Erosion Control Mat with Embedded Mesh and Paste Blocks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for more efficient and cost-effective methods to form flexible erosion prevention mats that can retain soil in areas susceptible to erosion until vegetation can mature and prevent surface soil erosion, as existing solutions like concrete mats are complex and costly.
Innovation Solution
A process and system utilizing a sheet of flexible, mesh material embedded in hardened paste blocks, where the mesh material provides sufficient tensile strength to connect the blocks without additional structures, using a cylindrical drum with mold cavities to form the blocks and embed the mesh material during the hardening process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional concrete panels or blocks with open mesh polymeric material are used, then erosion control effectiveness is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the mesh material and concrete blocks into a single integrated forming process. The mesh is embedded within the concrete matrix during casting, creating a unified structure where the mesh and concrete work together as one component rather than separate assembled parts. This merging eliminates the need for separate mesh attachment steps and reduces manufacturing complexity while maintaining erosion control effectiveness.
Solution Approach 2:
The mesh material serves multiple functions simultaneously: it provides structural reinforcement within the concrete blocks, creates interconnection between blocks, and forms the flexible mat structure. This multi-functionality eliminates the need for additional connecting structures or separate reinforcement elements, simplifying the overall manufacturing process while ensuring reliable erosion control.
2Strength
If additional connecting structures are used to join blocks, then structural integrity is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The connection function is merged into the mesh material itself, which is embedded within the concrete blocks. The mesh continues through multiple blocks, creating inherent connections without requiring separate joining mechanisms. This integration maintains structural integrity while eliminating the complexity of additional connecting structures.
Solution Approach 2:
The mesh material inherently provides the connection function as it is embedded in the blocks during casting. The same mesh that reinforces the individual blocks also automatically connects them together, making the system self-sufficient without requiring separate connection components or assembly steps.
3Ease of operation
If flexible mat structures with embedded mesh are used, then ease of deployment is improved, but manufacturing process complexity increases
Solution Approach 1:
The forming process merges multiple operations into a single casting step: the mesh is positioned, concrete is poured, and blocks are formed simultaneously. This integrated approach creates the flexible mat structure with embedded mesh in one continuous process, reducing manufacturing complexity while ensuring the ease of deployment characteristics are built into the final product.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution simplifies the manufacturing process, reduces costs, and effectively forms a continuous erosion control mat that can be easily deployed to prevent soil erosion, with the mesh material ensuring the blocks are securely interconnected and able to withstand environmental factors.
Implementation Method 1
the flowable paste hardens into dimensionally stable blocks in the mold cavities
Implementation Method 2
at least a portion of the sheet becomes embedded in the paste
Data Source
AI summary
A process for making an erosion control mat includes rotating a cylindrical drum having a plurality of mold cavities; depositing a paste into the mold cavities; selecting the sheet of mesh material to have sufficient tensile strength to join the blocks of hardened paste together without tearing or separating from the blocks of hardened paste, and to have sufficient density to retain the paste within the mold cavities as the drum rotates; covering an outer surface of the cylindrical drum and outer surfaces of the paste with the sheet of mesh material; continuing to rotate the cylindrical drum as the paste hardens into dimensionally stable blocks, and holding the sheet against the outer surface such that the sheet retains the paste within the mold cavities and the sheet becomes embedded in the paste; and separating the dimensionally stable blocks from the mold cavities.