US6802669B2
Expired / Lapsed
US
⏱️ 0.0 years remaining
Void-maintaining synthetic drainable base courses and methods for extending the useful life of paved structures
Assignee: Tenax Corp
•
Filing: 2002-09-03
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Granted: 2004-10-12
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Expires: 2022-09-03
Abstract
Abstract Numerous embodiments of a synthetic drainable base course (“SDBC”), and paved structures that may advantageously include an SDBC, are provided. As a key advantage of SDBC's according to the invention, they are of sufficient capacities and structural strength to be used within layered paved structures such as highways, airport runways and parking lots, to provide drainage superior to that afforded by conventional means and methods involving the use of open graded base courses that are typically formed of natural soils and aggregate and are extremely expensive to install. The invention includes means and methods that use conventional heavy equipment for installing an SDBC during the construction of a roadway or other paved surface.
Inventors
- 👤 Peter J. Ianniello
- 👤 Giovanni Capra
- 👤 Aigen Zhao
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-06 12:16
CPC Classifications
E; E02; E02B; E02B11/00; E01; E01F; E01F5/00; E02D; E02D31/00; E02D31/02
Claims Analysis
Total Claims: 53
Claim 1
Independent Claim
174 words
A synthetic drainable base course for draining fluids away from a roadway or other large structure, comprising: A) a void-maintaining geocomposite comprising i) a geocomposite core element having a plurality of ribs constructed and arranged to form a plurality of interconnected voids, said core element having an upper surface and a lower surface, a no-load thickness and a thickness under load, wherein said thicknesses are measured substantially perpendicular to said surfaces, ii) at least one fluid-transmissible layer adjacent said upper surface, and iii) at least one fluid-transmissible layer adjacent said lower surface of said geocomposite, wherein said layers and said core are constructed and arranged so that, under a load of at least 750 lbs/foot for a period of at least 100 hours, said geocomposite maintains voids of sufficient dimension that fluid from said roadway or other large structure can move freely through said geocomposite at rate of at least 1,000 feet 3 /day/foot, and wherein said geocomposite is sloped downwardly in a gradient from a portion of said roadway or other large structure.
Claim 2
Dependent Claim
174 words
A synthetic drainable base course for draining fluids away from a roadway or other large structure, comprising: A) a void-maintaining geocomposite comprising i) a geocomposite core element having a plurality of ribs constructed and arranged to form a plurality of interconnected voids, said core element having an upper surface and a lower surface, a no-load thickness and a thickness under load, wherein said thicknesses are measured substantially perpendicular to said surfaces, ii) at least one fluid-transmissible layer adjacent said upper surface, and iii) at least one fluid-transmissible layer adjacent said lower surface of said geocomposite, wherein said layers and said core are constructed and arranged so that, under a load of at least 750 lbs/foot for a period of at least 100 hours, said geocomposite maintains voids of sufficient dimension that fluid from said roadway or other large structure can move freely through said geocomposite at rate of at least 1,000 feet 3 /day/foot, and wherein said geocomposite is sloped downwardly in a gradient from a portion of said roadway or other large structure.
Claim 3
Dependent Claim
70 words
The synthetic drainable base course of claim 1 , wherein said layers and said core are constructed and arranged so that, under a load of at least 1,000 lbs/foot 2 for a period of at least 100 hours, said void-maintaining geocomposite maintains voids of sufficient dimension that fluid from said roadway or other large structure can move freely through said geocomposite at rate of at least 2,000 feet 3 /day/foot.
Claim 4
Dependent Claim
79 words
The synthetic drainable base course of claim 1 , wherein said ribs of said core are provided in a first set and a second set, and a) said ribs of said first set are disposed substantially parallel to one another and substantially in a first plane, and 2) said ribs of said second set being disposed substantially parallel to one another and substantially in a second plane, and wherein said first and second planes are disposed adjacent one another.
Claim 5
Dependent Claim
58 words
The synthetic drainable base course of claim 3 , wherein further ribs are provided in at least a third set wherein said ribs of said third set are disposed substantially parallel to one another and said third set of ribs is disposed in a third plane adjacent and non-parallel to the ribs of said first or second sets.
Claim 6
Dependent Claim
35 words
The synthetic drainable base course of claim 1 , wherein the cross-section of any one of said ribs approximates one or more shapes from the group consisting of a square, a rectangle and a trapezoid.
Claim 7
Dependent Claim
36 words
The synthetic drainable base course of claim 5 , wherein said square has a width and a height approximately equal to one another, and said width and height have dimensions of from 1.0 to 10.0 mm.
Claim 8
Dependent Claim
40 words
The synthetic drainable base course of claim 5 , wherein said rectangle has a width and a height, and said width has dimensions of from 2.0 to 15.0 mm and said height has dimensions of from 1.0 to 10.0 mm.
Claim 9
Dependent Claim
56 words
The synthetic drainable base course of claim 5 , wherein said trapezoid has a major width, a minor width and a height, and said major width has dimensions of from 2.0 to 15.0 mm, said minor width has dimensions of from 1.0 to 10.0 mm and said height has dimensions of from 1.0 to 10.0 mm.
Claim 10
Dependent Claim
30 words
The synthetic drainable base course of claim 1 , wherein at least some of said ribs comprise crenulations and said crenulations are disposed longitudinally along the surfaces of said ribs.
Claim 11
Dependent Claim
28 words
The synthetic drainable base course of claim 1 , wherein all of said ribs are crenulated and said crenulations are disposed longitudinally along the surfaces of said ribs.
Claim 12
Dependent Claim
33 words
The synthetic drainable base course of claim 1 , wherein under a load of 1,200 kPa for at least 10,000 hours, said thickness under load is at least 65% of said no-load thickness.
Claim 13
Dependent Claim
33 words
The synthetic drainable base course of claim 1 , wherein under a load of 1,200 kPa for at least 10,000 hours, said thickness under load is at least 60% of said no-load thickness.
Claim 14
Dependent Claim
33 words
The synthetic drainable base course of claim 1 , wherein under a load of 1,200 kPa for at least 10,000 hours, said thickness under load is at least 50% of said no-load thickness.
Claim 15
Dependent Claim
24 words
The synthetic drainable base course of claim 1 , wherein said no-load thickness is in the range of from 0.20 inches to 1.00 inches.
Claim 16
Dependent Claim
24 words
The synthetic drainable base course of claim 1 , wherein said no-load thickness is in the range of from 0.20 inches to 0.75 inches.
Claim 17
Dependent Claim
24 words
The synthetic drainable base course of claim 1 , wherein said no-load thickness is in the range of from 0.25 inches to 0.35 inches.
Claim 18
Dependent Claim
32 words
The synthetic drainable base course of claim 1 , wherein said core element has a tensile strength of at least 400 lbs per square foot in both machine direction and cross-machine direction.
Claim 19
Dependent Claim
32 words
The synthetic drainable base course of claim 1 , wherein said core element has a tensile strength of at least 500 lbs per square foot in both machine direction and cross-machine direction.
Claim 20
Dependent Claim
33 words
The synthetic drainable base course of claim 1 , wherein under a load of 721 kPa for at least 100 hours, said thickness under load is at least 65% of said no-load thickness.
Claim 21
Dependent Claim
33 words
The synthetic drainable base course of claim 1 , wherein under a load of 721 kPa for at least 100 hours, said thickness under load is at least 60% of said no-load thickness.
Claim 22
Dependent Claim
33 words
The synthetic drainable base course of claim 1 , wherein under a load of 721 kPa for at least 100 hours, said thickness under load is at least 55% of said no-load thickness.
Claim 23
Dependent Claim
33 words
The synthetic drainable base course of claim 1 , wherein under a load of 721 kPa for at least 100 hours, said thickness under load is at least 50% of said no-load thickness.
Claim 24
Dependent Claim
26 words
The synthetic drainable base course of claim 1 , wherein said gradient is at least 2% in a direction away from said portion of said roadway.
Claim 25
Dependent Claim
18 words
The synthetic drainable base course of claim 1 , wherein said portion of said roadway is the centerline.
Claim 26
Dependent Claim
41 words
The synthetic drainable base course of claim 1 , wherein under a load of 721 kPa for at least 100 hours, said voids maintain an average width of at least 2.0 mm and an average height of at least 10.0 mm.
Claim 27
Dependent Claim
34 words
The synthetic drainable base course of claim 1 , wherein under a load of 721 kPa for at least 100 hours, said voids maintain an average width of from 2.0 mm to 10.0 mm.
Claim 28
Dependent Claim
34 words
The synthetic drainable base course of claim 1 , wherein under a load of 721 kPa for at least 100 hours, said voids maintain an average width of from 3.0 mm to 8.0 mm.
Claim 29
Dependent Claim
34 words
The synthetic drainable base course of claim 1 , wherein under a load of 1,200 kPa for at least 100 hours, said voids maintain an average width of from 2.0 mm to 10.0 mm.
Claim 30
Dependent Claim
34 words
The synthetic drainable base course of claim 1 , wherein under a load of 1,200 kPa for at least 100 hours, said voids maintain an average width of from 3.0 mm to 8.0 mm.
Claim 31
Dependent Claim
34 words
The synthetic drainable base course of claim 1 , wherein under a load of 1,200 kPa for at least 100 hours, said voids maintain an average height of from 2.0 mm to 10.0 mm.
Claim 32
Dependent Claim
34 words
The synthetic drainable base course of claim 1 , wherein under a load of 1,200 kPa for at least 100 hours, said voids maintain an average height of from 3.0 mm to 8.0 mm.
Claim 33
Dependent Claim
41 words
The synthetic drainable base course of claim 1 , wherein under a load of 721 kPa for at least 100 hours, said voids maintain an average width of at least 3.0 mm and an average height of at least 10.0 mm.
Claim 34
Dependent Claim
41 words
The synthetic drainable base course of claim 1 , wherein under a load of 1,200 kPa for at least 100 hours, said voids maintain an average width of at least 2.0 mm and an average height of at least 8.0 mm.
Claim 35
Dependent Claim
41 words
The synthetic drainable base course of claim 1 , wherein under a load of 721 kPa for at least 100 hours, said voids maintain an average width of at least 6.0 mm and an average height of at least 8.0 mm.
Claim 36
Dependent Claim
41 words
The synthetic drainable base course of claim 1 , wherein under a load of 1,200 kPa for at least 1,000 hours, said voids maintain an average width of at least 2.0 mm and an average height of at least 8.0 mm.
Claim 37
Dependent Claim
41 words
The synthetic drainable base course of claim 1 , wherein under a load of 721 kPa for at least 1,000 hours, said voids maintain an average width of at least 6.0 mm and an average height of at least 8.0 mm.
Claim 38
Dependent Claim
25 words
The synthetic drainable base course of claim 1 , wherein said ribs are constructed and arranged to form preferential flow paths and non-preferential flow paths.
Claim 39
Dependent Claim
31 words
The synthetic drainable base course of claim 37 , wherein said preferential flow paths and said non-preferential flow paths are not parallel to one another and are formed by said ribs.
Claim 40
Dependent Claim
29 words
The synthetic drainable base course of claim 37 , disposed in a roadway or other large structure such that said preferential flow path is substantially perpendicular to said portion.
Claim 41
Dependent Claim
31 words
The synthetic drainable base course of claim 37 , wherein at least 65% of the volume of fluid moving through said SDBC does so by way of said preferential flow path.
Claim 42
Dependent Claim
18 words
The synthetic drainable base course of claim 39 , wherein said portion of said roadway is the centerline.
Claim 43
Dependent Claim
36 words
The synthetic drainable base course of claim 1 , wherein said geocomposite core comprises at least one margin constructed and arranged to transmit fluids from said base course away from said roadway or other large structure.
Claim 44
Dependent Claim
42 words
The synthetic drainable base course of claim 42 , wherein said at least one margin is constructed and arranged to connect with one or more selected from the group consisting of perforated pipes, non-perforated pipes, drainage ditches, sumps, canals, streams and rivers.
Claim 45
Dependent Claim
135 words
The synthetic drainable base course of claim 42 , wherein said drain means comprises perforated piping adjacent said synthetic drainable base course and communicating therewith such that said fluid can move from said base course to said perforated piping, wherein said perforated piping is sloped downwardly from said base course, wherein said base course is constructed and arranged to form a wrapping adjacent to and around the circumference of at least a portion of said perforated piping such that a portion of one of said upper or lower fluid-transmissible geotextile layers is removed along the length of the wrapping so that said geocomposite core contacts said piping and said removed portion of said one of said upper or lower fluid-transmissible geotextile layers comprises overlapping portions and is connected to the other surface fluid-transmissible geotextile layer.
Claim 46
Dependent Claim
211 words
A layered paved structure comprising I. a base layer formed at least partially of native soil components, II. a synthetic drainable base course disposed above said base layer and comprising A) a void-maintaining geocomposite including i) a geocomposite core element having a plurality of ribs constructed and arranged to form a plurality of interconnected voids, said core element having an upper surface and a lower surface, a no-load thickness and a thickness under load, wherein said thicknesses are measured substantially perpendicular to said surfaces, ii) at least one fluid-transmissible layer attached adjacent said upper surface, and iii) at least one fluid-transmissible layer attached adjacent said lower surface of said geocomposite, wherein said layers and said core are constructed and arranged so that, under a load of at least 750 lbs/foot 2 for a period of at least 100 hours, said geocomposite maintains voids of sufficient dimension that fluid from said roadway or other large structure can move freely through said geocomposite at rate of at least 1,000 feet 3 /day/foot, and III. above said synthetic drainable base course, pavement comprising one or more layers of asphalt or cementitious materials, wherein said synthetic drainable base course is sloped downwardly in a gradient from a portion of said roadway or other large structure.
Claim 47
Dependent Claim
211 words
A layered paved structure comprising I. a base layer formed at least partially of native soil components, II. a synthetic drainable base course disposed above said base layer and comprising A) a void-maintaining geocomposite including i) a geocomposite core element having a plurality of ribs constructed and arranged to form a plurality of interconnected voids, said core element having an upper surface and a lower surface, a no-load thickness and a thickness under load, wherein said thicknesses are measured substantially perpendicular to said surfaces, ii) at least one fluid-transmissible layer attached adjacent said upper surface, and iii) at least one fluid-transmissible layer attached adjacent said lower surface of said geocomposite, wherein said layers and said core are constructed and arranged so that, under a load of at least 750 lbs/foot 2 for a period of at least 100 hours, said geocomposite maintains voids of sufficient dimension that fluid from said roadway or other large structure can move freely through said geocomposite at rate of at least 1,000 feet 3 /day/foot, and III. above said synthetic drainable base course, pavement comprising one or more layers of asphalt or cementitious materials, wherein said synthetic drainable base course is sloped downwardly in a gradient from a portion of said roadway or other large structure.
Claim 48
Dependent Claim
28 words
The layered paved structure of claim 45 , further comprising a support layer, said support layer being disposed above said synthetic drainable base course, and below said pavement.
Claim 49
Dependent Claim
28 words
The layered paved structure of claim 46 , wherein said support layer comprises one or more from the group consisting of native soil components, and non-native soil components.
Claim 50
Independent Claim
227 words
A method of forming a layered paved structure having no open graded base course, comprising the steps of I. providing a base layer formed at least partially of native soil components, II. providing a synthetic drainable base course disposed above said base layer and comprising A) a void-maintaining geocomposite including i) a geocomposite core element having a plurality of ribs constructed and arranged to form a plurality of interconnected voids, said core element having an upper surface and a lower surface, a no-load thickness and a thickness under load, wherein said thicknesses are measured substantially perpendicular to said surfaces, ii) at least one fluid-transmissible layer attached adjacent said upper surface, and iii) at least one fluid-transmissible layer attached adjacent said lower surface of said geocomposite, wherein said layers and said core are constructed and arranged so that, under a load of at least 750 lbs/foot 2 for a period of at least 100 hours, said geocomposite maintains voids of sufficient dimension that fluid from said roadway or other large structure can move freely through said geocomposite at rate of at least 1,000 feet 3 /day/foot, and III. above said synthetic drainable base course, providing pavement comprising one or more layers of asphalt or cementitious materials, wherein said synthetic drainable base course is sloped downwardly in a gradient from a portion of said roadway or other large structure.
Claim 51
Independent Claim
227 words
A method of forming a layered paved structure having no open graded base course, comprising the steps of I. providing a base layer formed at least partially of native soil components, II. providing a synthetic drainable base course disposed above said base layer and comprising A) a void-maintaining geocomposite including i) a geocomposite core element having a plurality of ribs constructed and arranged to form a plurality of interconnected voids, said core element having an upper surface and a lower surface, a no-load thickness and a thickness under load, wherein said thicknesses are measured substantially perpendicular to said surfaces, ii) at least one fluid-transmissible layer attached adjacent said upper surface, and iii) at least one fluid-transmissible layer attached adjacent said lower surface of said geocomposite, wherein said layers and said core are constructed and arranged so that, under a load of at least 750 lbs/foot 2 for a period of at least 100 hours, said geocomposite maintains voids of sufficient dimension that fluid from said roadway or other large structure can move freely through said geocomposite at rate of at least 1,000 feet 3 /day/foot, and III. above said synthetic drainable base course, providing pavement comprising one or more layers of asphalt or cementitious materials, wherein said synthetic drainable base course is sloped downwardly in a gradient from a portion of said roadway or other large structure.
Claim 52
Dependent Claim
51 words
The method of claim 48 , further comprising the step of IV. providing a support layer, said support layer being disposed above said synthetic drainable base course, and below said pavement, wherein said support layer comprises one or more from the group consisting of native soil components, and non-native soil components.
Claim 53
Dependent Claim
67 words
The method of claim 48 , wherein said layers and said core are constructed and arranged so that, under a load of at least 1,000 lbs/foot 2 for a period of at least 100 hours, said void-maintaining geocomposite maintains voids of sufficient dimension that fluid from said roadway or other large structure can move freely through said geocomposite at rate of at least 2,000 feet 3 /day/foot.
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| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 2007-10-12 | 2008-04-12 | 2008-10-12 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2011-10-12 | 2012-04-12 | 2012-10-12 | $3760.00 | Window Closed / Lapsed |
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