This invention relates generally to a structural surface enhancing panel for use in configuring an artificial trackway or temporary roadway, runway, landing pad, etc. It is known to provide structural surface enhancing panels that can be connected or linked together in order to form a temporary surface of above- mentioned type. In particular, temporary surfaces of this type dramatically improve the ability of vehicles, including cars, trucks, freight vehicles and aircraft to access areas which would not otherwise be suitable due to low substrate strength or excessive debris. This kind of roadway formation is applicable to a number of different situations, including, but not limited to, international development, military, and emergency operations.

Structural surface enhancing panels of this type are transported by air, sea, rail and land vehicles, to the location where they are needed. They are subsequently unloaded and then connected together in the configuration required to form a temporary surface. Logistics represent by far the greatest contribution to the cost of providing temporary roadways, etc., and as such, there is an ongoing desire to reduce the cost of storing and/or transporting such panels, and, more specifically, to reduce the logistical burden of storing and/or transporting such panels.

It will be well known to a person skilled in the art that the structural surface enhancing panels require significant structural integrity in order to withstand the weight and impact forces of heavy goods vehicles, aircraft, and other vehicles which utilise the temporary road surfaces created therefrom. Furthermore, the panels must be able to withstand the thermal cycles induced by the engines of aircraft and other large vehicles, as well as extreme weather conditions, without sustaining damage, deformation and/or stress-fractures forming within the panels themselves.

Typically, a structural surface enhancing panel is a fluted panel, formed of aluminium or the like, and having alternating peaks and troughs, with each trough on one surface of the panel corresponding to a respective peak on the opposing surface. Whilst the outer profiles of the peaks on both surfaces of the panel are essentially substantially the same, the inner profile of each corresponding trough is significantly smaller. As a result, when the panels are stacked one on top of the other, the peaks simply‘sit’ on top of the widest part of the adjacent troughs. This results in large portions of ‘wasted’ space. In the case where shipping containers are used to transport structural surface enhancing panels to the location of deployment, it is clearly desirable to minimise the number of containers and/or number of journeys required to transport a defined number of panels to the location of deployment, and it has long been the subject of technical endeavour to try and minimise this‘wasted’ space. However, in view of the thickness of material and depth of profile necessary to achieve the required structural integrity of the panels, it has thus far proved impossible to sufficiently alter their configuration to reduce the gaps between stacked panels caused by a mismatch between the outer profile of the peaks and the inner profile of the troughs thereof.

It is an object of aspects of the present invention to provide a structural surface enhancing panel configured such that, when two or more such panels are stacked, the area they occupy (and particularly their combined height) is significantly reduced compared with prior art structural surface enhancing panels.

In accordance with a first aspect of the present invention, there is provided a structural surface enhancing panel comprising a flat primary surface and an opposing fluted surface, the fluted surface comprising a plurality of alternating peaks and troughs, wherein the configuration and dimensions of the troughs are substantially the same as those defined by the outer profile of the peaks, such that when the peaks of one panel are nested within the troughs of another panel, an uppermost portion or crest of each peak contacts a lowermost portion or bed of a respective trough opposing trough.

In accordance with one exemplary embodiment, when the peaks of one panel are nested within the troughs of another panel, an outer surface of the peaks contact an inner surface of the respective trough, substantially along the entire surface area thereof. In accordance with one exemplary embodiment of the invention, each peak may comprise a pair of side walls. Optionally, the side walls of each peak may form the side walls of each adjacent trough. The side walls may be angled relative to said flat primary surface.

In accordance with one exemplary embodiment of the invention the major angle formed between the flat primary surface and the side walls may be within the range of 90° to 160°. Optionally, the major angle formed between the flat primary surface and the side walls may be exactly 120°. In one exemplary embodiment of the present invention, the pair of side walls may be angled toward each other, to define a substantially trapezoidal peak and/or trough. Optionally, each peak may comprise a flattened crest. Each trough may comprise a flattened bed. Optionally, the side walls, crest and bed may be substantially equal in thickness.

In accordance with one exemplary embodiment of the present invention, the peaks and troughs may be uniform along the plane of said panel in one direction so as to define a plurality of alternating ridges and channels. According to an exemplary embodiment of the invention the panel may comprise a connecting means along at least one edge. Optionally, the panel may comprise a pair of connecting means, wherein a first connecting means is along a first edge, and a second connecting means is along an opposing edge.

In accordance with one exemplary embodiment of the invention, one of said pair of connecting means may comprise a male connecting member, and one of said pair of connecting means may comprise a female connecting member, such that a plurality of said panels can be connected together in side-by-side relation to form a larger surface.

Optionally, the male connecting member may comprise a flange protruding from an edge of said panel. The female connecting member may comprise a hook defining a recess. The recess may be shaped and configured to receive said male connecting member. In accordance with an exemplary embodiment of the present invention, the male connecting member may further comprise a cavity shaped and configured to be dimensionally similar to said female connecting member.

In accordance with a further aspect of the present invention there is provided a kit of parts comprising at least a first and second structural surface enhancing panel according to any of the preceding claims and configured to be moveable between a storage configuration, wherein said first panel is inversely oriented relative to said second panel and nested therewith such that said fluted surfaces of each panel are adjacent and the peaks of said first panel are received within said troughs of said second panel and the peaks of said second panel are received within said troughs of said first panel, and a surfacing configuration wherein said first and second panels are connected together at respective adjacent side edges thereof, and in side-by-side relation.

In accordance with a further aspect of the present invention there is provided, a temporary trackway comprising a plurality of pairs of structural surface enhancing panels as described above.

These and other aspects of the present invention will be apparent from the following specific description, in which embodiments of the present invention are described, by way of examples only, and with reference to the accompanying drawings, in which:

Figure 1 is a schematic side view diagram of a panel according to an exemplary embodiment of the invention; Figure 2A and 2B are schematic diagrams of a side view and top perspective views of a pair of panels according to an exemplary embodiment of the invention;

Figures 3A and 3B are schematic diagrams of the pair of panels of Figure 2, shown in a temporary surfacing configuration, illustrated as side and top perspective view diagrams respectively;

Figure 4 is a schematic side view diagram according to one exemplary embodiment, wherein exemplary dimensions are given.

In the following description, embodiments of the invention may be described using directional language such as upper, lower, clockwise, inner, front, rear, top, left, right, and so on. Such descriptors are not intended to be limiting and should not be construed as such. In particular, it would be clear to a skilled reader that the descriptors used in the following description refer to the invention in the orientation as shown in the corresponding drawings unless otherwise indicated. The invention may be used in other orientations not shown in the drawings and therefore the invention is not limited to be oriented as described.

Referring to Figure 1 of the drawings, there is illustrated a single structural surface enhancing panel indicated generally at 10, as seen from one side. It will be understood by those skilled in the art that in use, a plurality of structural surface enhancing panels will be connected together to form a temporary trackway. A temporary trackway is defined in the art as a temporary road surface which can be laid down relatively quickly, without the need to establish and create a permanent road surface. Temporary trackways may be used to allow the traverse of vehicles through difficult terrain (such as sand, forest floor, mud, and marshland), and may provide a safe landing surface for airborne vehicles such as helicopters and other aircraft. Since each panel is identical in shape and configuration, a single panel will now be described in isolation. The structural surface enhancing panel 10 comprises a primary planar surface 12. During use, the primary planar surface 12 will provide the temporary surface which forms the airfield, roadway and/or runway as required. It will be clear to a person skilled in the art, therefore, that the primary planar surface 12 is generally flat in nature, and may, in some exemplary embodiments of the invention, comprise a textured surface for frictional engagement with tyres and/or wheels. In some cases, it may be suitable for the primary surface 12 to comprise markings or symbols thereon, for example an “H” symbol to indicate to a helicopter pilot that the surface is suitable to land on for their helicopter. The exact composition and appearance of the primary surface 12 is not limited in the present invention, and it will be clear to a person skilled in the art that a number of suitable coverings may be used for different purposes.

At one end of the primary surface 12, is a male connector end 14. The male connector end 14 comprises a first wall 15 which extends away from the edge of the primary surface 12. Protruding from the first wall 15 there is a flange 16 which extends from underneath the primary surface 12 and curves in an upward fashion (i.e. toward the primary surface 12). The flange 16 is therefore generally hook-shaped. More specifically, the flange 16 comprises a first part which is generally parallel to the primary surface 12, and a second part which is generally parallel to the first wall 15, wherein the first and second parts are joined by a bend. The upper-most point of the flange 16 (i.e. uppermost when oriented for use as a temporary trackway surface) terminates short of the plane of the primary surface 12. The difference in height between the top of the primary surface 12 and the point of the flange 16 is approximately equal to the thickness of the primary surface.

At an opposing end of the primary surface 12 there is provided a female connector end 18. The female connector end comprises a second wall 19 which extends away from the edge of the primary surface 12, in the same direction as the wall 15 at the opposing edge of the primary surface 12. The second wall 19 comprises a lip 20 which extends in a direction parallel to the primary surface 12 at the end of the lip 20. Near the primary surface 12, a hooked portion 22 protrudes from the second wall 19. The hooked portion 22 is oriented such that the“point” of the hooked portion 22 is directed toward the lip 20. The hooked portion 22 defines a recess 24. The recess 24 is shaped and configured to receive at least a portion of the flange 16 of another structural surface enhancing panel

10.

As discussed above, the primary surface 12 comprises a flat surface on one side for use as a temporary surface. On the opposing side, between the male end 14 and the female end 18, there is a fluted surface, comprising a plurality of alternating peaks 26 and troughs 28. The peaks 26 and troughs 28 are aligned in a direction generally parallel to the male and female connector ends 14, 18 of the primary surface 12. In the exemplary embodiment shown in the drawings, three pairs of peaks and troughs 26, 28 are shown, however it will be clear to those skilled in the art that any suitable number of peaks and troughs 26, 28 may be provided, and the invention is not necessarily intended to be limited in this regard.

Each peak 26 comprises a flattened crest 30, which is parallel to the primary surface. The peaks 26 also each comprise a pair of angled side walls 32, 34. The side wall 32 of each peak closest to the male connector end 14 is parallel with the first wall 15, second wall 19 and the second part of the flange 16, all of which form a first angle Q with the primary surface 12. The opposing side wall 34 of each peak forms a second angle f with the primary surface 12. f may be defined as approximately f=-q wherein a positive angle is measure in a clockwise direction and a negative angle is measure in an anticlockwise direction. The side walls 32, 34 of each peak 26 are also the side walls 32, 34 of each trough 28. Each trough 28 comprises a flattened bed 31 , equal in length to the flattened crest 30 of each peak 26. Therefore, the peaks 26, and troughs 28 are substantially equal in height and length. The sidewalls 32, 34 are angled such that the widest part of each peak 26 is at its base, and the widest part of each trough 28 is at its mouth.

As such, each peak 26, and subsequently each trough 28, comprises a generally trapezoidal shape, having a flattened crest 30 or bed 31. Each peak, and the generally trapezoidal portion defined thereby, may be described as a cell. In one exemplary embodiment of the invention, the peaks 26 and troughs 28 are uniform in a first direction, and continue along the width of the panel 10 in order to define a plurality of ridges and channels thereon.

Near the male connector end 14, there is provided a cavity 36 between the first wall 15 and the peak 26 closest thereto. The cavity 36 is equal in width to the lip 20 of the female connector portion 18. The cavity 36 is equal in depth to the height of the second wall 19 of the female connector portion 18. More specifically, the cavity 36 is shaped and configured to be equal to the shape of the female connector end 18. Referring now to Figure 2 of the drawings, a pair of structural surface enhancing panels 10a, 10b are illustrated, configured for storage. The structural surface enhancing panels 10a, 10b are oriented inversely relative to one another, such that the fluted surfaces are adjacent. It is important that the peaks 26a, 26b and troughs 28a, 28b of the respective panels 10a, 10b are dimensionally similar. This is to allow the peaks 26a of a first panel 10a to fit within the troughs 28b of a second panel, and vice versa. It is preferable that the peaks 26a, 26b are dimensionally slightly smaller than the troughs 28a, 28b, to allow for clearance. This is simpler for manufacturing purposes, and ensures a flush fit between the two structural surface enhancing panels 10a, 10b when in the configuration illustrated in Figure 2 of the drawings.

Therefore, in order to ensure this is the case, in the given exemplary embodiment illustrated in the drawings and described herein, each peak 26a, 26b is dimensionally similar to each other peak 26a, 26b, and each trough 28a, 28b is dimensionally similar to each other trough 28a, 28b. The second wall 19a and lip 20a of the female connector end 18a of the first panel 10a, fit within the cavity 36b near the male connector end 14b of the second panel 10b, and vice versa. Therefore the outermost features of the stacked panels 10a, 10b are their respective flanges 16a, 16b. This dimensional similarity of the peaks 26a, 26b and troughs 28a, 28b, and also the parallel walls 15, 16, 19, 32 means that a first structural surface enhancing panel 10a can be flipped such that it is inverted relative to a second structural surface enhancing panel 10b, and subsequently placed adjacent a second panel 10b, and the structural surface enhancing panels 10a, 10b nest together, without adding significantly to the overall height of the single panel 10. In this respect, when nested, the peaks extend fully into the opposing troughs such that uppermost portion or crest 30 of the peak contacts a lowermost portion or bed 31 of the opposing trough. Moreover, when arranged in the nested configuration, the outer surface of the peaks contact the inner surface of the respective trough substantially along the entire interface therebetween. The nesting of the structural surface enhancing panels in this manner adds only the height of the thickness of a single primary surface 12 to the overall height of a single panel.

This unique configuration means that the panels 10 can be stacked on top of one another whilst taking up approximately 50% to 55% of the height than if the panels had been stacked as is known in the art, by placing one panel directly on top of another. During transit, a plurality of panel pairs 10a, 10b may be stacked on top of one another, because the primary surfaces 12a, 12b are outwardly facing. The overall size of the structural surface enhancing panels 10a, 10b may be such that they can be loaded into a standard ISO container (any length) through the door sideways. Therefore, there is no requirement for specialist containers to be provided, as with known temporary surfacing technologies. Specialist container costs are therefore avoided with the present invention. The weight and dimensions of the panels 10 allow standard bundles to be created which maximise the weight and space capacities of air, sea, rail and land transport systems. The space to mass constraint ratio is therefore optimised in the present invention. This reducing the number of transport cycles required in order to move the panels from their storage location to their required location. The following table gives the ratios of the number of transport cycles required for each mode of transport for the panels of the present invention, against existing prior art panels:

These ratios were calculated by the Applicant conducting tests comparing exemplary embodiments of the present invention against known prior art structural surface enhancing panels using standard air, sea, rail and land containers.

Referring to Figures 3A and 3B of the drawings, when not configured for transport, as shown in Figure 2 of the drawings, the panels may be laid out in side-by-side relation. The male connector end 14 of one panel 10 may be removably received within the female connector end 18 of another panel 10, wherein both panels 10 are oriented the same way, such that the primary surfaces 12 are facing upwardly (or indeed, downwardly, as required). More specifically, a structural surface enhancing panel 10 is angled relative to a structural surface enhancing panel 10 already positioned for use as a temporary trackway. The male connector end 14 is inserted such that the flange 16 is removably received within the recess 24 of the female connector end 18 of the structural surface enhancing panel 10. The new panel 10 is pushed downwardly toward the ground in the direction of arrow A in Figure 3A. This pushes the flange 16 to be fully received within the recess 24. The trackway is therefore extended by the addition of a further panel 10. A multitude of panels 10 may be connected together in this way to create a modular temporary trackway suitable for aircraft landing, HGV traverse, and similar purposes as will be known in the art. To separate structural surface enhancing panels 10, the user simply lifts the outermost panel edge to disengage the flange 16 from the adjacent panels recess 24.

The angles of the sidewalls 32, 34 of the peaks 26, and the thickness of the peaks 26, mean that the surface is structurally integral enough to withstand the weight of such vehicles. Referring now to Figure 4 of the drawings, exact dimensions of one structural surface enhancing panel indicated generally at 100 according to one exemplary embodiment is illustrated.

In this particular exemplary embodiment, the total length of the structural surface enhancing panel 10 from the tip of the flange 160 to the end of the lip 200 is 284.24mm. The structural surface enhancing panels 100 may be as wide as is required by the use, but preferably are approximately 2.5 to 3.5 metres. The total depth, or thickness, of the structural surface enhancing panel 100 is 22.5 mm.

The length of the primary surface 120 is 270.39mm, and the thickness of the primary surface 120 is 4.21 mm. The major angle, Q, made between the side wall 320 and the primary surface 120 is given as 120°. This is also the major angle, f, made between the side wall 340 and the primary surface. Therefore, in this particular exemplary embodiment the angles Q and f are equal in magnitude. The minor angles correspond to the angles inside each peak and may be calculated by subtracting the corresponding major angle from 180°. Therefore in this case, the minor angles are 60°. The thickness of the sidewalls 320, 340 is 3.00mm.

The ‘height’ of each peak 260, from the lower surface of the primary surface 120 to the lower surface of the crest 300 of each peak is given to be 19.5mm. The thickness of the crest is exactly 3mm, therefore the height of each peak 260 from the lower surface of the primary surface 120 to the upper surface of the crest 300 is 16.5mm. Each crest 300 has a length of 26.46mm, and is spaced apart from adjacent crests by a distance of 50.52mm.

The base of each peak has a width of 42.05mm. The bed 310 of each trough 280 is 28mm. The length of the lip 200 is 1 1.5mm and the length of the cavity 360 is 17mm exactly. It will be apparent to those skilled in the art that these dimensions are very precise and may be varied, provided that the ratios of the measurements are kept the same in order to provide the same structural support.

Due to the angle of the sidewalls 320, 340, the structure is able to support weight much greater than if the angles were different. The structural surface enhancing panel 100 provides one exemplary embodiment of the present invention, however other suitable angles of Q and f may be provided. For example they may be equal to any angle within the range 90 °- 160°, including (but not limited to): 90°, 95°, 100°, 105°, 1 10°, 1 15°, 120°, 125°, 130°, 135°, 140°, 145°,

150°, 155° and 160°. Referring to any of the drawings, the panels 10 may be formed of a single piece of extruded plastic or metal. Preferably the structural surface enhancing panel will be constructed from aluminium. Aluminium provides a number of advantages over other materials, being easily malleable, lightweight and strong, whilst also being easily recycled. Alternatively, each structural surface enhancing panel 10 may be formed of a plurality of pieces bolted or otherwise secured together. It will be clear to the person skilled in the art that the invention is not necessarily limited in this regard.

It will be understood by those skilled in the art that the orientation of the structural surface enhancing panels when configured for use as a temporary surface is not limited to the orientation described above and in the appended drawings. Alternatively embodiments may provide the primary flat surface 12 face down against the ground when putting together a temporary surface. Therefore, in the alternative embodiment, the fluted surface would provide the surface on which aircraft and other vehicles traverse and/or land. This embodiment may provide specific advantages such as providing further grip, and preventing the structural surface enhancing panels from sinking into the ground by having a greater surface area adjacent to the ground.

It will be clear to those skilled in the art that modifications and variations to the above-described embodiments of the present invention may be made without departing from the scope of invention as defined by the appended claims.