Rotating Drum Mat Forming System with Embedded Mesh
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Solution Overview
Problem
Existing methods for forming flexible erosion control mats, such as those described in US Patent No. 6,793,858, are effective but lack efficiency in manufacturing processes, particularly in embedding open mesh structures within concrete blocks to create a sturdy and drivable surface for erosion control in areas like airport runways and waterways.
Innovation Solution
A system and method involving a rotating drum with mold cavities for casting cement blocks, embedding an open mesh sheet within the cement paste, and using a flexible sheet to retain the mesh as the cement hardens, forming a tied block mat that can be used as a drivable erosion control surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the open mesh structure is embedded in concrete blocks using traditional methods, then the erosion control function is achieved, but the manufacturing efficiency is low and the process is complex
Solution Approach 1:
The patent combines multiple operations into a single integrated forming process. The open mesh structure, concrete blocks, and tying elements are all embedded and connected in one continuous operation within the mold cavities, eliminating separate steps for mesh placement, concrete pouring, and tying. This merging of operations directly improves manufacturing efficiency while reducing process complexity.
Solution Approach 2:
The open mesh structure is pre-positioned within the mold cavities before concrete is poured. This preliminary placement ensures proper alignment and integration of the mesh with the concrete blocks and tying elements, streamlining the subsequent forming process and improving overall manufacturing efficiency without requiring complex post-processing steps.
2Manufacturing precision
If a flexible sheet is added to retain the open mesh during hardening, then the embedding quality improves, but the device complexity increases
Solution Approach 1:
A flexible sheet is used as a retaining element within the mold cavity to hold the open mesh structure in place during concrete pouring and hardening. This thin film component provides the necessary support to ensure proper embedding quality without adding significant complexity to the overall system, as the sheet is a simple, easily replaceable element.
Solution Approach 2:
The flexible retaining sheet is designed as a consumable component that remains within the concrete block after hardening. This disposable element serves its purpose during the forming process and becomes part of the final product structure, eliminating the need for complex reusable retaining mechanisms.
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 system enhances the quality and efficiency of flexible mat production, enabling the creation of sturdy tied block mats suitable for erosion control on various surfaces, including sloped areas, with improved manufacturing efficiency and reduced waste.
Implementation Method 1
a hardenable paste deposited in the mold cavities; a sheet of the open mesh that is fed over the mold cavities so that the mesh is embedded in the hardenable paste deposited in the mold cavities
Data Source
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AI summary
In an exemplary embodiment, a system (300) for forming a flexible mat (74) having an open mesh (358) embedded in and interconnecting a plurality of blocks (76) of a hardened paste includes a rotating drum (314) having a plurality of mold cavities (324) about an outer periphery thereof that receive a hardenable paste (25); a sheet of the open mesh that is fed over the mold cavities so that the mesh is embedded in the hardenable paste deposited in the mold cavities; and a flexible sheet (302) that is placed against the outer periphery of the drum over the mold cavities containing the hardenable paste and the sheet of open mesh of the rotating drum to retain the hardenable paste within the mold cavities and retain the open mesh embedded in the hardenable paste as the hardenable paste solidifies to form the flexible mat.