US5237945A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Water barrier formed from a clay-fiber mat
Assignee: Amcol International Corp
•
Filing: 1991-04-02
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Granted: 1993-08-24
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Expires: 2011-04-02
Abstract
Abstract A method of manufacturing a water barrier fabric, in flexible or rigid form, and article manufactured thereby, formed by dispersing a water-absorbent material, in powdered or granular form, among a mass of fibers during the formation of a loose mat of said fibers, to homogeneously disperse the powdered or granular water-absorbent material above, below and on each side of the fibers forming the mat, and thereafter densifying and structurally consolidating the mat, to secure the fibers in position surrounding and entrapping the water-absorbent material, such as by sewing, quilting, needle punching or otherwise bonding the fibers into a consolidated, structurally secure fabric at least partially filled with the powdered or granular water-absorbent material.
Inventors
- 👤 Alec W. White
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 10:23
CPC Classifications
E; E02; E02D; E02D31/00; E02D31/002; E02D31/004; E02D31/02; B; B09; B09B; B09B1/00; E02B; E02B3/00; E02B3/04; E02B3/12; E02B3/122; Y; Y10; Y10S; Y10S210/00; Y10S210/901; Y10S210/902; Y10S210/911; Y10S210/912; Y10S55/00; Y10S55/09; Y10T; Y10T428/00; Y10T428/24; Y10T428/24033; Y10T428/24802; Y10T428/24893; Y10T442/00; Y10T442/10; Y10T442/102; Y10T442/159; Y10T442/60; Y10T442/699
Claims Analysis
Total Claims: 59
Claim 1
Independent Claim
91 words
An article of manufacture comprising a mat formed by incorporating a powdered or granular bentonite clay into a mat comprising a mass of fibers to blend the powdered or granular bentonite clay above, below and on each side of the fibers throughout at least a portion of a thickness of the mat and densifying and structurally consolidating the mat to secure the fibers in position surrounding or entraping or interlocking the bentonite clay to prevent substantial loss of the powdered or granular bentonite clay during handling and installation of the mat.
Claim 2
Dependent Claim
91 words
An article of manufacture comprising a mat formed by incorporating a powdered or granular bentonite clay into a mat comprising a mass of fibers to blend the powdered or granular bentonite clay above, below and on each side of the fibers throughout at least a portion of a thickness of the mat and densifying and structurally consolidating the mat to secure the fibers in position surrounding or entraping or interlocking the bentonite clay to prevent substantial loss of the powdered or granular bentonite clay during handling and installation of the mat.
Claim 3
Dependent Claim
17 words
The article of claim 1, wherein the article is flexible and capable of being rolled upon itself.
Claim 4
Dependent Claim
19 words
The article of claim 1, wherein the fibrous mat is formed from fibers of a plurality of different materials.
Claim 5
Dependent Claim
36 words
The article of claim 1, wherein the article contains a weight ratio of bentonite clay to fiber within the range of about 1 to about 80 parts by weight of bentonite clay per part of fiber.
Claim 6
Dependent Claim
125 words
An article of manufacture comprising a mat formed by incorporating a powdered or granular material into a mat comprising a mass of fibers to blend the powdered or granular material above, below and on each side of the fibers throughout at least a portion of a thickness of the mat and densifying the structurally consolidating the mat to secure the fibers in position surrounding or entraping or interlocking the powdered or granular material to prevent substantial loss of the powdered or granular material during handling and installation of the mat; wherein the article contains a weight ratio of powdered or granular material to fiber with the range of about 5 to about 20 parts by weight of powdered or granular material per part of fiber.
Claim 7
Dependent Claim
125 words
An article of manufacture comprising a mat formed by incorporating a powdered or granular material into a mat comprising a mass of fibers to blend the powdered or granular material above, below and on each side of the fibers throughout at least a portion of a thickness of the mat and densifying the structurally consolidating the mat to secure the fibers in position surrounding or entraping or interlocking the powdered or granular material to prevent substantial loss of the powdered or granular material during handling and installation of the mat; wherein the article contains a weight ratio of powdered or granular material to fiber with the range of about 5 to about 20 parts by weight of powdered or granular material per part of fiber.
Claim 8
Dependent Claim
15 words
The article of claim 5, wherein the powdered or granular material comprises sodium bentonite clay.
Claim 9
Dependent Claim
125 words
An article of manufacture comprising a mat formed by incorporating a powdered or granular material into a mat comprising a mass of fibers to blend the powdered or granular material above, below and on each side of the fibers throughout at least a portion of a thickness of the mat and densifying and structurally consolidating the mat to secure the fibers in position surrounding or entraping or interlocking the powdered or granular material to prevent substantial loss of the powdered or granular material during handling and installation of the mat; wherein the article contains a weight ratio of powdered or granular material to fiber with the range of about 8 to about 15 parts by weight of powdered or granular material per part of fiber.
Claim 10
Dependent Claim
125 words
An article of manufacture comprising a mat formed by incorporating a powdered or granular material into a mat comprising a mass of fibers to blend the powdered or granular material above, below and on each side of the fibers throughout at least a portion of a thickness of the mat and densifying and structurally consolidating the mat to secure the fibers in position surrounding or entraping or interlocking the powdered or granular material to prevent substantial loss of the powdered or granular material during handling and installation of the mat; wherein the article contains a weight ratio of powdered or granular material to fiber with the range of about 8 to about 15 parts by weight of powdered or granular material per part of fiber.
Claim 11
Dependent Claim
15 words
The article of claim 7, wherein the powdered or granular material comprises sodium bentonite clay.
Claim 12
Dependent Claim
111 words
An article of manufacture comprising a mat formed by incorporating a powdered or granular material into a mat comprising a mass of fibers to blend the powdered or granular material above, below and on each side of the fibers throughout at least a portion of a thickness of the mat and densifying and structurally consolidating the mat to secure the fibers in position surrounding or entraping or interlocking the powdered or granular material to prevent substantial loss of the powdered or granular material during handling and installation of the mat; and an elongated reinforcing material aligned along the length of the article and encased therein between major upper and lower surfaces.
Claim 13
Dependent Claim
111 words
An article of manufacture comprising a mat formed by incorporating a powdered or granular material into a mat comprising a mass of fibers to blend the powdered or granular material above, below and on each side of the fibers throughout at least a portion of a thickness of the mat and densifying and structurally consolidating the mat to secure the fibers in position surrounding or entraping or interlocking the powdered or granular material to prevent substantial loss of the powdered or granular material during handling and installation of the mat; and an elongated reinforcing material aligned along the length of the article and encased therein between major upper and lower surfaces.
Claim 14
Dependent Claim
15 words
The article of claim 9, wherein the powdered or granular material comprises sodium bentonite clay.
Claim 15
Dependent Claim
126 words
An article of manufacture comprising a mat formed by incorporating a powdered or granular material into a mat comprising a mass of fibers to blend the powdered or granular material above, below and on each side of the fibers throughout at least a portion of a thickness of the mat and densifying and structurally consolidating the mat to secure the fibers in position surrounding or entraping or interlocking the powdered or granular material to prevent substantial loss of the powdered or granular material during handling and installation of the mat; wherein the article includes a volume of a defined thickness containing essentially no powdered or granular material between fibers in said defined thickness such that the article is capable of venting gas laterally through said volume.
Claim 16
Dependent Claim
126 words
An article of manufacture comprising a mat formed by incorporating a powdered or granular material into a mat comprising a mass of fibers to blend the powdered or granular material above, below and on each side of the fibers throughout at least a portion of a thickness of the mat and densifying and structurally consolidating the mat to secure the fibers in position surrounding or entraping or interlocking the powdered or granular material to prevent substantial loss of the powdered or granular material during handling and installation of the mat; wherein the article includes a volume of a defined thickness containing essentially no powdered or granular material between fibers in said defined thickness such that the article is capable of venting gas laterally through said volume.
Claim 17
Dependent Claim
15 words
The article of claim 11, wherein the powdered or granular material comprises sodium bentonite clay.
Claim 18
Dependent Claim
51 words
The article of claim 11, wherein the article includes a water-absorbent powdered or granular material filling a portion of the mat, and the article includes a concentration of fibers throughout a thickness of the article disposed under the water-absorbent material, wherein the fiber concentration has essentially no powdered or granular material.
Claim 19
Independent Claim
163 words
A method of manufacturing a fabric at least partially filled with a powdered or granular material dispersed throughout at least a portion of a thickness of the fabric comprising: depositing fibers onto a support surface to form a loose mat of fibers having spaces between adjacent fibers; depositing the powdered or granular material among the fibers such that the powdered or granular material is received in a portion of said spaces between adjacent fibers; compressing the fibers together to eliminate a substantial portion of said spaces that are not filled with said powdered or granular material; and securing the fibers together while the fibers are in the compressed state to structurally consolidate the fibers together and form a partially filled fabric and to lock the powdered or granular material in position between said fibers; wherein the fibers are secured together by needle punching a portion of the fibers to intertangle the fibers together sufficiently to structurally consolidate the fibers into a handleable fabric.
Claim 20
Independent Claim
163 words
A method of manufacturing a fabric at least partially filled with a powdered or granular material dispersed throughout at least a portion of a thickness of the fabric comprising: depositing fibers onto a support surface to form a loose mat of fibers having spaces between adjacent fibers; depositing the powdered or granular material among the fibers such that the powdered or granular material is received in a portion of said spaces between adjacent fibers; compressing the fibers together to eliminate a substantial portion of said spaces that are not filled with said powdered or granular material; and securing the fibers together while the fibers are in the compressed state to structurally consolidate the fibers together and form a partially filled fabric and to lock the powdered or granular material in position between said fibers; wherein the fibers are secured together by needle punching a portion of the fibers to intertangle the fibers together sufficiently to structurally consolidate the fibers into a handleable fabric.
Claim 21
Dependent Claim
69 words
The method of claim 14, wherein a portion of the fibers is thermoplastic and tacky when heated to a fiber melt temperature, and wherein the fibers are secured together by heating the fibers sufficiently to tackify the fibers such that adjacent contacting fibers adhere together, and thereafter cooling the tackified fibers to a temperature below the melt temperature while the adjacent, adhered fibers are in contact with each other.
Claim 22
Dependent Claim
12 words
The method of claim 14, wherein the fibers are adhesively secured together.
Claim 23
Dependent Claim
28 words
The method of claim 14, wherein the weight ratio of powdered or granular material to fibers is in the range of about 1 to about 80 to 1.
Claim 24
Dependent Claim
11 words
The method of claim 14, wherein the fibers are continuous monofilaments.
Claim 25
Dependent Claim
15 words
The method of claim 14, wherein the powdered or granular material comprises sodium bentonite clay.
Claim 26
Dependent Claim
15 words
The method of claim 14, wherein the powdered or granular material is a water-absorbent material.
Claim 27
Dependent Claim
22 words
The method of claim 14, wherein the fibers have a length within the range of about 0.5 inch to about 25 inches.
Claim 28
Dependent Claim
17 words
The method of claim 21, wherein the fibers have a denier of about 1 to about 5000.
Claim 29
Dependent Claim
39 words
The method of claim 14 further including the step of applying a sealing material to at least one major surface of the fabric to reduce the loss of powdered or granular material during handling and installation of the fabric.
Claim 30
Dependent Claim
14 words
The method of claim 23, wherein the sealing material is a flexible sheet material.
Claim 31
Dependent Claim
15 words
The method of claim 24, wherein the flexible sheet material is a water-impermeable sheet material.
Claim 32
Independent Claim
157 words
A method of manufacturing a fabric at least partially filled with a powdered or granular material dispersed throughout at least a portion of a thickness of the fabric comprising: depositing fibers onto a support surface to form a loose mat of fibers having spaces between adjacent fibers; depositing the powdered or granular material among the fibers such that the powdered or granular material is received in a portion of said spaces between adjacent fibers; compressing the fibers together to eliminate a substantial portion of said spaces that are not filled with said powdered or granular material; and securing the fibers together while the fibers are in the compressed state to structurally consolidate the fibers together and form a partially filled fabric and to lock the powdered or granular material in position between said fibers; wherein the weight ratio of powdered or granular material to fibers is in the range of about 5 to about 20 to 1.
Claim 33
Independent Claim
157 words
A method of manufacturing a fabric at least partially filled with a powdered or granular material dispersed throughout at least a portion of a thickness of the fabric comprising: depositing fibers onto a support surface to form a loose mat of fibers having spaces between adjacent fibers; depositing the powdered or granular material among the fibers such that the powdered or granular material is received in a portion of said spaces between adjacent fibers; compressing the fibers together to eliminate a substantial portion of said spaces that are not filled with said powdered or granular material; and securing the fibers together while the fibers are in the compressed state to structurally consolidate the fibers together and form a partially filled fabric and to lock the powdered or granular material in position between said fibers; wherein the weight ratio of powdered or granular material to fibers is in the range of about 5 to about 20 to 1.
Claim 34
Dependent Claim
15 words
The method of claim 26, wherein the powdered or granular material comprises sodium bentonite clay.
Claim 35
Independent Claim
145 words
A method of manufacturing a fabric at least partially filled with a powdered or granular material dispersed throughout at least a portion of a thickness of the fabric comprising: depositing fibers onto a support surface to form a loose mat of fibers having spaces between adjacent fibers; depositing the powdered or granular material among the fibers such that the powdered or granular material is received in a portion of said spaces between adjacent fibers; compressing the fibers together to eliminate a substantial portion of said spaces that are not filled with said powdered or granular material; and securing the fibers together while the fibers are in the compressed state to structurally consolidate the fibers together and form a partially filled fabric and to lock the powdered or granular material in position between said fibers; wherein the fibers are secured together by sewing the fibers together.
Claim 36
Independent Claim
145 words
A method of manufacturing a fabric at least partially filled with a powdered or granular material dispersed throughout at least a portion of a thickness of the fabric comprising: depositing fibers onto a support surface to form a loose mat of fibers having spaces between adjacent fibers; depositing the powdered or granular material among the fibers such that the powdered or granular material is received in a portion of said spaces between adjacent fibers; compressing the fibers together to eliminate a substantial portion of said spaces that are not filled with said powdered or granular material; and securing the fibers together while the fibers are in the compressed state to structurally consolidate the fibers together and form a partially filled fabric and to lock the powdered or granular material in position between said fibers; wherein the fibers are secured together by sewing the fibers together.
Claim 37
Independent Claim
143 words
A method of manufacturing a fabric at least partially filled with a powdered or granular material dispersed throughout at least a portion of a thickness of the fabric comprising: depositing fibers onto a support surface to form a loose mat of fibers having spaces between adjacent fibers; depositing the powdered or granular material among the fibers such that the powdered or granular material is received in a portion of said spaces between adjacent fibers; compressing the fibers together to eliminate a substantial portion of said spaces that are not filled with said powdered or granular material; and securing the fibers together while the fibers are in the compressed state to structurally consolidate the fibers together and form a partially filled fabric and to lock the powdered or granular material in position between said fibers; wherein the powdered or granular material is bentonite clay.
Claim 38
Independent Claim
143 words
A method of manufacturing a fabric at least partially filled with a powdered or granular material dispersed throughout at least a portion of a thickness of the fabric comprising: depositing fibers onto a support surface to form a loose mat of fibers having spaces between adjacent fibers; depositing the powdered or granular material among the fibers such that the powdered or granular material is received in a portion of said spaces between adjacent fibers; compressing the fibers together to eliminate a substantial portion of said spaces that are not filled with said powdered or granular material; and securing the fibers together while the fibers are in the compressed state to structurally consolidate the fibers together and form a partially filled fabric and to lock the powdered or granular material in position between said fibers; wherein the powdered or granular material is bentonite clay.
Claim 39
Independent Claim
157 words
A method of manufacturing a fabric at least partially filled with a powdered or granular material dispersed throughout at least a portion of a thickness of the fabric comprising: depositing fibers onto a support surface to form a loose mat of fibers having spaces between adjacent fibers; depositing the powdered or granular material among the fibers such that the powdered or granular material is received in a portion of said spaces between adjacent fibers; compressing the fibers together to eliminate a substantial portion of said spaces that are not filled with said powdered or granular material; and securing the fibers together while the fibers are in the compressed state to structurally consolidate the fibers together and form a partially filled fabric and to lock the powdered or granular material in position between said fibers; wherein the weight ratio of powdered or granular material to fibers is in the range of about 8 to about 15 to 1.
Claim 40
Independent Claim
157 words
A method of manufacturing a fabric at least partially filled with a powdered or granular material dispersed throughout at least a portion of a thickness of the fabric comprising: depositing fibers onto a support surface to form a loose mat of fibers having spaces between adjacent fibers; depositing the powdered or granular material among the fibers such that the powdered or granular material is received in a portion of said spaces between adjacent fibers; compressing the fibers together to eliminate a substantial portion of said spaces that are not filled with said powdered or granular material; and securing the fibers together while the fibers are in the compressed state to structurally consolidate the fibers together and form a partially filled fabric and to lock the powdered or granular material in position between said fibers; wherein the weight ratio of powdered or granular material to fibers is in the range of about 8 to about 15 to 1.
Claim 41
Dependent Claim
15 words
The method of claim 30, wherein the powdered or granular material comprises sodium bentonite clay.
Claim 42
Independent Claim
163 words
A method of manufacturing a fabric at least partially filled with a powdered or granular material dispersed throughout at least a portion of a thickness of the fabric comprising: depositing fibers onto a support surface to form a loose mat of fibers having spaces between adjacent fibers; depositing the powdered or granular material among the fibers such that the powdered or granular material is received in a portion of said spaces between adjacent fibers; compressing the fibers together to eliminate a substantial portion of said spaces that are not filled with said powdered or granular material; securing the fibers together while the fibers are in the compressed state to structurally consolidate the fibers together and form a partially filled fabric and to lock the powdered or granular material in position between said fibers; and securing a layer of a rigid material to the fabric to form a fabric capable of standing vertically against a wall prior to securing the fabric against said wall.
Claim 43
Independent Claim
163 words
A method of manufacturing a fabric at least partially filled with a powdered or granular material dispersed throughout at least a portion of a thickness of the fabric comprising: depositing fibers onto a support surface to form a loose mat of fibers having spaces between adjacent fibers; depositing the powdered or granular material among the fibers such that the powdered or granular material is received in a portion of said spaces between adjacent fibers; compressing the fibers together to eliminate a substantial portion of said spaces that are not filled with said powdered or granular material; securing the fibers together while the fibers are in the compressed state to structurally consolidate the fibers together and form a partially filled fabric and to lock the powdered or granular material in position between said fibers; and securing a layer of a rigid material to the fabric to form a fabric capable of standing vertically against a wall prior to securing the fabric against said wall.
Claim 44
Dependent Claim
15 words
The method of claim 32, wherein the powdered or granular material comprises sodium bentonite clay.
Claim 45
Dependent Claim
27 words
The method of claim 32, wherein the rigid material is applied to an interior of the fabric, between fibers, during the manufacture of the partially filled fabric.
Claim 46
Dependent Claim
55 words
The method of claim 34 including the steps of: depositing lower fibers onto a support surface to form a loose mat of lower fibers above the support surface; depositing said rigid material over said loose mat of fibers; depositing upper fibers over said rigid material; and depositing powdered or granular material surrounding said upper fibers.
Claim 47
Dependent Claim
24 words
The method of claim 35, including the step of depositing a sheet of polymeric netting onto one of the outer surfaces of the fabric.
Claim 48
Dependent Claim
25 words
The method of claim 35, wherein said rigid material is a sheet of corrugated cardboard that is substantially coextensive with said mat of lower fiber.
Claim 49
Independent Claim
71 words
A method of impeding the flow of Radon gas comprising disposing an article of manufacture comprising a mat of fibers having a powdered or granular material distributed among the fibers throughout at least a portion of a thickness of the article and consolidated sufficiently to prevent substantial loss of the powdered or granular material during handling and installation between the Radon gas and an area to be protected from said gas.
Claim 50
Independent Claim
71 words
A method of impeding the flow of Radon gas comprising disposing an article of manufacture comprising a mat of fibers having a powdered or granular material distributed among the fibers throughout at least a portion of a thickness of the article and consolidated sufficiently to prevent substantial loss of the powdered or granular material during handling and installation between the Radon gas and an area to be protected from said gas.
Claim 51
Dependent Claim
15 words
The method of claim 38, wherein the powdered or granular material comprises sodium bentonite clay.
Claim 52
Dependent Claim
78 words
A water submersible article of manufacture comprising a mat of fibers having a first powdered or granular material distributed among the fibers throughout at least a portion of a thickness of the article and consolidated sufficiently to prevent substantial loss of the first powdered or granular material during handling and installation, wherein the article further is loaded with a heavy, water-insoluble powdered or granular material distributed relatively uniformly to provide an overall mat specific gravity greater than 1.0.
Claim 53
Dependent Claim
78 words
A water submersible article of manufacture comprising a mat of fibers having a first powdered or granular material distributed among the fibers throughout at least a portion of a thickness of the article and consolidated sufficiently to prevent substantial loss of the first powdered or granular material during handling and installation, wherein the article further is loaded with a heavy, water-insoluble powdered or granular material distributed relatively uniformly to provide an overall mat specific gravity greater than 1.0.
Claim 54
Dependent Claim
15 words
The article of claim 40, wherein the first powdered or granular material is bentonite clay.
Claim 55
Dependent Claim
79 words
An article of manufacture that is buoyant in water comprising a mat of fibers having a powdered or granular material distributed among the fibers throughout at least a portion of a thickness of the article and consolidated sufficiently to prevent substantial loss of the powdered or granular material during handling and installation, wherein the article further includes a buoyant material distributed essentially coextensive with a major surface of the article to provide buoyancy of the entire article on water.
Claim 56
Dependent Claim
79 words
An article of manufacture that is buoyant in water comprising a mat of fibers having a powdered or granular material distributed among the fibers throughout at least a portion of a thickness of the article and consolidated sufficiently to prevent substantial loss of the powdered or granular material during handling and installation, wherein the article further includes a buoyant material distributed essentially coextensive with a major surface of the article to provide buoyancy of the entire article on water.
Claim 57
Dependent Claim
16 words
The article of claim 42, wherein the article has a specific gravity less than about 0.90.
Claim 58
Dependent Claim
21 words
The article of claim 42, wherein the buoyant material is selected from the group consisting of expanded perlite and expanded vermiculite.
Claim 59
Dependent Claim
14 words
The article of claim 42, wherein the powdered or granular material is bentonite clay.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1996-08-23 | 1997-02-22 | 1997-08-24 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2000-08-23 | 2001-02-22 | 2001-08-24 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2004-08-23 | 2005-02-22 | 2005-08-24 | $7700.00 | Window Closed / Lapsed |