US5552207A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Open grid fabric for reinforcing wall systems, wall segment product and methods of making same
Assignee: Saint Gobain Technical Fabrics Canada Ltd
•
Filing: 1995-06-07
•
Granted: 1996-09-03
•
Expires: 2015-06-07
Abstract
Abstract An open grid fabric for reinforcing wall systems and a method of making same. First and second sets of substantially parallel, selected rovings are combined using certain knits, leno weaves, or adhesive methods. The rovings are direct-sized with at least a silane sizing and preferably have a linear density between 100 and 2000 grams per thousand meters and are arranged at an average of 3 to 10 ends per inch. A polymeric coating is applied to the fabric at a level of 10 to 150 parts dry weight of resin to 100 parts by weight of the fabric while assuring that the open grid remains open. A method for reinforcing a wall system and a wall segment product utilizing the novel open grid fabric of the present invention are also disclosed.
Inventors
- 👤 John F. Porter
- 👤 Mark O. Kittson
- 👤 Mark Tucker
- 👤 Larry Ferris
- 👤 Steve LePage
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 00:35
CPC Classifications
D; D03; D03D; D03D13/00; D03D13/006; D03D15/00; D03D15/20; D03D15/242; D03D15/267; D03D15/283; D03D19/00; D03D9/00; E; E04; E04C; E04C5/00; E04C5/07; E04F; E04F13/00; E04F13/02; E04F13/04; D10; D10B; D10B2101/00; D10B2101/02; D10B2101/06; D10B2201/00; D10B2201/01; D10B2201/02; D10B2201/20; D10B2201/22; D10B2201/24; D10B2201/28; D10B2321/00; D10B2321/02; D10B2321/04; D10B2321/041; D10B2321/10; D10B2321/101; D10B2331/00; D10B2331/02; D10B2331/04; D10B2401/00; D10B2401/06; D10B2401/063; D10B2503/00; D10B2503/04; D10B2505/00; D10B2505/02; D10B2505/20; Y; Y10; Y10S; Y10S52/00; Y10S52/07; Y10T; Y10T428/00; Y10T428/24; Y10T428/24058; Y10T428/24074; Y10T428/24091; Y10T428/24132; Y10T428/24273; Y10T428/24322; Y10T428/24331; Y10T442/00; Y10T442/10; Y10T442/102; Y10T442/103; Y10T442/133
Claims Analysis
Total Claims: 39
Claim 1
Independent Claim
293 words
An impact resistant wall segment product comprising: rigid insulation board; a stucco coating mixture; and a high strength, alkali and impact resistant, resin-coated open grid wall reinforcement fabric comprising: a first set of substantially parallel impact resistant rovings comprising an effective impact-resisting amount of a direct-sized silane sizing, having a linear density between 130 and 400 grams per thousand meters, and being arranged in the set at an average of 1.5 to 12 ends per inch; a second set of substantially parallel impact resistant rovings comprising an effective impact-resisting amount of a direct-sized silane sizing, having a linear density between 130 and 400 grams per thousand meters, and being arranged in the set at an average of 1.5 to 12 ends per inch; the first and second sets of rovings being arranged next to each other with the rovings of one set being arranged at a substantial angle to the rovings of the other set, without compressing rovings of one set between rovings of the other set, to form an open grid fabric wall reinforcement weighing between 50 to 650 gm/square meter to provide strength and impact resistance to the wall segment product; and an effective impact-resisting amount of polymeric coating on the rovings of the wall reinforcement at a level of 10 to 150 parts dry weight of resin to 100 parts by weight of the open grid fabric wall reinforcement, the stucco coating mixture being affixed to the insulation board and binding the fabric to the board by penetrating the openings between the rovings to the board, filling the openings in the open grid and covering the reinforcement fabric, such that the open grid fabric is embedded in the stucco coating mixture and provides impact resistance to the wall segment product.
Claim 2
Dependent Claim
293 words
An impact resistant wall segment product comprising: rigid insulation board; a stucco coating mixture; and a high strength, alkali and impact resistant, resin-coated open grid wall reinforcement fabric comprising: a first set of substantially parallel impact resistant rovings comprising an effective impact-resisting amount of a direct-sized silane sizing, having a linear density between 130 and 400 grams per thousand meters, and being arranged in the set at an average of 1.5 to 12 ends per inch; a second set of substantially parallel impact resistant rovings comprising an effective impact-resisting amount of a direct-sized silane sizing, having a linear density between 130 and 400 grams per thousand meters, and being arranged in the set at an average of 1.5 to 12 ends per inch; the first and second sets of rovings being arranged next to each other with the rovings of one set being arranged at a substantial angle to the rovings of the other set, without compressing rovings of one set between rovings of the other set, to form an open grid fabric wall reinforcement weighing between 50 to 650 gm/square meter to provide strength and impact resistance to the wall segment product; and an effective impact-resisting amount of polymeric coating on the rovings of the wall reinforcement at a level of 10 to 150 parts dry weight of resin to 100 parts by weight of the open grid fabric wall reinforcement, the stucco coating mixture being affixed to the insulation board and binding the fabric to the board by penetrating the openings between the rovings to the board, filling the openings in the open grid and covering the reinforcement fabric, such that the open grid fabric is embedded in the stucco coating mixture and provides impact resistance to the wall segment product.
Claim 3
Dependent Claim
18 words
The wall segment product of claim 1, in which the segment is prefabricated before installation on a wall.
Claim 4
Dependent Claim
22 words
The wall segment product of claim 1, wherein the polymeric coating has a glass transition temperature between -40° C. to +40° C.
Claim 5
Dependent Claim
65 words
The wall segment product of claim 1, in which the polymeric coating is alkali and water resistant and is selected from the group consisting of polyvinyl chloride, polyvinylidene chloride, styrene butadiene rubber, urethane, silicone, acrylic and styrene acrylate polymers and copolymers, and the coating is applied at a level of 5 to 40 parts dry weight of resin to 100 parts by weight of fabric.
Claim 6
Dependent Claim
28 words
The wall segment product of claim 1, wherein the first and second sets of rovings are selected from the group consisting of fiberglass, nylon, aramid, polyolefin and polyester.
Claim 7
Dependent Claim
42 words
The wall segment product of claim 1, wherein the first set of rovings and the second set of rovings are arranged at an average of 3 to 10 strands per inch and each set of rovings lies essentially in its own plane.
Claim 8
Dependent Claim
23 words
The wall segment product of claim 1, in which the rovings are direct-sized with a silane sizing that consists essentially of silane sizing.
Claim 9
Dependent Claim
21 words
The wall segment product of claim 1, wherein the first and second sets of rovings are affixed together with tie yarn.
Claim 10
Dependent Claim
43 words
The wall segment product of claim 8, wherein the tie yarn is knit to the first and second sets of rovings at a tension of at least about 3.1 yards of tie yarn for every 1 yard of ends in a warp direction.
Claim 11
Dependent Claim
68 words
The wall segment product of claim 8, in which the two sets of rovings are affixed together with tie yarn in a staggered leno weaving process in which the tie yarn is arranged in pairs with rovings in one of the sets of rovings, and the tie yarns and the rovings are alternately twisted in a right hand and left hand direction crossing before weft roving is inserted.
Claim 12
Dependent Claim
68 words
The wall segment product of claim 8, in which the two sets of rovings are affixed together with tie yarn in a hurl leno weaving process in which the tie yarn is arranged in pairs with rovings in one of the sets of rovings, and the tie yarn and the rovings are alternately twisted in a right hand and left hand direction crossing before weft roving is inserted.
Claim 13
Dependent Claim
68 words
The wall segment product of claim 8, in which the two sets of rovings are affixed together with tie yarn in a staggered hurl weaving process in which the tie yarn is arranged in pairs with rovings in one of the sets of rovings, and the tie yarns and the rovings are alternately twisted in a right hand and left hand direction crossing before weft roving is inserted.
Claim 14
Dependent Claim
290 words
A strength imparting wall segment product comprising: rigid insulation board; a stucco coating mixture; and a high strength, alkali resistant and strength imparting, resin-coated open grid wall reinforcement fabric comprising: a first set of substantially parallel strength-imparting rovings comprising an effective strength-imparting amount of a direct-sized silane sizing, having a linear density between 130 and 400 grams per thousand meters, and being arranged in the set at an average of 1.5 to 12 ends per inch; a second set of substantially parallel strength-imparting rovings comprising an effective strength-imparting amount of a direct-sized silane sizing, having a linear density between 130 and 400 grams per thousand meters, and being arranged in the set at an average of 1.5 to 12 ends per inch; the first and second sets of rovings being arranged next to each other with the rovings of one set being arranged at a substantial angle to the rovings of the other set, without compressing rovings of one set between rovings of the other set, to form an open grid fabric wall reinforcement weighing between 50 to 650 gm/square meter to provide strength and impact resistance to the wall segment product; and an effective strength-imparting amount of polymeric coating on the rovings of the wall reinforcement at a level of 10 to 150 parts dry weight of resin to 100 parts by weight of the open grid fabric wall reinforcement, the stucco coating mixture being affixed to the insulation board and binding the fabric to the board by penetrating the openings between the rovings to the board, filling the openings in the open grid and covering the reinforcement fabric, such that the open grid is embedded in the stucco coating mixture and imparts strength to the wall segment product.
Claim 15
Dependent Claim
290 words
A strength imparting wall segment product comprising: rigid insulation board; a stucco coating mixture; and a high strength, alkali resistant and strength imparting, resin-coated open grid wall reinforcement fabric comprising: a first set of substantially parallel strength-imparting rovings comprising an effective strength-imparting amount of a direct-sized silane sizing, having a linear density between 130 and 400 grams per thousand meters, and being arranged in the set at an average of 1.5 to 12 ends per inch; a second set of substantially parallel strength-imparting rovings comprising an effective strength-imparting amount of a direct-sized silane sizing, having a linear density between 130 and 400 grams per thousand meters, and being arranged in the set at an average of 1.5 to 12 ends per inch; the first and second sets of rovings being arranged next to each other with the rovings of one set being arranged at a substantial angle to the rovings of the other set, without compressing rovings of one set between rovings of the other set, to form an open grid fabric wall reinforcement weighing between 50 to 650 gm/square meter to provide strength and impact resistance to the wall segment product; and an effective strength-imparting amount of polymeric coating on the rovings of the wall reinforcement at a level of 10 to 150 parts dry weight of resin to 100 parts by weight of the open grid fabric wall reinforcement, the stucco coating mixture being affixed to the insulation board and binding the fabric to the board by penetrating the openings between the rovings to the board, filling the openings in the open grid and covering the reinforcement fabric, such that the open grid is embedded in the stucco coating mixture and imparts strength to the wall segment product.
Claim 16
Dependent Claim
18 words
The wall segment product of claim 13, in which the segment is prefabricated before installation on a wall.
Claim 17
Dependent Claim
22 words
The wall segment product of claim 13, wherein the polymeric coating has a glass transition temperature between -40° C. to +40° C.
Claim 18
Dependent Claim
65 words
The wall segment product of claim 13, in which the polymeric coating is alkali and water resistant and is selected from the group consisting of polyvinyl chloride, polyvinylidene chloride, styrene butadiene rubber, urethane, silicone, acrylic and styrene acrylate polymers and copolymers, and the coating is applied at a level of 5 to 40 parts dry weight of resin to 100 parts by weight of fabric.
Claim 19
Dependent Claim
28 words
The wall segment product of claim 13, wherein the first and second sets of rovings are selected from the group consisting of fiberglass, nylon, aramid, polyolefin and polyester.
Claim 20
Dependent Claim
42 words
The wall segment product of claim 13, wherein the first set of rovings and the second set of rovings are arranged at an average of 3 to 10 strands per inch and each set of rovings lies essentially in its own plane.
Claim 21
Dependent Claim
23 words
The wall segment product of claim 13, in which the rovings are direct-sized with a silane sizing that consists essentially of silane sizing.
Claim 22
Dependent Claim
21 words
The wall segment product of claim 13, wherein the first and second sets of rovings are affixed together with tie yarn.
Claim 23
Dependent Claim
43 words
The wall segment product of claim 20, wherein the tie yarn is knit to the first and second sets of rovings at a tension of at least about 3.1 yards of tie yarn for every 1 yard of ends in a warp direction.
Claim 24
Dependent Claim
68 words
The wall segment product of claim 20, in which the two sets of rovings are affixed together with tie yarn is a staggered leno weaving process in which the tie yarn is arranged in pairs with rovings in one of the sets of rovings, and the tie yarns and the rovings are alternately twisted in a right hand and left hand direction crossing before weft roving is inserted.
Claim 25
Dependent Claim
68 words
The wall segment product of claim 20, in which the two sets of rovings are affixed together with tie yarn in a hurl leno weaving process in which the tie yarn is arranged in pairs with rovings in one of the sets of rovings, and the tie yarns and the rovings are alternately twisted in a right hand and left hand direction crossing before weft roving is inserted.
Claim 26
Dependent Claim
68 words
The wall segment product of claim 20, in which the two sets of rovings are affixed together with tie yarn in a staggered hurl weaving process in which the tie yarn is arranged in pairs with rovings in one of the sets of rovings, and the tie yarn and the rovings are alternately twisted in a right hand and left hand direction crossing before weft roving is inserted.
Claim 27
Dependent Claim
311 words
An impact resisting and strength-imparting wall segment product comprising: rigid insulation board; a stucco coating mixture; and a high strength, alkali resistant, impact resistant and strength imparting, resin-coated open grid wall reinforcement fabric comprising: a first set of substantially parallel impact resistant and strength-imparting rovings comprising an effective impact-resisting and strength-imparting amount of a direct-sized silane containing sizing, having a linear density between 130 and 400 grams per thousand meters, and being arranged in the set at an average of 1.5 to 12 ends per inch; a second set of substantially parallel impact resistant and strength imparting rovings comprising an effective impact-resisting and strength-imparting amount of a direct-sized silane containing sizing, having a linear density between 130 and 400 grams per thousand meters, and being arranged in the set at an average of 1.5 to 12 ends per inch; the first and second sets of rovings being arranged next to each other with the rovings of one set being arranged at a substantial angle to the rovings of the other set, without compressing rovings of one set between rovings of the other set, to form an open grid wall reinforcement fabric weighing between 50 to 650 gm/square meter to provide strength and impact resistance to the wall segment product; and an effective strength-imparting amount of polymeric coating on the rovings of the wall reinforcement at a level of 10 to 150 parts dry weight of resin to 100 parts by weight of the open grid fabric wall reinforcement, the stucco coating mixture being affixed to the insulation board and binding the fabric to the board by penetrating the openings between the rovings to the board, filling the openings in the open grid and covering the reinforcement fabric, such that the open grid is embedded in the stucco coating mixture and imparts strength and provides impact resistance to the wall segment product.
Claim 28
Dependent Claim
311 words
An impact resisting and strength-imparting wall segment product comprising: rigid insulation board; a stucco coating mixture; and a high strength, alkali resistant, impact resistant and strength imparting, resin-coated open grid wall reinforcement fabric comprising: a first set of substantially parallel impact resistant and strength-imparting rovings comprising an effective impact-resisting and strength-imparting amount of a direct-sized silane containing sizing, having a linear density between 130 and 400 grams per thousand meters, and being arranged in the set at an average of 1.5 to 12 ends per inch; a second set of substantially parallel impact resistant and strength imparting rovings comprising an effective impact-resisting and strength-imparting amount of a direct-sized silane containing sizing, having a linear density between 130 and 400 grams per thousand meters, and being arranged in the set at an average of 1.5 to 12 ends per inch; the first and second sets of rovings being arranged next to each other with the rovings of one set being arranged at a substantial angle to the rovings of the other set, without compressing rovings of one set between rovings of the other set, to form an open grid wall reinforcement fabric weighing between 50 to 650 gm/square meter to provide strength and impact resistance to the wall segment product; and an effective strength-imparting amount of polymeric coating on the rovings of the wall reinforcement at a level of 10 to 150 parts dry weight of resin to 100 parts by weight of the open grid fabric wall reinforcement, the stucco coating mixture being affixed to the insulation board and binding the fabric to the board by penetrating the openings between the rovings to the board, filling the openings in the open grid and covering the reinforcement fabric, such that the open grid is embedded in the stucco coating mixture and imparts strength and provides impact resistance to the wall segment product.
Claim 29
Dependent Claim
18 words
The wall segment product of claim 25, in which the segment is prefabricated before installation on a wall.
Claim 30
Dependent Claim
22 words
The wall segment product of claim 25, wherein the polymeric coating has a glass transition temperature between -40° C. to +40° C.
Claim 31
Dependent Claim
65 words
The wall segment product of claim 25, in which the polymeric coating is alkali and water resistant and is selected from the group consisting of polyvinyl chloride, polyvinylidene chloride, styrene butadiene rubber, urethane, silicone, acrylic and styrene acrylate polymers and copolymers, and the coating is applied at a level of 5 to 40 parts dry weight of resin to 100 parts by weight of fabric.
Claim 32
Dependent Claim
28 words
The wall segment product of claim 25, wherein the first and second sets of rovings are selected from the group consisting of fiberglass, nylon, aramid, polyolefin and polyester.
Claim 33
Dependent Claim
42 words
The wall segment product of claim 25, wherein the first set of rovings and the second set of rovings are arranged at an average of 3 to 10 strands per inch and each set of rovings lies essentially in its own plane.
Claim 34
Dependent Claim
23 words
The wall segment product of claim 25, in which the rovings are direct-sized with a silane sizing that consists essentially of silane sizing.
Claim 35
Dependent Claim
22 words
The wall segment product of claim 25, wherein the first and second sets of rovings are affixed together with the tie yarn.
Claim 36
Dependent Claim
43 words
The wall segment product of claim 32, wherein the tie yarn is knit to the first and second sets of rovings at a tension of at least about 3.1 yards of tie yarn for every 1 yard of ends in a warp direction.
Claim 37
Dependent Claim
68 words
The wall segment product of claim 32, in which the two sets of rovings are affixed together with tie yarn in a staggered leno weaving process in which the tie yarn is arranged in pairs with rovings in one of the sets of rovings, and the tie yarns and the rovings are alternately twisted in a right hand and left hand direction crossing before weft roving is inserted.
Claim 38
Dependent Claim
67 words
The wall reinforcement of claim 32, in which the two sets of rovings are affixed together with tie yarn in a hurl leno weaving process in which the tie yarn is arranged in pairs with rovings in one of the sets of rovings, and the tie yarn and the rovings are alternately twisted in a right hand and left hand direction crossing before weft roving is inserted.
Claim 39
Dependent Claim
67 words
The wall reinforcement of claim 32, in which the two sets of rovings are affixed together with tie yarn in a staggered hurl weaving process in which the tie yarn is arranged in pairs with rovings in one of the sets of rovings, and the tie yarns and the rovings are alternately twisted in a right hand and left hand direction crossing before weft roving is inserted.
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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) | 1999-09-03 | 2000-03-04 | 2000-09-03 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2003-09-03 | 2004-03-04 | 2004-09-03 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2007-09-03 | 2008-03-04 | 2008-09-03 | $7700.00 | Window Closed / Lapsed |