Pull Mat Composite Structure for Tunnel Composting
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Solution Overview
Problem
Existing pull mats for tunnel composting lack sufficient resistance against elongation and rupture while maintaining high air permeability, which hampers the efficient removal of compostable materials and can lead to material loss and reduced composting efficiency.
Innovation Solution
A pull mat comprising a layer of straight, unidirectionally oriented threads combined with an open material layer, such as woven fabric, nonwoven fabric, or perforated film, to enhance tensile strength and air permeability, with the open material positioned on either side of the thread layer to minimize friction and prevent material loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional woven fabric pull mat is used, then air permeability is maintained, but tensile strength and resistance against elongation and rupture are insufficient
Solution Approach 1:
The patent applies composite materials by combining a geotextile layer (providing tensile strength and rupture resistance) with an open material layer (providing air permeability). This composite structure allows the pull mat to simultaneously achieve high mechanical strength and high air permeability, resolving the contradiction between strength and reliability.
Solution Approach 2:
The pull mat is divided into two distinct functional layers: a geotextile layer for mechanical strength and an open material layer for air permeability. This segmentation allows each layer to optimize its specific function without compromising the other, enabling the overall structure to meet both strength and air permeability requirements.
2Strength
If the pull mat structure is made denser to increase strength, then resistance against rupture improves, but air permeability decreases
Solution Approach 1:
The pull mat is segmented into two layers with distinct functions: the geotextile layer provides rupture resistance through its dense, strong structure, while the open material layer maintains high air permeability through its open, porous structure. This segmentation allows each layer to be optimized for its specific function without compromising the other.
Solution Approach 2:
The composite structure combines a geotextile material (dense, strong) with an open material (porous, air-permeable). The geotextile layer handles mechanical strength requirements while the open material layer handles air permeability requirements, allowing the pull mat to achieve both high rupture resistance and high air permeability simultaneously.
3Device complexity
If direct contact between pull mat and grid is used, then structural simplicity is maintained, but friction increases and material loss occurs
Solution Approach 1:
The patent introduces a gliding mat as an intermediary layer between the pull mat and the grid. This gliding mat reduces friction and prevents direct contact between the pull mat and grid, thereby reducing material loss. The intermediary layer absorbs the harmful friction effect while maintaining the simplicity of the overall system.
Data Source
AI summary
A pull mat for tunnel composting includes: a layer of straight unidirectionally oriented threads oriented in the longitudinal direction of the pull mat, the layer including a multitude of straight individual threads which are placed essentially parallel to each other in a single plane, the straight unidirectionally oriented threads being spaced apart from each other, at least one layer of open material, the at least one layer of open material being selected from a woven fabric, a laid scrim, a nonwoven fabric, and a perforated film, and optionally, a further layer of open material, wherein when the optional further layer of open material is present, the at least one layer of open material and the further layer of open material are positioned on opposite sides of the layer of straight, unidirectionally oriented threads.