a lip structure for secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional wooden boards or planks are used to construct support surfaces, then the support surface can be provided in remote areas, but the installation and removal process is time-consuming and labor-intensive
Solution Approach 1:
The support surface is divided into multiple modular mat units that can be independently handled and quickly assembled. Each mat unit contains integrated connection features (interlocking tabs, recesses, and engagement mechanisms) that enable rapid assembly without requiring extensive labor or specialized equipment, thereby reducing installation time while maintaining ease of operation.
Solution Approach 2:
The mat design integrates multiple functions into a single component: structural support, connection to adjacent mats, and separation capability are all incorporated into one mat unit. This consolidation allows for quicker installation since separate fastening components and assembly steps are eliminated, directly addressing the time-loss issue while preserving operational simplicity.
2Adaptability or versatility
If traditional mat systems are used, then support surfaces can be provided, but the systems lack flexibility for customization and separation into sub-sections
Solution Approach 1:
Each mat is designed with pre-defined separation lines and structural features that allow the mat to be divided into smaller sub-mats. The internal structure includes weak points or designated separation zones that enable clean division without compromising the integrity of the resulting sub-sections, providing customization flexibility while maintaining manageable system complexity.
Solution Approach 2:
The mat system transitions from a fixed, monolithic structure to a dynamic, reconfigurable system. The ability to separate mats into sub-mats and reassemble them in different configurations allows the support surface to adapt to various site requirements and load conditions, enhancing versatility without significantly increasing operational complexity.
3Strength
If solid mat structures are used to provide strength and stability, then load-bearing capacity is improved, but the weight and difficulty of handling increase
Solution Approach 1:
The mat incorporates a honeycomb or cellular internal structure that provides high strength-to-weight ratio. The porous or cellular pattern creates geometric rigidity and load distribution pathways while removing excess material, thereby maintaining load-bearing capacity while reducing overall mat weight for easier handling and deployment.
Solution Approach 2:
The mat utilizes composite construction combining different materials or structural layers: a rigid outer shell for strength, an optimized internal core for structural support with reduced weight, and connection features for assembly. This composite approach achieves high load-bearing capacity while minimizing weight, directly addressing the contradiction between strength and handling ease.
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.