US5651641A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Geosynthetics
Assignee: Nicolon Corp
•
Filing: 1995-05-31
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Granted: 1997-07-29
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Expires: 2015-05-31
Abstract
Abstract Tufted mats for a broad variety of erosion control, turf reinforcement, and earth reinforcement applications. The mats are formed of scrim which is tufted, preferably on conventional carpet machinery, with a number of tufted ends in order to provide high tensile strength, greatly porous and flexible mats which may be easily installed, but which contain a number of interstices for capturing root systems, retaining soil, and controlling the flow of water. The properties of the mats may be easily controlled and optimized by controlling the properties and arrangements of the cross machine ends and machine ends forming the scrim if woven (or corresponding ends, filaments or fibers if knitted or nonwoven), as well as the tufted ends which are tufted into the scrim. Therefore, process technology such as settings on conventional weaving and tufting equipment, may be employed to provide cost-effective, customized, lightweight but strong and durable mats for a broad variety of erosion control, turf reinforcement, and earth reinforcement applications.
Inventors
- 👤 Thomas C. Stephens
- 👤 Teri L. Frauenfelder Krock
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-07 07:56
CPC Classifications
E; E02; E02D; E02D17/00; E02D17/20; E02D17/202; D; D04; D04H; D04H11/00; Y; Y10; Y10T; Y10T428/00; Y10T428/23907; Y10T428/23957
Claims Analysis
Total Claims: 42
Claim 1
Independent Claim
126 words
A geosynthetic structure comprising: a. a substrate of particulate material; b. a layer of tufted geosynthetic mat disposed on the substrate of particulate material, comprising a scrim formed of a plurality of synthetic ends, the scrim tufted with a plurality of synthetic tufted ends, with each tufted end forming a coil tufted to the scrim, each coil including a repeated pattern of loops, each repeated pattern of loops defining a plurality of interstices for capturing vegetation and retaining soil whereby the interstices are oriented in three dimensions to create a light penetration of no less than substantially 1.5%; and c. vegetation rooted at least partially in the substrate of particulate material and extending at least partially through the interstices in the layer of tufted geosynthetic mat.
Claim 2
Dependent Claim
126 words
A geosynthetic structure comprising: a. a substrate of particulate material; b. a layer of tufted geosynthetic mat disposed on the substrate of particulate material, comprising a scrim formed of a plurality of synthetic ends, the scrim tufted with a plurality of synthetic tufted ends, with each tufted end forming a coil tufted to the scrim, each coil including a repeated pattern of loops, each repeated pattern of loops defining a plurality of interstices for capturing vegetation and retaining soil whereby the interstices are oriented in three dimensions to create a light penetration of no less than substantially 1.5%; and c. vegetation rooted at least partially in the substrate of particulate material and extending at least partially through the interstices in the layer of tufted geosynthetic mat.
Claim 3
Dependent Claim
37 words
A structure according to claim 1 in which the layer of geosynthetic mat features a machine direction tensile strength (in pounds per foot) to density (in ounces per square yard) ratio of between substantially 27.5 and 66.
Claim 4
Dependent Claim
38 words
A structure according to claim 1 in which the layer of geosynthetic mat features a cross machine direction tensile strength (in pounds per foot) to density (in ounces per square yard) ratio of between substantially 27.5 and 48.
Claim 5
Dependent Claim
39 words
A structure according to claim 1 in which the layer of geosynthetic mat features machine and cross machine direction tensile strength (in pounds per foot) to density (in ounces per square yard) ratio of between substantially 27.5 and 66.
Claim 6
Dependent Claim
16 words
A structure according to claim 1 in which the tufted ends comprise a plurality of filaments.
Claim 7
Dependent Claim
138 words
A geosynthetic structure comprising: a. a substrate of particulate material; b. a layer of tufted geosynthetic mat disposed on the substrate of particulate material, comprising a woven scrim formed of a plurality of synthetic cross machine direction ends and a plurality of synthetic machine direction ends, the scrim tufted with a plurality of synthetic tufted ends with each tufted end forming a coil tufted to the scrim, each coil including a repeated pattern of loops, each repeated pattern of loops defining a plurality of interstices for capturing vegetation and retaining soil whereby the interstices are oriented in three dimensions to create a light penetration of no less than substantially 15%; and c. vegetation rooted at least partially in the substrate of particulate material and extending at least partially through the interstices in the layer of tufted geosynthetic mat.
Claim 8
Dependent Claim
138 words
A geosynthetic structure comprising: a. a substrate of particulate material; b. a layer of tufted geosynthetic mat disposed on the substrate of particulate material, comprising a woven scrim formed of a plurality of synthetic cross machine direction ends and a plurality of synthetic machine direction ends, the scrim tufted with a plurality of synthetic tufted ends with each tufted end forming a coil tufted to the scrim, each coil including a repeated pattern of loops, each repeated pattern of loops defining a plurality of interstices for capturing vegetation and retaining soil whereby the interstices are oriented in three dimensions to create a light penetration of no less than substantially 15%; and c. vegetation rooted at least partially in the substrate of particulate material and extending at least partially through the interstices in the layer of tufted geosynthetic mat.
Claim 9
Dependent Claim
37 words
A structure according to claim 6 in which the layer of geosynthetic mat features a machine direction tensile strength (in pounds per foot) to density (in ounces per square yard) ratio of between substantially 47 and 66.
Claim 10
Dependent Claim
37 words
A structure according to claim 6 in which the layer of geosynthetic mat features a cross direction tensile strength (in pounds per foot) to density (in ounces per square yard) ratio of between substantially 34 and 48.
Claim 11
Dependent Claim
39 words
A structure according to claim 6 in which the layer of geosynthetic mat features machine and cross machine direction tensile strength (in pounds per foot) to density (in ounces per square yard) ratio of between substantially 34 and 66.
Claim 12
Dependent Claim
20 words
A structure according to claim 6 in which the cross machine ends and the machine ends are structurally the same.
Claim 13
Dependent Claim
17 words
A structure according to claim 6 in which the machine ends are intertwisted between cross machine ends.
Claim 14
Dependent Claim
27 words
A structure according to claim 6 in which the machine ends and the cross machine ends are extruded filaments having a thickness substantially at least 11.5 mils.
Claim 15
Dependent Claim
27 words
A structure according to claim 6 in which the tufted ends are between 1 and 30 ply of filaments having a thickness substantially at least 11.5 mils.
Claim 16
Dependent Claim
16 words
A structure according to claim 6 in which the tufted ends comprise a plurality of filaments.
Claim 17
Dependent Claim
199 words
A geosynthetic structure comprising: a. a substrate of particulate material; b. a layer of tufted geosynthetic mat disposed on the substrate of particulate material, comprising a woven scrim formed of a plurality of cross machine direction ends and a plurality of machine direction ends, both machine and cross machine ends comprising filaments having a thickness of substantially at least 11.5 mils; the scrim tufted with a plurality of tufted ends comprising between substantially 1 and 30 ply of filaments, each filament having a thickness of at least substantially 11.5 mils, with each tufted end forming a coil tufted to the scrim, each coil including a repeated pattern of loops, each repeated pattern of loops defining a plurality of interstices for capturing vegetation and retaining soil whereby the interstices are oriented in three dimensions to create a light penetration between substantially 15% and 20%; and exhibits a cross machine and machine direction tensile strength (in pounds per foot) to density (in ounces per square yard) ratio of between substantially 34 and 66; and c. vegetation rooted at least partially in the substrate of particulate material and extending at least partially through the interstices in the layer of tufted geosynthetic mat.
Claim 18
Dependent Claim
199 words
A geosynthetic structure comprising: a. a substrate of particulate material; b. a layer of tufted geosynthetic mat disposed on the substrate of particulate material, comprising a woven scrim formed of a plurality of cross machine direction ends and a plurality of machine direction ends, both machine and cross machine ends comprising filaments having a thickness of substantially at least 11.5 mils; the scrim tufted with a plurality of tufted ends comprising between substantially 1 and 30 ply of filaments, each filament having a thickness of at least substantially 11.5 mils, with each tufted end forming a coil tufted to the scrim, each coil including a repeated pattern of loops, each repeated pattern of loops defining a plurality of interstices for capturing vegetation and retaining soil whereby the interstices are oriented in three dimensions to create a light penetration between substantially 15% and 20%; and exhibits a cross machine and machine direction tensile strength (in pounds per foot) to density (in ounces per square yard) ratio of between substantially 34 and 66; and c. vegetation rooted at least partially in the substrate of particulate material and extending at least partially through the interstices in the layer of tufted geosynthetic mat.
Claim 19
Dependent Claim
149 words
A geosynthetic structure comprising: a. a substrate of particulate material; b. a layer of tufted geosynthetic mat disposed on the substrate of particulate material, comprising a woven scrim formed of a plurality of synthetic cross machine direction ends and a plurality of synthetic machine direction ends, the scrim tufted with a plurality of synthetic tufted ends, with each tufted end forming a coil tufted to the scrim, each coil including a repeated pattern of loops, each repeated pattern of loops defining a plurality of interstices for capturing vegetation and retaining soil whereby the interstices are oriented in three dimensions to create a light penetration of no less than substantially 15%; and c. an overstratum of particulate material disposed on the layer of tufted geosynthetic mat, at least some of the particulate material of the overstratum captured and retained within the interstices formed in the layer of tufted geosynthetic mat.
Claim 20
Dependent Claim
149 words
A geosynthetic structure comprising: a. a substrate of particulate material; b. a layer of tufted geosynthetic mat disposed on the substrate of particulate material, comprising a woven scrim formed of a plurality of synthetic cross machine direction ends and a plurality of synthetic machine direction ends, the scrim tufted with a plurality of synthetic tufted ends, with each tufted end forming a coil tufted to the scrim, each coil including a repeated pattern of loops, each repeated pattern of loops defining a plurality of interstices for capturing vegetation and retaining soil whereby the interstices are oriented in three dimensions to create a light penetration of no less than substantially 15%; and c. an overstratum of particulate material disposed on the layer of tufted geosynthetic mat, at least some of the particulate material of the overstratum captured and retained within the interstices formed in the layer of tufted geosynthetic mat.
Claim 21
Dependent Claim
37 words
A structure according to claim 16 in which the layer of geosynthetic mat features a machine direction tensile strength (in pounds per foot) to density (in ounces per square yard) ratio of between substantially 47 and 66.
Claim 22
Dependent Claim
38 words
A structure according to claim 16 in which the layer of geosynthetic mat features a cross machine direction tensile strength (in pounds per foot) to density (in ounces per square yard) ratio of between substantially 34 and 48.
Claim 23
Dependent Claim
39 words
A structure according to claim 16 in which the layer of geosynthetic mat features cross machine and machine direction tensile strength (in pounds per foot) to density (in ounces per square yard) ratio of between substantially 34 and 66.
Claim 24
Dependent Claim
20 words
A structure according to claim 16 in which the cross machine ends and the machine ends are structurally the same.
Claim 25
Dependent Claim
17 words
A structure according to claim 16 in which the machine ends are intertwisted between cross machine ends.
Claim 26
Dependent Claim
28 words
A structure according to claim 16 in which the machine ends and the cross machine ends comprising filaments that have a thickness of at least substantially 11.5 mils.
Claim 27
Dependent Claim
28 words
A structure according to claim 16 in which the tufted ends are between 1 and 30 ply of filaments having a thickness of at least substantially 11.5 mils.
Claim 28
Dependent Claim
16 words
A structure according to claim 16 in which the tufted ends comprise a plurality of filaments.
Claim 29
Dependent Claim
210 words
A geosynthetic structure comprising: a. a substrate of particulate material; b. a layer of tufted geosynthetic mat disposed on the substrate of particulate material, comprising a woven scrim formed of a plurality of cross machine direction ends and a plurality of machine direction ends, both machine and cross machine ends comprising filaments having a thickness of at least substantially 11.5 mils; the scrim tufted with a plurality of tufted ends comprising between substantially 1 and 30 ply of filaments, each filament having a thickness of at least substantially 11.5 mils, and each tufted end forming a coil tufted to the scrim, each coil including a repeated pattern of loops, each repeated pattern of loops defining a plurality of interstices for capturing vegetation and retaining soil whereby the interstices are oriented in three dimensions to create a light penetration between substantially 15% and 20%; and exhibits a cross machine and machine direction tensile strength (in pounds per foot) to density (in ounces per square yard) ratio of between substantially 34 and 66; and c. an overstratum of particulate material disposed on the layer of tufted geosynthetic mat, at least some of the particulate material of the overstratum captured and retained within the interstices formed in the layer of tufted geosynthetic mat.
Claim 30
Dependent Claim
210 words
A geosynthetic structure comprising: a. a substrate of particulate material; b. a layer of tufted geosynthetic mat disposed on the substrate of particulate material, comprising a woven scrim formed of a plurality of cross machine direction ends and a plurality of machine direction ends, both machine and cross machine ends comprising filaments having a thickness of at least substantially 11.5 mils; the scrim tufted with a plurality of tufted ends comprising between substantially 1 and 30 ply of filaments, each filament having a thickness of at least substantially 11.5 mils, and each tufted end forming a coil tufted to the scrim, each coil including a repeated pattern of loops, each repeated pattern of loops defining a plurality of interstices for capturing vegetation and retaining soil whereby the interstices are oriented in three dimensions to create a light penetration between substantially 15% and 20%; and exhibits a cross machine and machine direction tensile strength (in pounds per foot) to density (in ounces per square yard) ratio of between substantially 34 and 66; and c. an overstratum of particulate material disposed on the layer of tufted geosynthetic mat, at least some of the particulate material of the overstratum captured and retained within the interstices formed in the layer of tufted geosynthetic mat.
Claim 31
Dependent Claim
144 words
A civil engineering structure comprising: a. a substrate of particulate material; b. a layer of tufted geosynthetic mat disposed on the substrate of particulate material, comprising a woven scrim formed of a plurality of synthetic cross machine direction ends and a plurality of synthetic machine direction ends, the scrim tufted with a plurality of synthetic tufted ends, with each tufted end forming a coil tufted to the scrim, each coil including a repeated pattern of loops, each repeated pattern of loops defining a plurality of interstices for capturing vegetation and retaining soil whereby the interstices are oriented in three dimensions to create a light penetration of no less than substantially 15%; and c. at least one retaining structure formed of concrete material attached to the layer of tufted geosynthetic mat and disposed to retain at least a portion of the substrate of particulate material.
Claim 32
Dependent Claim
144 words
A civil engineering structure comprising: a. a substrate of particulate material; b. a layer of tufted geosynthetic mat disposed on the substrate of particulate material, comprising a woven scrim formed of a plurality of synthetic cross machine direction ends and a plurality of synthetic machine direction ends, the scrim tufted with a plurality of synthetic tufted ends, with each tufted end forming a coil tufted to the scrim, each coil including a repeated pattern of loops, each repeated pattern of loops defining a plurality of interstices for capturing vegetation and retaining soil whereby the interstices are oriented in three dimensions to create a light penetration of no less than substantially 15%; and c. at least one retaining structure formed of concrete material attached to the layer of tufted geosynthetic mat and disposed to retain at least a portion of the substrate of particulate material.
Claim 33
Dependent Claim
23 words
A structure according to claim 26 in which the retaining structure formed of concrete is cast to the layer of tufted geosynthetic mat.
Claim 34
Dependent Claim
18 words
A structure according to claim 26 in which the retaining structure comprises at least one retaining wall component.
Claim 35
Dependent Claim
18 words
A structure according to claim 26 in which the retaining structure comprises at least one earth stabilization block.
Claim 36
Dependent Claim
16 words
A structure according to claim 26 in which the tufted ends comprise a plurality of filaments.
Claim 37
Dependent Claim
163 words
A civil engineering structure comprising: a. a substrate of particulate material; b. a layer of tufted geosynthetic mat disposed adjacent to the substrate of particulate material, comprising a woven scrim formed of a plurality of synthetic cross machine direction ends and a plurality of synthetic machine direction ends, the scrim tufted with a plurality of synthetic tufted ends, with each tufted end forming a coil tufted to the scrim, each coil including a repeated pattern of loops, each repeated pattern of loops defining a plurality of interstices for capturing vegetation and retaining soil whereby the interstices are oriented in three dimensions to create a light penetration of no less than substantially 15% and features cross machine and machine direction tensile strength (in pounds per foot) to density (in ounces per square yard) ratio of between substantially 34 and 66; and c. at least one membrane which is substantially impermeable to liquid, which membrane is disposed adjacent to the layer of tufted geosynthetic mat.
Claim 38
Dependent Claim
163 words
A civil engineering structure comprising: a. a substrate of particulate material; b. a layer of tufted geosynthetic mat disposed adjacent to the substrate of particulate material, comprising a woven scrim formed of a plurality of synthetic cross machine direction ends and a plurality of synthetic machine direction ends, the scrim tufted with a plurality of synthetic tufted ends, with each tufted end forming a coil tufted to the scrim, each coil including a repeated pattern of loops, each repeated pattern of loops defining a plurality of interstices for capturing vegetation and retaining soil whereby the interstices are oriented in three dimensions to create a light penetration of no less than substantially 15% and features cross machine and machine direction tensile strength (in pounds per foot) to density (in ounces per square yard) ratio of between substantially 34 and 66; and c. at least one membrane which is substantially impermeable to liquid, which membrane is disposed adjacent to the layer of tufted geosynthetic mat.
Claim 39
Dependent Claim
16 words
A structure according to claim 31 in which the tufted ends comprise a plurality of filaments.
Claim 40
Dependent Claim
155 words
A filter structure comprising: a. a substrate of particulate material; b. a layer of tufted geosynthetic mat disposed on the substrate of particulate material, comprising a woven scrim formed of a plurality of synthetic cross machine direction ends and a plurality of synthetic machine direction ends, the scrim tufted with a plurality of synthetic tufted ends, with each tufted end forming a coil tufted to the scrim, each coil including a repeated pattern of loops, each repeated pattern of loops defining a plurality of interstices for capturing vegetation and retaining soil whereby the interstices are oriented in three dimensions to create a light penetration of no less than substantially 15% and features cross machine and machine direction tensile strength (in pounds per foot) to density (in ounces per square yard) ratio of between substantially 34 and 66; and c. at least one layer of crushed rock material disposed on the layer of tufted geosynthetic mat.
Claim 41
Dependent Claim
155 words
A filter structure comprising: a. a substrate of particulate material; b. a layer of tufted geosynthetic mat disposed on the substrate of particulate material, comprising a woven scrim formed of a plurality of synthetic cross machine direction ends and a plurality of synthetic machine direction ends, the scrim tufted with a plurality of synthetic tufted ends, with each tufted end forming a coil tufted to the scrim, each coil including a repeated pattern of loops, each repeated pattern of loops defining a plurality of interstices for capturing vegetation and retaining soil whereby the interstices are oriented in three dimensions to create a light penetration of no less than substantially 15% and features cross machine and machine direction tensile strength (in pounds per foot) to density (in ounces per square yard) ratio of between substantially 34 and 66; and c. at least one layer of crushed rock material disposed on the layer of tufted geosynthetic mat.
Claim 42
Dependent Claim
16 words
A structure according to claim 33 in which the tufted ends comprise a plurality of filaments.
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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) | 2000-07-28 | 2001-01-27 | 2001-07-29 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2004-07-28 | 2005-01-27 | 2005-07-29 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2008-07-28 | 2009-01-27 | 2009-07-29 | $7700.00 | Window Closed / Lapsed |