Variable thickness mat for use at the stress transition zone juncture of a bridge-roadway or the juncture of a railroad crossing-roadway

Claim 2

An elongated, variable thickness, non-woven, integral fiber mat pervious to liquid and which is adapted for use at a stress transition zone juncture, such as for instance at the juncture between a bridge and an adjacent roadway, or at a roadway-railroad grade crossing or the like, said mat being adapted for disposal beneath the roadway proper lengthwise thereof commencing at said juncture for spreading the forces applied to the roadway by traffic moving thereon, over an increased area, said mat being of variable thickness in directions both lengthwise and transverse of said mat, the thickest portion of said mat being located at the forward end thereof, said forward end having a frontal surface which is disposed in a generally vertical plane, and which is adapted for disposal at said juncture, said mat decreasing in thickness lengthwise of said mat in a direction rearwardly from said frontal surface, and decreasing in thickness in a direction transverse of said mat, said transverse decrease in thickness providing a lateral shoulder portion for said mat extending for the full length of the latter and being of generally uniform thickness throughout said length.

Claim 3

A mat in accordance with claim 1 wherein said mat in a direction lengthwise thereof is of a stepped configuration and comprises individual layers of fabric material connected together into an integral member, each of said layers being of a predetermined length and width so as to provide said variable thickness of said mat in said lengthwise and transverse directions of said mat.

Claim 4

A mat in accordance with claim 2 wherein the mat is formed of at least three layers of non-woven fiberous fabric material, said layers being of different lengths and at least one of said layers being of a wider width as compared to the other of said layers, said wider width layer being the lower most layer in said mat, with said layers being disposed in superimposed relation to form said stepped configuration in directions both lengthwise and transverse of said mat.

Claim 5

A mat in accordance with claim 2 wherein each of said layers is of a thickness within the range of approximately 60 mils to approximately 100 mils, said fabric being formed of polyester fiber.

Claim 6

A mat in accordance with claim 2 wherein the means connecting the layers together comprises interlocked fibers from the various layers produced by needle punching of the mat.

Claim 7

A mat in accordance with claim 2 wherein the layers of fabric material comprise non-woven fabric formed of non-continuous polyester fiber.

Claim 8

A mat in accordance with claim 6 wherein the fibers of the non-woven fabric are between approximately 5 to 9 denier.

Claim 9

A mat in accordance with claim 1 wherein the fibers of the fabric are crimped.

Claim 10

A mat in accordance with claim 1 wherein the mat is multi-layered and is needle punched, thereby providing means connecting the layers of the mat together.

Claim 11

A mat in accordance with claim 1 wherein the uppermost surface of the mat includes a layer of flexible non-pervious material.

Claim 12

A rectangular shaped, in plan, integral fabric mat of non-woven material adapted for use at a stress transition zone juncture, such as a bridge-roadway juncture, or a railroad crossing-roadway juncture, or the like, said mat being adapted for disposal beneath the roadway generally lengthwise thereof commencing at said juncture, said mat being comprised of a plurality of individual, superimposed layers of non-woven liquid pervious fabric material, and means connecting the layers together into an integral member, said mat having a stepped-like configuration in a direction lengthwise thereof as well as in a direction transversely thereof, one defining side surface of said mat being generally vertically oriented, with the respective defining side surface of the fabric layers being generally coplanar with said one defining side surface of said mat, the other side surface of said mat transversely thereof being of stepped configuration formed by having at least one of said layers being of a greater width as compared to the width of the other layers, with the greater width layer being the bottommost layer in the mat, the thickest portion of said mat being located at the forward end thereof and having a frontal surface which is disposed in a generally vertical plane, the mat thickness lengthwise of said mat diminishing in thickness in a direction rearwardly from said frontal surface and diminishing in thickness in a direction transverse of said mat from said one side surface to said other side surface, resulting in a lateral shoulder portion of generally uniform thickness extending for the full length of said mat.

Claim 13

A rectangular shaped, in plan, integral fabric mat of non-woven material adapted for use at a stress transition zone juncture, such as a bridge-roadway juncture, or a railroad crossing-roadway juncture, or the like, said mat being adapted for disposal beneath the roadway generally lengthwise thereof commencing at said juncture, said mat being comprised of a plurality of individual, superimposed layers of non-woven liquid pervious fabric material, and means connecting the layers together into an integral member, said mat having a stepped-like configuration in a direction lengthwise thereof as well as in a direction transversely thereof, one defining side surface of said mat being generally vertically oriented, with the respective defining side surface of the fabric layers being generally coplanar with said one defining side surface of said mat, the other side surface of said mat transversely thereof being of stepped configuration formed by having at least one of said layers being of a greater width as compared to the width of the other layers, with the greater width layer being the bottommost layer in the mat, the thickest portion of said mat being located at the forward end thereof and having a frontal surface which is disposed in a generally vertical plane, the mat thickness lengthwise of said mat diminishing in thickness in a direction rearwardly from said frontal surface and diminishing in thickness in a direction transverse of said mat from said one side surface to said other side surface, resulting in a lateral shoulder portion of generally uniform thickness extending for the full length of said mat.

Claim 14

A mat in accordance with claim 2 wherein at least one of said layers possesses a weight of between approximately four to six ounces per square yard.

Claim 15

A mat in accordance with claim 2 wherein at least one of said layers has been treated with a resin-like binder to increase the tensile strength of the fabric thereof, and possesses a weight of between approximately eight to twelve ounces per square yard.

Claim 16

A mat in accordance with claim 2 wherein certain of said layers possess a weight of between approximately eight to twelve ounces per square yard while the remainder of said layers are of a lesser weight per square yard.

Claim 17

A mat in accordance with claim 4 wherein the mat is needle punched thereby providing means connecting the layers of the mat together, at least one of said layers being treated with a resin-like binder material which increases the tensile strength of the fabric thereof, said one layer possessing a weight of between approximately eight to twelve ounces per square yard, the non-treated layers, if any, being of a lesser weight per square yard.