Three-Dimensional Turf Reinforcement Mat Weave

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Solution Overview

Problem

Traditional turf reinforcement mats (TRMs) require heat treatment to achieve the necessary loft, which increases production costs and causes fiber shrinkage, and often have inadequate compression resistance due to single fibers at peak and valley points in the weave pattern.

Innovation Solution

A three-dimensional turf-reinforcement fabric is created without heat treatment by using a specific weave pattern and tension in the manufacturing process, incorporating fibers of varying heights to achieve a loft thickness of at least 0.25 inches, and incorporating features like increased diameter fibers at crests for enhanced compression resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If heat treatment is applied to achieve necessary loft, then loft thickness is improved, but production cost increases and fiber shrinkage occurs

Engineering Contradiction:

Improveloft thicknessVSAvoidproduction cost

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The patent replaces the thermal field (heat treatment) with a mechanical field (controlled tension during weaving). By applying specific tension forces during the weaving process, the fabric achieves the desired loft thickness without requiring heat treatment, thereby reducing production costs and avoiding fiber shrinkage while maintaining the necessary three-dimensional structure for turf reinforcement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Shape

If heat treatment is applied to achieve necessary loft, then loft thickness is improved, but fiber length is reduced due to shrinkage

Engineering Contradiction:

Improveloft thicknessVSAvoidfiber length

Core Design Contradiction:

ShapeVSLength of moving object

Solution Approach 1:

The patent substitutes thermal processing with mechanical tension control during weaving. This approach achieves loft thickness without the fiber shrinkage caused by heat treatment, thereby preserving fiber length and maintaining the structural integrity and durability of the turf reinforcement mat.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If single fibers are used at peak and valley points in the weave pattern, then manufacturing simplicity is maintained, but compression resistance is inadequate

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidcompression resistance

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent applies local quality by incorporating multi-filament fibers specifically at the peak and valley points of the weave pattern, while maintaining simpler single-fiber construction elsewhere. This localized enhancement provides improved compression resistance at critical stress points without significantly complicating the overall manufacturing process.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses composite fiber structures (multi-filament fibers) at specific locations within the weave pattern to enhance compression resistance. These composite fibers combine multiple filaments to create a stronger, more durable structure at peak and valley points while maintaining the overall simplicity of the weaving process.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS9243356B2Method for manufacturing a turf reinforcement mat

Publication Date: 2016.01.26 LUMITE

AI summary

A turf reinforcement fabric and a method for producing such a fabric by weaving a plurality of filaments in a predetermined pattern to form a three-dimensional structure formed to have a loft thickness without requiring the application of heat to heat shrink the fibers, and/or formed with one or more fibers of increased thickness at peaks and valleys of the woven structure, and/or incorporating flame retardant and/or UV stabilizing fiber additives.