Turf reinforcement mat having multi-dimensional fibers and method for erosion control

• US 20050020157A1
• Filed: 07/24/2003
• Published: 01/27/2005
• Est. Priority Date: 07/24/2003
• Status: Active Grant

• Current Assignee: Propex Operating Company LLC (Solmax International Incorporated)
• Original Assignee: Propex Operating Company LLC (Solmax International Incorporated)
• Inventors: Weaver, Patti, Sickler, Warren, Weiser, Sidney M.
• Granted Patent: US 7,820,560 B2
• Time in Patent Office: Days
• US Class Current: 442/49
• CPC Class Codes: B32B 2250/20 All layers being fibrous or filamentary
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2262/0261 Polyamide fibres
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/14 Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2305/08 Reinforcements
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/028 Net structure, e.g. spaced apart filaments bonded at the crossing points
• 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: D04H 1/4374 using different kinds of webs, e.g. by layering webs
• CPC Class Codes: D04H 1/43912 fibres with noncircular cross-sections
• CPC Class Codes: D04H 1/52 by applying or inserting filamentary binding elements
• CPC Class Codes: D04H 3/018 characterised by the shape
• CPC Class Codes: D04H 3/045 for net manufacturing
• CPC Class Codes: E02B 3/122 Flexible prefabricated covering elements, e.g. mats, strips
• CPC Class Codes: Y10T 442/153 Including an additional scrim layer
• CPC Class Codes: Y10T 442/159 Including a nonwoven fabric which is not a scrim
• CPC Class Codes: Y10T 442/183 Synthetic polymeric fiber
• CPC Class Codes: Y10T 442/609 Cross-sectional configuration of strand or fiber material is specified
• CPC Class Codes: Y10T 442/611 : Cross-sectional configuration of strand or fiber material is other than circular

Abstract

A turf reinforcement mat (10) comprises at least one polymer net layer (11); a non-woven mat (13) comprising a plurality of multi-dimensional polymer fibers (15); and, a polymer yarn (80, 81), stitching the net layer to the non-woven mat. A method for erosion control and revegetation facilitation comprises providing a turf reinforcement mat comprising at least one polymer net layer; a non-woven mat comprising a plurality of multi-dimensional polymer fibers; and, a polymer yarn, stitching the net layer to the non-woven mat; laying the turf reinforcement mat on a section of ground to be reinforced; securing the turf reinforcement mat to the ground; distributing soil and seed onto the turf reinforcement mat such that the section of ground is quickly revegetated and thereby protected from further erosion.

Claims

1. A turf reinforcement mat comprising:

at least one polymer net layer;

a non-woven mat comprising a plurality of multi-dimensional polymer fibers; and

,

a polymer yarn, stitching said net layer to said non-woven mat.

2. The turf reinforcement mat of claim 1, wherein said multi-dimensional polymer fiber has at least three edges and at least three channels.

3. The turf reinforcement mat of claim 1, wherein said multi-dimensional polymer fiber is selected from the group consisting of polyolefins, polyesters, polyamides and blends thereof.

4. The turf reinforcement mat of claim 1, wherein said multi-dimensional fibers have a length from about 2 inches (5 cm) to about 12 inches (30 cm).

5. The turf reinforcement mat of claim 1, wherein said multi-dimensional polymer fiber has a density of from about 300 denier (333 decitex) to about 2000 denier (2222 decitex).

6. The turf reinforcement mat of claim 5, wherein said multi-dimensional polymer fiber has a density of from about 500 denier (555 decitex) to about 1100 denier (1222 decitex).

7. The turf reinforcement mat of claim 1, wherein the polymer of set net layer is selected from the group consisting of polyolefins, polyesters, polyamides and blends thereof.

8. The turf reinforcement mat of claim 1, further comprising a second polymer net layer, said non-woven mat being located between said first and second nets.

9. The turf reinforcement mat of claim 1, wherein the tensile strength of the turf reinforcement mat is at least 30% greater than the tensile strength of an otherwise identical turf reinforcement mat having round multi-dimensional polymer fibers.

10. A method for erosion control and revegetation facilitation comprising:

providing a turf reinforcement mat comprising

at least one polymer net layer,

a non-woven mat comprising a plurality of multi-dimensional polymer fibers; and

,

a polymer yarn, stitching said net layer to said non-woven mat;

laying said turf reinforcement mat on a section of ground to be reinforced;

securing said turf reinforcement mat to the ground;

distributing soil and seed onto said turf reinforcement mat such that the section of ground is quickly revegetated and thereby protected from further erosion.

11. A method for erosion control and revegetation facilitation as set forth in claim 10, wherein said multi-dimensional polymer fiber has at least three edges and at least three channels.

12. A method for erosion control and revegetation facilitation as set forth in claim 10, wherein said multi-dimensional polymer fiber is selected from the group consisting of polyolefins, polyesters, polyamides and blends thereof.

13. A method for erosion control and revegetation facilitation as set forth in claim 10, wherein said multi-dimensional fibers have a length from about 2 inches (5 cm) to about 12 inches (30 cm).

14. A method for erosion control and revegetation facilitation as set forth in claim 10, wherein said multi-dimensional polymer fiber has a density of from about 300 denier (333 decitex) to about 2000 denier (2222 decitex).

15. A method for erosion control and revegetation-facilitation as set forth in claim 14, wherein said multi-dimensional polymer fiber has a density of from about 500 denier (555 decitex) to about 1100 denier (1222 decitex).

16. A method for erosion control and revegetation facilitation as set forth in claim 10, wherein the polymer of set net layer is selected from the group consisting of polyolefins, polyesters, polyamides and blends thereof.

17. A method for erosion control and revegetation facilitation as set forth in claim 10, further comprising a second polymer net layer, said non-woven mat being located between said first and second nets.