Reinforced Nonwoven Material and Method of Use for Landscaping

• US 20200130322A1
• Filed: 12/23/2019
• Published: 04/30/2020
• Est. Priority Date: 06/14/2017
• Status: Abandoned Application

• Current Assignee: Novum Microfiber Corp.
• Original Assignee: Novum Microfiber Corp.
• Inventors: Shokar, Bobby
• Application Number:
  US16/726,233
• Publication Number:
  US 20200130322A1
• Time in Patent Office: Days
• 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 2307/518 bi-axially
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• 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 3/30 characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/024 Woven fabric
• CPC Class Codes: B32B 5/08 the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• 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

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 of a polymer;

ii) heating 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 a landscaping location; and

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

2. ) The method as in claim 1 wherein the step of creating a material mixture of a polymer further comprises adding from seventy percent to one hundred percent by weight of polypropylene.

3. ) The method as in claim 1 wherein the step of creating a material mixture of a polymer further comprises adding from seventy-five percent to ninety-five percent by weight of polypropylene.

4. ) The method as in claim 1 wherein the step of creating a material mixture of a polymer further comprises adding from eighty percent to ninety percent by weight of polyethylene.

5. ) The method as in claim 1 wherein the step of creating a material mixture of a polymer further comprises adding from seventy percent to one hundred percent by weight of polyethylene.

6. ) The method as in claim 1 wherein the step of creating a material mixture of a polymer further comprises adding from seventy-five percent to ninety-five percent by weight of polyethylene.

7. ) The method as in claim 1 wherein the step of creating a material mixture of a polymer further comprises adding from eighty percent to ninety percent by weight of polyethylene.

8. ) The method as in claim 1 wherein the step of creating a material mixture of a polymer further comprises adding up to three percent by weight of ethyl methyl acetate.

9. ) The method as in claim 1 wherein the step of creating a material mixture of a polymer further comprises adding up to two percent by weight of a UV stabilizer.

10. ) 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.

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

12. ) 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.

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

14. ) The method as in claim 1 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.

15. ) The method as in claim 1 further comprising

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

and

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

16. ) 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.

17. ) 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.

18. ) 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 preferred values

i) wherein said set of preferred 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.

19. ) 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 preferred values

i) wherein said set of preferred 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.