Tri-Layer Synthetic Oil Field Mat Design
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Solution Overview
Problem
There is a need for a synthetic, easy-to-install and remove, durable oil field mat that can withstand extreme temperatures, resist oil contaminants, ensure personnel safety, maintain shape under torque, weight, and movement, and provide a slip-resistant surface, while also protecting rig containment materials from machinery.
Innovation Solution
A tri-layer oil field support mat made from synthetic boards, using a central coupler and half couplers with parallel and beveled boards, interconnected with fasteners and connectors to prevent movement and maintain shape, and incorporating antistatic carbon black for non-slip properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional materials are used for oil field mats, then the mats can be easily manufactured, but they absorb oil field contaminants and lose durability under extreme temperatures
Solution Approach 1:
The patent uses a tri-layer composite structure with bottom layer (4-8 inch thick synthetic boards), middle layer (2-4 inch thick synthetic boards perpendicular to bottom layer), and top layer (synthetic boards parallel to bottom layer). This composite construction provides thermal resistance, structural stability, and contaminant resistance while maintaining manufacturability through modular assembly.
Solution Approach 2:
The patent changes the material parameter from traditional wood or metal to synthetic boards with specific thermal and chemical resistance properties. The synthetic material composition is selected to withstand extreme temperatures and resist oil field contaminants, fundamentally changing the material parameters to achieve the desired reliability.
2Stability of the object's composition
If the mat is made from a single layer, then the assembly is simple, but it cannot maintain shape under torque, weight, and movement
Solution Approach 1:
The mat is segmented into three distinct layers with different orientations and functions. The bottom layer provides base support, the middle layer (perpendicular orientation) provides structural reinforcement and shape maintenance, and the top layer provides a stable working surface. This segmentation allows each layer to specialize in maintaining shape under specific types of loads.
Solution Approach 2:
The middle layer is oriented perpendicular to the bottom and top layers, adding a dimensional aspect to the structure. This perpendicular orientation creates a three-dimensional lattice structure that resists deformation from multiple directions, maintaining shape under torque, weight, and movement while keeping the assembly method straightforward.
3Ease of operation
If the surface is made smooth for easy cleaning, then maintenance is simple, but personnel safety is compromised due to slip hazards
Solution Approach 1:
The top layer is made from synthetic boards with specific surface properties that provide slip resistance through texture or material characteristics, while the bottom and middle layers maintain smoother surfaces for structural integrity and ease of assembly. This local differentiation of surface quality addresses both safety and maintenance requirements.
4Productivity
If the mat uses traditional fastening methods with pins and mechanical connectors, then the assembly is secure, but installation and removal become time-consuming
Solution Approach 1:
The patent replaces traditional mechanical fastening systems (pins, bolts, connectors) with a friction-based or interlocking system where the layers are secured through their structural design alone. The perpendicular orientation of the middle layer and the weight distribution create inherent stability without requiring additional mechanical fasteners, enabling rapid installation and removal while maintaining assembly security.
Data Source
AI summary
A method making an oil field mat from a plurality of synthetic board to create a tri-layer oil field mat usable to support trucks, equipment, and personnel around a derrick, or a Christmas tree having central couplers and end caps.