Reinforced nonwoven material and method of use for landscaping

• US 10,513,809 B2
• Filed: 10/02/2017
• Issued: 12/24/2019
• Est. Priority Date: 06/14/2017
• Status: Active Grant

• Current Assignee: Novum Microfiber Corp.
• Original Assignee: Novum Microfiber Corp.
• Inventors: Shokar, Bobby
• Primary Examiner(s): Tucker, Philip C
• Assistant Examiner(s): Wu, Vicki
• Application Number:
  US15/722,557
• Publication Number:
  US 20180363180A1
• Time in Patent Office: 813 Days
• Field of Search: 156242
• CPC Class Codes: A01G 13/0268 Mats or sheets, e.g. nets or fabrics A01G13/0281 takes precedence
• CPC Class Codes: A01G 13/0293 Anchoring means for ground coverings
• CPC Class Codes: A47C 31/04 Clamps for attaching flat elastic strips or flat meandering springs to frames
• CPC Class Codes: A47C 31/10 Loose or removable furniture covers
• CPC Class Codes: B29C 59/04 using rollers or endless belts
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2250/20 All layers being fibrous or filamentary
• CPC Class Codes: B32B 2262/0246 Acrylic resin fibres
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2305/38 Meshes, lattices or nets
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/5825 Tear resistant
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2307/72 Density
• CPC Class Codes: B32B 2307/726 Permeability to liquids, absorption
• CPC Class Codes: B32B 2601/00 Upholstery
• CPC Class Codes: B32B 27/18 characterised by the use of special additives
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 3/08 characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/06 : characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 7/05 : the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection using interposed adhesives or bonding materials applied in spaced arrangements B32B7/14
• CPC Class Codes: D04H 1/4374 : using different kinds of webs, e.g. by layering webs
• CPC Class Codes: D10B 2321/021 : polyethylene
• CPC Class Codes: D10B 2321/022 : polypropylene
• CPC Class Codes: D10B 2505/08 : Upholstery, mattresses

Abstract

A novel nonwoven material for use as underlayment in landscaping is disclosed. The inventive method comprises creating a layered nonwoven material, identifying a landscaping location for receiving a portion of said layered nonwoven material; preparing a landscaping location; placing a portion of said layered nonwoven material on said landscaping location. The method may further comprise measuring a portion of said landscaping location; measuring a portion of said layered nonwoven material; comprise cutting one or more desired shapes from a portion of said layered nonwoven material; and securing a portion of said layered nonwoven material to said landscaping location by pushing one or more landscaping pins through said layered nonwoven material and into a portion of ground underneath said layered nonwoven material.

Claims

1. A method for utilizing a nonwoven material comprising

a) creating a layered nonwoven material, comprising the steps

i) creating a material mixture;

wherein creating comprises the steps of

(1) adding eighty-five percent by weight of polypropylene;

(2) adding ten percent by weight of polyethylene;

(3) adding three percent by weight of ethylene methyl acrylate;

(4) adding two percent by weight of a UV stabilizer;

ii) melting said material mixture;

iii) extruding said material mixture;

iv) creating a first layer of nonwoven material formed from said material mixture after said material mixture is heated and extruded;

v) placing a layer of woven mesh on top of said first layer;

vi) depositing a second layer of nonwoven material formed from said material mixture, after said material mixture is heated and extruded, on top of said layer of woven mesh such that said layer of woven mesh is disposed between said first layer of nonwoven material and said second layer of nonwoven material;

b) calendaring said layered nonwoven material;

c) identifying a landscaping location for receiving a portion of said layered nonwoven material;

d) preparing said landscaping location after identifying said landscaping location; and

e) placing a portion of said layered nonwoven material on said landscaping location.

2. The method as in claim 1 further comprising

a) measuring a portion of said landscaping location;

and

b) measuring a portion of said layered nonwoven material.

3. The method as in claim 1 further comprising cutting one or more desired shapes from a portion of said layered nonwoven material.

4. The method as in claim 1 further comprising securing a portion of said layered nonwoven material to said landscaping location by pushing one or more landscaping pins through said layered nonwoven material and into a portion of ground underneath said layered nonwoven material.

5. The method as in claim 1 further comprising placing a portion of soil, a portion of sod, or one or more rocks on top of said layered nonwoven material.

6. The method as in claim 1 wherein said step of preparing said landscape location is selected from a group consisting of:

scraping a section of topsoil, digging a hole in a portion of ground, removing a portion of soil from said landscaping location, and raking a portion of soil or infill.

7. The method as in claim 1 further comprising

a) placing a portion of soil on top of said layered nonwoven material;

b) placing one or more seeds into said portion of soil disposed on top of said layered nonwoven material; and

c) watering said portion of soil disposed on top of said layered nonwoven material.

8. The method as in claim 1 further comprising

a) heating a portion of said layered nonwoven material;

b) stretching a portion of said layered nonwoven material over a mold.

9. The method as in claim 1 further comprising placing an embossing pattern on a top surface of said layered nonwoven material with an embossing roll.

10. The method as in claim 1 further comprising

a) testing a plurality of physical properties of a portion of said layered nonwoven material;

b) verifying that each of said plurality of physical properties are within a variance of ten percent of a set of values

i) wherein said set of values comprise

(1) a density of 0.9 grams per cubic centimeter;

(2) a product weight of 55 grams per square meter;

(3) a machine direction tensile strength of 41 pounds;

(4) a cross direction tensile strength of 33 pounds;

(5) a machine direction elongation of 65%;

(6) a cross direction elongation of 75%;

(7) a machine direction trapezoid tear of 14 pounds;

(8) a cross direction trapezoid tear of 14 pounds;

(9) a water permeability of 52 liters per square meter per second; and

(10) a permittivity of 1.04 per second.

11. The method as in claim 1 further comprising

a) testing a plurality of physical properties of a portion of said layered nonwoven material;

b) verifying that each of said plurality of physical properties are within a variance of ten percent of a set of values

i) wherein said set of values comprise

(1) a density of 0.9 grams per cubic centimeter;

(2) a product weight of 85 grams per square meter;

(3) a machine direction tensile strength of 72 pounds;

(4) a cross direction tensile strength of 51 pounds;

(5) a machine direction elongation of 65%;

(6) a cross direction elongation of 75%;

(7) a machine direction trapezoid tear of 17 pounds;

(8) a cross direction trapezoid tear of 22 pounds;

(9) a water permeability of at least 40 liters per square meter per second; and

(10) a permittivity of 0.8 per second.

12. The method as in claim 10 further comprising

a) measuring a portion of said landscaping location;

b) measuring a portion of said layered nonwoven material;

c) cutting one or more desired shapes from a portion of said layered nonwoven material;

d) securing a portion of said layered nonwoven material to said landscaping location by pushing one or more landscaping pins through said layered nonwoven material and into a portion of ground underneath said layered nonwoven material; and

e) placing a portion of soil, a portion of sod, or one or more rocks on top of said layered nonwoven material.

13. The method as in claim 12 wherein a step of preparing a landscape location is selected from a group consisting of:

scraping a section of topsoil, digging a hole in a portion of ground, removing a portion of soil from a landscaping location, and raking a portion of soil or infill.

14. The method as in claim 13 further comprising placing an embossing pattern on a top surface of said layered nonwoven material with an embossing roll.

15. The method as in claim 14 further comprising

a) heating a portion of said layered nonwoven material;

and

b) stretching a portion of said layered nonwoven material over a mold.

16. The method as in claim 11 further comprising

a) measuring a portion of said landscaping location;

b) measuring a portion of said layered nonwoven material;

c) cutting one or more desired shapes from a portion of said layered nonwoven material;

d) securing a portion of said layered nonwoven material to said landscaping location by pushing one or more landscaping pins through said layered nonwoven material and into a portion of ground underneath said layered nonwoven material; and

e) placing a portion of soil, a portion of sod, or one or more rocks on top of said layered nonwoven material.

17. The method as in claim 16 wherein a step of preparing a landscape location is selected from a group consisting of:

scraping a section of topsoil, digging a hole in a portion of ground, removing a portion of soil from a landscaping location, and raking a portion of soil or infill.

18. The method as in claim 17 further comprising placing an embossing pattern on a top surface of said layered nonwoven material with an embossing roll.

19. The method as in claim 18 further comprising

a) heating a portion of said layered nonwoven material;

and

b) stretching a portion of said layered nonwoven material over a mold.