Static Resistant Synthetic Interconnectable Structural Mat
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Solution Overview
Problem
The oil and gas drilling industry faces challenges with static charge buildup on drilling rig surfaces, which can lead to safety hazards and equipment issues, and existing solutions have a high carbon footprint and require complex assembly processes.
Innovation Solution
A static-resistant synthetic inter-connectable structural mat made from recycled materials, such as post-consumer waste, that can support heavy loads without deformation and reduce static charge buildup, featuring a three-layered design with antistatic particles and a slip-resistant coating, allowing for easy interconnection without fasteners or adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional mats made from new plastics and rubbers are used, then structural strength and load support are achieved, but carbon footprint and environmental impact increase
Solution Approach 1:
The patent utilizes post-consumer waste materials including recycled plastics and rubber tires to manufacture the mat system. This recovers valuable materials from waste streams, reducing the need for virgin plastic and rubber production, thereby lowering carbon footprint while maintaining structural integrity required for supporting drilling rig loads up to 20 tons
Solution Approach 2:
The mat system employs composite construction combining recycled plastic particles, rubber tire particles, and bonding agents to create a unified structural material. This composite approach leverages the strength properties of both plastics and rubbers while utilizing post-consumer waste, achieving load-bearing capacity with reduced environmental impact
2Reliability
If static charge dissipation features are added to the mat, then safety hazards from static buildup are reduced, but mat complexity increases
Solution Approach 1:
The patent incorporates static charge dissipation granules specifically at the interface between the mat and drilling rig equipment. This localized application of conductive material addresses static buildup at the critical contact point without requiring complex modifications throughout the entire mat structure, maintaining simplicity while improving safety
Solution Approach 2:
The mat system modifies the electrical conductivity parameter of the mat surface by incorporating conductive granules and antistatic additives. This changes the electrostatic properties of the mat material, enabling static charge dissipation while maintaining the overall simplicity of the mat design through material composition rather than structural complexity
3Ease of operation
If modular interconnectable mat design is used, then ease of assembly and transportation is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the mat system into modular interconnected sections that can be easily transported and assembled on-site. Each module contains integrated connection features allowing rapid assembly without fasteners or adhesives. While this segmentation increases manufacturing steps, it enables standardized production of individual modules that simplify field installation and reduce transportation requirements
4Strength
If heavy load support capability is achieved, then drilling rig stability is improved, but mat weight increases
Solution Approach 1:
The patent varies the material composition and density of different mat layers to optimize load distribution. The top layer contacting equipment uses materials optimized for load bearing, while lower layers may use lighter materials for stability. This localized optimization achieves required load support capacity while minimizing overall mat weight through strategic material placement
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 mat effectively reduces static charge buildup, enhances safety, supports heavy equipment, and has a lower environmental impact while simplifying assembly and transportation, reducing labor costs and the need for special permits.
Implementation Method 1
static charge dissipation granules embedded in the first bottom layer structural board
Implementation Method 2
slip-resistant coating on the top layer
Data Source
AI summary
A drilling rig with static resistant synthetic inter-connectable structural mat assembly. The assembly has a plurality of static resistant mats, wherein each mat engages another mat without tools or fasteners and each mat has a top layer, a middle layer, a bottom layer, a static charge conduction conduit through the mats, and an optional non-skid coating partially embedded in the mats to support drilling rigs. The mats are made from 100 percent recycled rust proof, non-absorbing post-consumer waste materials.