Articulating Composite Surface Mat for Uneven Slopes
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Solution Overview
Problem
Conventional surface covering mats for slopes are inflexible, difficult to install, and unable to articulate over uneven surfaces, posing challenges in terms of aesthetics, maintenance, and cost-effectiveness.
Innovation Solution
An articulating composite surface covering mat composed of multiple units with a natural or irregular appearance, formed of a filler with a flexible geogrid extending between and through the units, allowing for irregular gaps and S-curve geometry for flexible installation and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional rigid surface covering mats are used, then structural stability is improved, but flexibility and ability to articulate over uneven surfaces deteriorates
Solution Approach 1:
The mat is divided into multiple individual units (e.g., hexagonal cells) that are connected through the geogrid structure. Each unit can independently deform and articulate over uneven terrain while remaining structurally stable, resolving the contradiction between rigidity and flexibility.
Solution Approach 2:
The mat combines rigid filler materials (concrete, stone, brick) with a flexible geosynthetic geogrid to create a composite structure. This composite design allows the mat to maintain structural stability from the rigid units while gaining flexibility and articulation capability from the geogrid framework.
2Shape
If hand placed natural stone is used, then aesthetic appearance is improved, but installation time and cost deteriorates
Solution Approach 1:
The natural stone units are pre-assembled into complete mat structures with irregular gaps and S-curve geometry before delivery to the site. This preliminary assembly allows complex aesthetic patterns to be created in the factory, then rapidly installed as complete units on-site, dramatically reducing installation time while maintaining aesthetic quality.
Solution Approach 2:
The mat design replicates the appearance of hand-placed natural stone with irregular shapes, varying sizes, and natural gap patterns. This copying of natural aesthetics through manufactured units achieves the desired visual appearance without the time-consuming manual placement process.
3Productivity
If manufactured blocks are used, then installation speed is improved, but adaptability to slopes and uneven terrain deteriorates
Solution Approach 1:
The mat incorporates a flexible geogrid structure that allows the rigid manufactured units to dynamically adjust and articulate over slopes and uneven terrain. The geogrid acts as a flexible framework that enables the mat to conform to various ground conditions while maintaining the speed of mechanical installation.
4Reliability
If geogrid with gravel ballast is used, then slope protection is improved, but aesthetic appeal deteriorates
Solution Approach 1:
The mat uses irregular gaps between natural stone units that provide porosity and drainage capability similar to gravel ballast, while maintaining aesthetic appeal. The natural stone arrangement with varying gap sizes allows water infiltration and slope protection without the unsightly appearance of exposed gravel and geogrid.
Data Source
AI summary
An articulating composite surface covering mat and process of forming the mat are provided. The mat has multiple units having a regular, natural or irregular appearance, and each unit a flexible geogrid extending therethrough. A method of forming the mat includes forming the mat upside-down on a bottom surface of a bottom mold, placing the top mold over the bottom mold to form the mold assembly, locating a geogrid in the mold assembly, latching the mold assembly together with magnets, and adding the filler to the mold assembly.