Note: Descriptions are shown in the official language in which they were submitted.
Atty. Dkt. No. 079834-00011USCP1
PROCESS AND SYSTEM FOR MAKING AN EROSION CONTROL MAT
TECHNICAL FIELD
[0001] The present disclosure relates to processes and systems for forming
flexible erosion
prevention mats, and more particularly, to processes and systems for forming
continuous erosion
prevention mats.
BACKGROUND
[0002] Erosion is a natural process in which meteorological elements such as
rain, wind, and
snow remove soil, rock, and dissolved material from one location on the
Earth's crust and
transport it to another location. While such erosion is a natural process,
certain localized human
activity increases the rate of erosion to many times that at which erosion
occurs naturally. Land
surfaces adjacent man-made structures such as canals, roads and other paved
surfaces, reservoirs
and other static bodies of water, and artificially created drainage channels
and other waterways
are particularly susceptible to erosion because naturally occurring indigenous
vegetation is
removed in order to form the structures.
[0003] Erosion can be mitigated in these areas by remediating the land surface
adjacent the
canal, road, reservoir, pond, or channel by planting vegetation to replace the
vegetation that was
stripped away during construction. However, there is a time interval between
the planting of the
replacement vegetation and the point at which the replacement vegetation is
sufficiently rooted
and developed to prevent surface soil erosion during which further erosion may
occur.
[0004] Efforts have been made to retain the surface soil in place in these
areas until such time
as vegetation can mature to the point where the root structure of the
vegetation retains the soil in
place. An example of such material is the flexible mat structure disclosed in
United States Patent
No. 6,793,858 titled "Method and Apparatus for Forming a Flexible Mat Defined
by
Interconnected Concrete Panels," the entire contents of which are incorporated
herein by
reference. That patent discloses a flexible mat structure in the form of
spaced, interconnected
concrete panels or blocks held together by an open mesh of a polymeric
material.
1
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
[0005] The flexible mat structure may be made by depositing concrete in the
block-shaped
mold cavities formed in the surface of a rotating drum and embedding in the
concrete material
the open mesh structure. While the flexible mat structure made by that method
is cost
competitive and has demonstrated effectiveness, there is a need to introduce
additional
efficiencies and variations in the structure and process of manufacture of
such flexible mat
structures.
SUMMARY
[0006] The present disclosure is a process for forming an erosion control mat
that possesses
advantages of cost effectiveness and simplicity. The process and manufacturing
system are less
complex than many comparable processes and manufacturing systems and utilize a
sheet that
consists of or includes flexible, mesh material that is at least partially
embedded in and
interconnects blocks of hardened paste. The sheet is selected to provide
sufficient tensile strength
to hold the blocks together without additional connecting structure.
[0007] In some embodiments, the sheet includes a three-dimensional mat made of
interconnected filaments in an mesh and a flat, two-dimensional base, which
may be a woven or
nonwoven geotextile. The mesh mat may be attached or bonded to project
upwardly from one
side of the base. The disclosed process and system cover molds filled with an
uncured,
hardenable paste with the sheet consisting of or including mesh mat such that
the sheet holds the
uncured paste in the molds, and the three-dimensional mesh embeds in the
paste. When the paste
hardens in the molds, the resultant blocks of hardened paste are attached to
and are
interconnected by the sheet, forming the finished erosion control mat.
[0008] In one embodiment of the disclosed process for making an erosion
control mat, the
process is used for making an erosion control mat consisting of a plurality of
blocks of hardened
paste attached to and joined together by a sheet of mesh material. A process
for making an
erosion control mat includes rotating a cylindrical drum having a plurality of
mold cavities
about an outer surface thereof shaped to form the blocks; depositing a
flowable, hardenable
paste into the mold cavities; selecting the sheet of mesh material to have
sufficient tensile
strength to join the blocks of hardened paste together without tearing or
separating from the
blocks of hardened paste, and to have sufficient density to retain the paste
within the mold
2
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
cavities as the drum rotates; covering an outer surface of the cylindrical
drum and outer surfaces
of the flowable paste in the mold cavities with the sheet of mesh material as
the cylindrical drum
rotates; continuing to rotate the cylindrical drum as the flowable, hardenable
paste hardens into
dimensionally stable blocks in the mold cavities, and holding the sheet of
mesh material against
the outer surface such that the sheet of mesh material retains the paste
within the mold cavities
and at least a portion of the sheet of mesh material becomes embedded in the
paste; and
separating the dimensionally stable blocks from the mold cavities, thereby
forming the erosion
control mat consisting of the sheet of mesh material embedded in the blocks
sufficiently to
connect the blocks to each other.
100091 In another embodiment, a process for making an erosion control mat
having a plurality
of blocks of hardened paste attached to and joined together by a sheet of mesh
material is
disclosed. The process includes rotating a cylindrical drum on a support
surface by displacing a
frame on which the cylindrical drum is rotatably mounted relative to the
support surface;
depositing a flowable, hardenable paste into a hopper adjacent the cylindrical
drum such that the
hardenable paste flows through an opening in the hopper into mold cavities
formed in an outer
surface of the cylindrical drum as the mold cavities move into alignment with
the opening;
paying out a continuous sheet of mesh material from a spindle on a downstream
side of the
hopper to cover the outer surface of the cylindrical drum and outer surfaces
of the paste
deposited in the mold cavities, such that the sheet retains the paste within
the mold cavities, and
at least a portion of the sheet projects into and embeds in the paste in the
mold cavities; holding
the sheet of mesh material against the outer surface of the cylindrical drum
by tension of the
sheet of mesh material from resistance of the spindle to rotation and a pinch
of the sheet between
the cylindrical drum and the support surface; and continuing to displace the
frame relative to the
support surface at a rate sufficient to rotate the cylinder at a speed that
enables the paste to
harden into solid blocks in the mold cavities and to embed the sheet in the
blocks, thereby
forming the erosion control mat of the sheet of flexible, mesh material
embedded in the blocks
sufficiently to join the blocks into a continuous mat.
[0010] In yet another embodiment, a system for making an erosion control mat
includes a
movable frame; a cylindrical drum having a plurality of mold cavities about a
periphery thereof,
the cylindrical drum rotatably mounted on the frame; a hopper positioned
transversely of the
3
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
cylindrical drum for receiving and distributing a flowable, hardenable paste
into the mold
cavities; a sheet having flexible, three-dimensional material supported on the
frame and fed to
cover an outer surface of the cylindrical drum and outer surfaces of the paste
in the mold cavities
such that the flexible sheet contacts the paste and retains the paste within
the mold cavities, so
that the paste hardens in the mold cavities to form the erosion control mat
having blocks of
hardened paste attached to the flexible sheet.
100111 In still another embodiment, a process for making an erosion control
mat consisting of
dimensionally stable blocks of hardened paste interconnected by a sheet having
a multiplicity of
protrusions is disclosed. The process includes depositing a hardenable paste
in flowable form
into a plurality of molds; covering the molds with the sheet having the
multiplicity of protrusions
projecting outwardly therefrom, the sheet oriented so that the multiplicity of
protrusions extend
into and embed in the paste in the plurality of molds; holding the sheet
against the molds until
the paste hardens sufficiently within the molds to form dimensionally stable
blocks attached to
the sheet by the multiplicity of protrusions embedded in the plurality of
molds; and removing the
dimensionally stable blocks from the molds to form the erosion control mat
consisting of the
dimensionally stable blocks interconnected by the sheet.
[0012] In a further embodiment, a process for making an erosion control mat
having a plurality
of blocks of hardened paste attached to and joined together by a sheet of mesh
material is
disclosed. The process includes rotating a cylindrical drum having a plurality
of mold cavities
about an outer surface thereof shaped to form the blocks; depositing a
flowable, hardenable paste
into the mold cavities; selecting the sheet of mesh material to have
sufficient tensile strength to
join the blocks of hardened paste together without tearing or separating from
the blocks of
hardened paste; covering an outer surface of the cylindrical drum and outer
surfaces of the
flowable paste in the mold cavities with an arcuate shield as the cylindrical
drum rotates;
continuing to rotate the cylindrical drum as the flowable, hardenable paste
hardens in the mold
cavities, and holding the arcuate shield against the outer surface such that
the arcuate shield
retains the paste within the mold cavities; rotating the cylindrical drum over
a sheet of matting
upon a support beneath the drum, the sheet of matting having upwardly
extending filaments,
such that the filaments project into and embed in the flowable, hardenable
paste; and releasing
dimensionally stable blocks of paste from the mold cavities and allowing the
dimensionally
4
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
stable blocks of paste to harden and solidify with the filaments embedded in
the blocks, which
attaches the blocks to the sheet of matting, thereby forming the erosion
control mat of the sheet
of mesh material embedded in the blocks sufficiently to connect the blocks to
each other.
[0013] Other objects and advantages of the disclosed process and system for
making an erosion
control mat using loop matting will be apparent from the following
description, the
accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Fig. 1 is a schematic, side elevational view of an embodiment of the
disclosed system
for making an erosion control mat using loop matting;
[0015] Figs. 2A and 2B show embodiments of the disclosed sheet having
flexible, mesh
material in the form of loop matting used in the disclosed method and system
in the form of a
mat of raised loops of filament attached to a flat, two-dimensional woven
geotextile base, and
differ by the density of the weave in the mat component;
[0016] Fig. 2C shows an embodiment of the disclosed sheet having flexible,
open mesh
material used in the disclosed method and system in the form of a mat of three-
dimensional,
nonwoven geotextile;
[0017] Fig. 2D shows an embodiment of the disclosed sheet having flexible,
open mesh
material used in the disclosed method and system in the form of a mat of three-
dimensional,
nonwoven filaments bonded to a geogrid base;
[0018] Figs. 2E and 2F show an embodiment of the disclosed sheet having
flexible, mesh
material used in the disclosed method and system in the form of a three-
dimensional mat of
interconnected filaments attached to a relatively flat, two-dimensional fabric
base;
[0019] Figs. 2G and 2H show an embodiment of the disclosed sheet having
flexible, mesh
material used in the disclosed method and system in the form of a mat of three-
dimensional, non-
woven filaments attached to a relatively flat, two-dimensional fabric base;
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
[0020] Figs. 21 and 2J show an embodiment of the disclosed sheet having
flexible, open mesh
material used in the disclosed method and system in the form of a three-
dimensional mat
attached to a relatively flat, dense mesh base;
[0021] Figs. 2K, 2L, and 2M show an embodiment of the disclosed sheet having
flexible, open
mesh material used in the disclosed method and system in the form of a three-
dimensional
undulating mat bonded to a flat, two-dimensional non-woven fabric sheet base;
[0022] Fig. 2N shows an embodiment of the disclosed sheet having flexible mesh
material used
in the disclosed method and system in the form of a three-dimensional mat with
upwardly
extending filaments bonded to a flat, two-dimensional geomembrane;
[0023] Fig. 3 is a detail perspective view of the hopper of the embodiment of
Fig. 1;
[0024] Fig. 4 is a another detail perspective view of the hopper of the
embodiment of Fig. 1;
[0025] Fig. 5 is a schematic top plan view of the erosion control mat made by
the disclosed
process and system;
[0026] Fig. 6 is a schematic, side elevation of the erosion control mat of
Fig. 5 in which the
blocks are broken away to reveal the embedded loops of the loop matting of
Figs. 2A and 2B;
[0027] Fig. 7 is another embodiment of the disclosed system for making an
erosion control mat
using loop matting;
[0028] Fig. 8 is a schematic, side elevational view of yet another embodiment
of the disclosed
system for making an erosion control mat using three-dimensional matting; and
[0029] Fig. 9 is a schematic, side elevational view of still another
embodiment of the disclosed
system for making an erosion control mat using three-dimensional matting.
DETAILED DESCRIPTION
[0030] As shown in Fig. 1, in an exemplary embodiment, the system for making
an erosion
control mat, generally designated 10, includes a movable frame 12 that is
attached to a motor
vehicle 14, such as a tractor or truck. Alternatively, the frame is self-
propelled. A cylindrical
6
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
drum 16 is rotatably attached to the frame 12. The drum 16 has, in an
embodiment, a plurality of
spaced transverse rows 18 of mold cavities 20 about a periphery thereof (see
also Figs. 3 and 4).
In other embodiments, the rows 18 of mold cavities 20 may take the form of
different patterns,
such as a staggered arrangement, a running bond, or a random pattern about the
periphery of the
drum 16. Accordingly, as used herein, the term "row" is not limited to a
rectilinear arrangement
of mold cavities 20 on the drum 16. The mold cavities 20 are recessed from the
outer, cylindrical
surface 22 of the drum 16.
[0031] In an exemplary embodiment, the mold cavities 20 have opposing pairs of
radially
inward tapering side walls 24 that meet flat bottom walls 26. The shape of the
mold cavities 20
thus is an inverted truncated pyramid with rounded corners and edges and a
square or rectangular
opening. In other embodiments, the side walls 24 do not taper, but instead are
perpendicular, or
substantially perpendicular to the outer, cylindrical surface 22 of the drum
16. In other
embodiments, the side walls 24 of the mold cavities 20 join to form other
regular polygonal
shaped openings, such as hexagons and octagons. In still other embodiments,
the side walls 24 of
the mold cavities 20 join to form irregular polygonal openings, rounded
openings, such as
circular, oval, or elliptical openings, or irregular curvilinear openings. The
mold cavities 20 all
may be the same size, or may vary in size relative to each other.
[0032] In an embodiment, the system 10 includes an elongate hopper, generally
designated 28,
which is mounted on the frame 12 and is fixed directly above the top of
rotating cylindrical drum
16, i.e., at the 12 o'clock position relative to the circular end face 80 of
the drum in Fig. 1. The
hopper 28 extends transversely along the entire length of the drum 16 and
receives a hardenable
paste 30, which is received in a wet or flowable form, such as a slurry. The
paste 30 is distributed
along the length of the hopper and down through an opening in the bottom of
the hopper into the
mold cavities 20. In embodiments, the hardenable paste 30 may be a fresh,
flowable cement
paste such as Portland cement, and in a particular embodiment, may be 5000 psi
wet-cast
Portland cement. In other embodiments, the hardenable paste 30 may be
concrete, a mixture of
Portland cement, sand, and/or gravel, or an uncured polymer.
[0033] In embodiments, the hardenable paste 30 is deposited into the hopper 28
through a
conduit or chute 32 from a vehicle 34, such as a front-discharge concrete
transport truck or other
7
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
transport vehicle, that is positioned alongside the frame 12. In embodiments,
the elongate hopper
28 is coextensive with the width of the drum 16, or at least with the rows 18
of mold cavities 20.
In embodiments, the hopper 28 includes downwardly and inwardly tapering front
and rear walls
36, 38, respectively, a bottom wall 40 that is connected to the side walls and
is curved to fit or
correspond to the curvature of the outer, cylindrical surface 22, and opposing
side walls 42, 44
(only side wall 42 is shown, it being understood that side wall 44 is
identical in shape) connected
to the front and rear walls and the bottom wall.
[0034] As shown in Figs. 3 and 4, the bottom wall 40 includes an opening 46
that extends the
width of the hopper 28 and allows the hardenable paste 30 to flow from the
hopper into the mold
cavities 20. In embodiments, the opening 46 takes the form of individual holes
or elongate slots
48. In embodiments, the slots 48 correspond in longitudinal dimension and/or
longitudinal (i.e.,
along the axial length of the drum 16) spacing to the width dimensions and/or
longitudinal
spacing of the mold cavities 20. In embodiments, the holes 48 are sized and
arranged to
correspond in size to, and align with, the mold cavities 20 of each transverse
row 18 as the drum
16 rotates beneath the hopper 28. In still other embodiments, the opening 46
takes the form of a
continuous and unbroken slot that extends the width of the drum 16 over the
mold cavities 20. In
other embodiments, the opening 46 is the size of, or substantially the size
of, the entire bottom
wall 40, so that there is little or no bottom wall. The bottom wall 40 and/or
opening 46 are
positioned above the top of the drum 16 with minimal clearance, such as less
than an inch, to not
impede the rotation of the drum but prevent the hardenable paste 30 from
flowing from the
hopper over the outer surface 22 of the drum between the mold cavities 20.
[0035] Although the hopper 28 is shown at, or at approximately the 12 o'clock
position relative
to the drum 16 in Fig. 1, in other embodiments the hopper is positioned either
upstream or
downstream of the 12 o'clock position, and anywhere from the 3 o'clock
position to the 9
o'clock position relative to the drum 16. With such embodiments, the front
wall 36 and rear wall
38 are lengthened to retain the hardenable paste 30 within the hopper 28. The
bottom wall 40
and/or opening 46 remain facing the outer surface 22 of the drum 16.
[0036] A mixing impeller 50 is rotatably mounted in the end walls 42, 44 of
the hopper 28 and
distributes the flowable, hardenable paste 30 deposited into the hopper from
the chute 32 evenly
8
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
along the width of the hopper. The mixing impeller 50 is rotated by a motor
52, which drives a
shaft 54 that is rotatably mounted to and extends between the end walls 42, 44
of the hopper 28.
Paddles 56 are angled relative to a central rotational axis of the shaft 54
for pushing the
hardenable paste 30 along the trough 28, and pegs 58 for mixing the paste and
facilitating its
flowing through the holes 48 of the opening 46 into the mold cavities 20
extend radially outward
from the shaft and are spaced along its length.
[0037] The system 10 and method for making the disclosed erosion control mat
66 (Fig. 1)
utilize a sheet, generally designated 900, having flexible, mesh material,
which in embodiments
is either an open mesh or a tightly woven impermeable mesh material. In
embodiments, the sheet
900 includes a three-dimensional mat of interconnected filaments. As used
herein, the term
"three-dimensional" refers to a mat having an open weave or mesh component,
and the mat
having a loft or thickness. In embodiments, the loft or thickness is on the
order of at least 5 mm.
(0.197 in.) and typically at least 10-15 mm. (0.393-0.590 in) and as much as
20 mm. (0.787 in.).
As used herein, the term "two-dimensional" refers to a comparatively flat
woven or non-woven
fabric or geogrid, which may be on the order of 1-3 mm. (0.039-0.118 in.).
[0038] As shown in Figs. 2A and 2B, in embodiments, the sheet 900 having
flexible, mesh
material takes the form of loop matting 60, 160 and is supported on the frame
12 and fed to cover
the outer surface 22 of the cylindrical drum 16 and outer surfaces 62 of the
hardenable paste 30
in the successive rows 18 of the mold cavities 20. The sheet of loop matting
60 retains the
hardenable paste 30 within the mold cavities 20 of the successive rows 18, and
the loops 64 (see
also Fig. 6), also referred to herein as filaments or protrusions, of the
sheet of loop matting
project into the mold cavities and embed in the hardenable paste in the mold
cavities, such that
the hardenable paste hardens in the mold cavities to form the erosion control
mat 66 having
blocks 67 of hardened paste attached to the sheet of loop matting 60, 160 by
the loops 64. Thus,
the sheet of loop matting 60, 160 alone interconnects the blocks 67 of
hardened paste to form the
erosion control mat 10. The loops 64 are selected to be sufficiently strong
and their connection to
the remainder of the sheet 900 is sufficiently strong so that the sheet
interconnects the blocks 67
of the mat 10 without need of additional connecting structure.
9
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
[0039] In embodiments, the sheet of loop matting 60, 160, shown best in Figs.
2A, 2B, is made
of a weather-resistant material, such as polypropylene. The loop matting 60,
160 may include a
two-dimensional woven geotextile base 68, 168 on which a three-dimensional mat
formed by the
addition of loops 64 of geotextile filaments or protrusions is attached, for
example by looping the
strands through the base, and extend upwardly from a flat surface 70, 170
thereof. In Fig. 2A, the
embodiment of the woven base 68 has a relatively tight weave with relatively
small or no
openings, which would be used to prevent vegetation growth up through the
loops 64, or prevent
or restrict very fine particulate matter or liquids, such as water, from
passing through. In that
embodiment, the woven base 68 is a geomembrane form of geosynthetic material,
which is
impermeable. In Fig. 2B, the embodiment of the woven mat 168 is a relatively
loose or open
weave, with openings sized to allow vegetation to grow through and/or water to
flow through. In
that embodiment, the woven mat 168 is a geotextile form of geosynthetic
material, which is a
permeable fabric. Examples of such sheets of loop matting 60, 160 are sold
under the trademark
ROBUSTA by Robusta B.V., Genemuiden, Netherlands.
[0040] As shown in Fig. 2C, in another embodiment, the sheet 900 of flexible,
mesh material is
in the form of a three-dimensional nonwoven geotextile 260 with an open
structure that is
supported on the frame 12 and fed to cover the outer surface 22 of the
cylindrical drum 16 and
outer surfaces 62 of the hardenable paste 30 in the successive rows 18 of the
mold cavities 20.
The geotextile 260 is in the form of a three-dimensional mat 264 made up of
filaments 268 that
are welded where they cross. In embodiments, the filaments 268 are polyamide
monofilaments,
and are randomly interconnected to provide thickness or loft to the mat 264 of
up to, or
approximately, 20 mm. (0.787 in.). The open structure and density of the
filaments 268 are
selected so that the filaments of the mat 264 penetrate the hardenable paste
30 in the molds 20,
but prevent the paste from flowing through the mat. Such a geotextile 260 is
commercially
available as Enlcamat from Low & Bonar PLC, London, United Kingdom.
[0041] As shown in Fig. 2D, in another embodiment, the sheet 900 of flexible,
mesh material is
in the form of a reinforced three-dimensional geotextile 360 with an open
structure that is
supported on the frame 12 and fed to cover the outer surface 22 of the
cylindrical drum 16 and
outer surfaces 62 of the hardenable paste 30 in the successive transverse rows
18 of the mold
cavities 20. The geotextile 360 includes a base 362 in the form of a
reinforcing geogrid,
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
consisting of longitudinal and transverse components 364, 366, respectively,
bonded to each
other at intersection points. The two-dimensional geogrid base 362 is attached
to a three-
dimensional mat 368 of randomly oriented and interconnected filaments 370
bonded to each
other where they cross to form an open mesh. The filaments 370 provide the
loft and three-
dimensional property to the mat 368 of the geotextile 360, projecting upwardly
from the
comparatively flat geogrid base 362 to define open space adjacent the geogrid.
[0042] In embodiments, the geogrid base 362 is made of a high-tensile
polyester bonded to the
mat 368 of filaments 370, which in embodiments are polyamide monofilaments
thermally fused
to each other at intersection points. The geotextile 360 is applied to the
outer surface 22 of the
cylindrical drum 16 and outer surfaces of the hardenable paste 30 such that
the geogrid base 362
faces radially outward, and the three-dimensional mat 368 faces radially
inward, so that the
filaments 370 extend into the hardenable paste 30 in the mold cavities 20. The
open structure and
density of the filaments 370 are selected so that the filaments of the mat 368
penetrate the
hardenable paste 30 in the molds 20, but prevents the paste from flowing
through the mat. Such a
geotextile 360 is commercially available as Enkamat R from Low & Bonar PLC,
London,
United Kingdom.
[0043] As shown in Figs. 2E and 2F, in another embodiment, the sheet 900 of
flexible, mesh
material is in the form of a three-dimensional nonwoven geocomposite 460 with
an open
structure that is supported on the frame 12 and fed to cover the outer surface
22 of the cylindrical
drum 16 and outer surfaces 62 of the hardenable paste 30 in the successive
rows 18 of the mold
cavities 20. The geocomposite 460 is in the form of a three-dimensional mat
468 consisting of
randomly oriented filaments 470 bonded to each other where they cross. The
filaments 470 also
are bonded, for example heat bonded, to a base 472 in the form of a geotextile
fabric sheet. The
filaments 470 provide the loft and three-dimensional quality to the
geocomposite 460, and
project upwardly from the comparatively flat and thinner base 472.
[0044] In embodiments, the three-dimensional mat 468 is made of nylon
monofilaments fused
together at their intersections. In embodiments, the mat 468 is a 95% open
structure. The base
472 is a polyester geotextile fabric. In embodiments, the fabric is an 8 ounce
fabric. The
geocomposite 460 is applied to the outer surface 22 of the cylindrical drum 16
and outer surfaces
11
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
of the hardenable paste 30 such that the base 472 faces radially outward, and
the three-
dimensional mat 468 faces radially inward, such that the filaments 470 extend
into the
hardenable paste 30 in the mold cavities 20. In an embodiment, the open
structure and density of
the filaments 470 are selected so that the filaments of the mat 468 penetrate
the hardenable paste
30 in the molds 20, but prevent the paste from flowing through the mat. In
other embodiments,
the density of the sheet 472 prevents the paste 30 from flowing through the
geotextile 460. Such
a geocomposite 460 is commercially available as EnkamatiI) Plus 7420 from Low
& Bonar PLC,
London, United Kingdom.
[0045] As shown in Figs. 2G and 2H, in another embodiment, the sheet 900 of
flexible, mesh
material is in the form of a geocomposite 560 that is supported on the frame
12 and fed to cover
the outer surface 22 of the cylindrical drum 16 and outer surfaces 62 of the
hardenable paste 30
in the successive transverse rows 18 of the mold cavities 20. The geocomposite
560 is in the
form of a three-dimensional mat 568 consisting of randomly oriented filaments
570 bonded to
each other where they cross. The filaments 570 are bonded, for example heat
bonded, to a base
572 of a two-dimensional geotextile fabric. In other embodiments, the base 572
is in the form of
a two-dimensional geomembrane. The filaments 570 provide the loft and three-
dimensional
quality to the geocomposite 560, and project upwardly from the comparatively
flat and thinner
base 572.
[0046] In embodiments, the three-dimensional mat 568 is made of randomly
oriented
polypropylene filaments 570, in particular post-industrial recycled
polypropylene, fused,
entangled filaments, which in embodiments are fused together at their
intersections. The base
572 is a two-dimensional nonwoven geocomposite fabric bonded or spot welded to
one surface
of the mat 568. The filaments 570 are attached in squares in a waffle pattern
to the base 572, the
waffle pattern formed by intersecting grid lines 574 where the mat 568 is
fused to the base 572.
[0047] In embodiments, the fabric is an 8 ounce fabric. The geocomposite 560
is applied to the
outer surface 22 of the cylindrical drum 16 and outer surfaces of the
hardenable paste 30 such
that the sheet 572 faces radially outward, and the three-dimensional mat 568
faces radially
inward, such that the filaments 570 extend into the hardenable paste 30 in the
mold cavities 20.
In an embodiment, the open structure and density of the filaments 570 are
selected so that the
12
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
filaments of the mat 568 penetrate the hardenable paste 30 in the molds 20,
but prevent the paste
from flowing through the mat. In other embodiments, the density of the base
572 prevents the
paste 30 from flowing through the geocomposite 560. Such a geocomposite 560 is
commercially
available as Enkadrain 3611 from Low & Bonar PLC, London, United Kingdom.
[0048] As shown in Figs. 21 and 2J, in another embodiment, the sheet 900 of
flexible, mesh
material is in the form of a geotextile 660 with an open structure that is
supported on the frame
12 and fed to cover the outer surface 22 of the cylindrical drum 16 and outer
surfaces 62 of the
hardenable paste 30 in the successive rows 18 of the mold cavities 20. In
embodiments, the
geotextile 660 is in the form of a three-dimensional mat 668 consisting of
randomly oriented
filaments 670 bonded to each other where they cross. The filaments 670 are
bonded to a flat,
two-dimensional base 672 of nonwoven filaments 674 that are fused to each
other in a relatively
denser pattern. The filaments 670 provide the loft and three-dimensional
quality to the geotextile
660, and generally project upwardly from the comparatively flat and thinner
base 672 and are
oriented to extend into the mold cavities 20 and embed in the hardenable paste
30.
[0049] In embodiments, the filaments 670, 674 are made of randomly oriented
polyamide
monofilaments that are welded where they cross. In embodiments, the geotextile
660 is, or is
approximately, up to 20 mm. (0.787 in.) thick. The geotextile 660 is applied
to the outer surface
22 of the cylindrical drum 16 and outer surfaces of the hardenable paste 30
such that the base
672 faces radially outward, and the three-dimensional mat 668 faces radially
inward, so that the
filaments 670 extend into the hardenable paste 30 in the mold cavities 20. In
an embodiment, the
open structure and density of the filaments 670 are selected so that the
filaments of the mat 668
penetrate the hardenable paste 30 in the molds 20, but prevent the paste from
flowing through the
mat. In other embodiments, the density of the two-dimensional flat base 672
prevents the paste
30 from flowing through the geotextile 660. Such a geotextile 660 is
commercially available as
Enkamat 7220 from Low & Bonar PLC, London, United Kingdom. The flat underside
of the
two-dimensional flat sheet 672 presents continuous flat surface or face to the
surface upon which
the formed erosion control mat 66 is placed.
[0050] As shown in Figs. 2K, 2L, and 2M, in another embodiment, the sheet 900
is of a
flexible, mesh material in the form of a three-dimensional nonwoven
geocomposite 760 with an
13
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
open structure that is supported on the frame 12 and fed to cover the outer
surface 22 of the
cylindrical drum 16 and outer surfaces 62 of the hardenable paste 30 in the
successive rows 18 of
the mold cavities 20. The geocomposite 760 is in the form of a three-
dimensional mat 768
consisting of randomly oriented, entangled filaments 770 bonded to each other
where they cross.
The filaments 770 are heat formed into parallel, inverted U-shaped ridges 772
separated by
channels 774.
[0051] The filaments 770 are bonded, for example heat bonded, to a flat, two-
dimensional
geotextile fabric base 776. In embodiments, the base 776 is made of non-woven
filaments of a
polymer, such as polyethylene terephthalate (PET). In embodiments, the
channels 774 are
formed by parallel lines fusing or spot welding the filaments 770 of the mat
768 to the base 776.
The filaments 770 provide the loft and three-dimensional quality to the
geocomposite 760, and
project upwardly from the comparatively flat and thinner base 776.
[0052] In embodiments, the geocomposite 760 is applied to the outer surface 22
of the
cylindrical drum 16 and outer surfaces of the hardenable paste 30 such that
the base 776 faces
radially outward, and the three-dimensional mat 768 faces radially inward, so
that the filaments
770 extend into the hardenable paste 30 in the mold cavities 20. In an
embodiment, the open
structure and density of the filaments 770 are selected so that the filaments
of the mat 768
penetrate the hardenable paste 30 in the molds 20, but prevent the paste from
flowing through the
mat. In other embodiments, the density of the base 776 prevents the paste 30
from flowing
through the geotextile 760. Such a geocomposite 760 is commercially available
as Enkadrain
3601 from Low & Bonar PLC, London, United Kingdom.
[0053] As shown in Fig. 2N, in another embodiment, the sheet 900 of flexible
material is in the
form of a three-dimensional geocomposite 860 that is supported on the frame 12
and fed to cover
the outer surface 22 of the cylindrical drum 16 and outer surfaces 62 of the
hardenable paste 30
in the successive transverse rows 18 of the mold cavities 20. The geocomposite
860 is in the
form of a three-dimensional mat 868 that includes randomly oriented filaments
870 that in
embodiments are formed to have the shape and color of blades of grass, thus
giving the
appearance of turf to the geocomposite 860 when viewed from above.
Accordingly, in
embodiments the geocomposite 860 is a synthetic turf. The filaments 870 are
bonded, for
14
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
example heat bonded, to a base 872 that, in embodiments, takes the form of a
permeable
geotextile fabric sheet. In an alternate embodiment, the base 872 is in the
form of an
impermeable geomembrane of geosynthetic material. In either case, the base 872
may be woven
or nonwoven. The filaments 870 in embodiments are bonded to the base 872 at
their ends and
project upwardly from the base. The filaments 870 thus provide the loft and
three-dimensional
quality to the geocomposite 860 by projecting upwardly from the comparatively
flat and thinner
base 872.
[0054] In embodiments, the filaments 870 of the three-dimensional mat 868 are
made of nylon
or polyester monofilaments. The base 872 is a woven or nonwoven geotextile
fabric that may be
polyester. The geocomposite 860 is applied to the outer surface 22 of the
cylindrical drum 16 and
outer surfaces of the hardenable paste 30 such that the base 872 faces
radially outward, and the
three-dimensional mat 868 faces radially inward, such that the filaments 870
extend into the
hardenable paste 30 in the mold cavities 20. In an embodiment, the open
structure and density of
the filaments 470 are selected so that the filaments of the mat 868 penetrate
the hardenable paste
30 in the molds 20, but prevent the paste from flowing through the mat. In
other embodiments,
the density of the sheet 872 prevents the paste 30 from flowing through the
geotextile 460. An
embodiment of such a geocomposite 860 is commercially available as HydroTurf
CS or
HytroTurf Z manufactured by Watershed Geosynthetics LLC of Alpharetta,
Georgia.
[0055] As shown in Fig. 1, in embodiments, the system 10 further includes a
spindle 72
rotatably mounted on the frame 12 in front of the drum 16 in the direction of
travel of the frame,
indicated by arrow A. The spindle 72 contains a coil 74 of the sheet 900 of
mesh material, which
may take the form of loop matting 60, 160, geotextile 260, geotextile 360,
geocomposite 460,
geotextile 560, geotextile 660, geocomposite 760, geocomposite 860, or
combinations thereof. In
embodiments, the sheet 900 is wound on the spindle 72. For loop matting 60,
160,
geocomposites 460, 760, geotextile 560, and geocomposite 860, the sheet 900 is
wound such that
the three-dimensional component thereof extends radially outward from the
center of the coil 74
so that when the sheet 900 covers the outer surface 22 of the drum 20. The
three-dimensional
component of the sheet 900, for example loops 64 of loop matting 60, 160,
extends into the mold
cavities 20, and embeds into the hardenable paste 30 within the mold cavities.
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
[0056] Also in embodiments, the system 10 further includes an idler roller 76
rotatably
mounted on the frame 12 between the spindle 72 and the cylindrical drum 16.
The idler roller 76
extends the width of the cylinder 16, or at least the width of the sheet 900,
which in embodiments
also is at least as wide as the transverse rows of mold cavities 18, and
preferably wider to
provide a border beyond the blocks 68 (see Fig. 5). The sheet 900 extends from
the bottom of the
coil 74, passes over the top of the idler roller 76, and downwardly from the
idler roller to cover
the outer surface 22 of the cylindrical drum 16 and outer surfaces 62 of the
hardenable paste 30
in the mold cavities 20. In embodiments, the idler roller 76 is positioned
relative to the drum 16
such that the sheet 900 covers at least the lower half of the downstream
portion (and in
embodiments, part of the upper half) of the outer surface 22 of the drum 16.
The downstream
portion of the outer surface 22 of the drum 16 is the portion whose mold
cavities contain
hardenable paste 30 deposited by the hopper 28.
[0057] The spindle 76 is positioned downstream of the hopper 28. The sheet 900
from the idler
roller 76 contacts the outer cylindrical surface 22 of the drum 16 at, or at
approximately, the 9
o'clock position 78 relative to the circular end 80 of the drum, and continues
to contact and
completely cover the outer cylindrical surface and the outer surfaces 62 of
the hardenable paste
30 in the mold cavities 20, which are flush with the outer surface of the drum
16, as the drum
rotates the mold cavities to the 6 o'clock or lowermost position 82, where the
loop matting 60,
160 contacts a support surface 84, which in embodiments is the ground, which
may be dirt,
gravel, asphalt pavement, or concrete pavement. In other embodiments, the
support surface 84
may take the form of a cover, such as a plastic or a fiber mat over the
ground, and in still other
embodiments, a prepared surface of crushed rock.
[0058] Another embodiment of the disclosed system, generally designated 100,
is shown in
Fig. 7. In that embodiment, a frame 112 supports a coil 172 of the sheet 900,
which in
embodiments the coil is mounted on a rotatable spindle 174 adjacent the drum
16. In
embodiments, the spindle is rotatably attached at its ends to the frame 112
and is positioned on
the frame such that the sheet 900 pays off of the top of the coil 172 and
extends downwardly to
contact and cover the outer surface 22 of the drum 16 beginning at or above
the 9 o'clock
position 178 and extending down to the 6 o'clock position 182.
16
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
[0059] In this embodiment of the system 100, as with the embodiment of the
system 10 shown
in Fig. 1, the sheet 900 is held against the outer surface 22 of the drum 16
by the tension
resulting from the resistance of the spindle 174 to rotation in the direction
of arrow B and
pinching the sheet of loop matting between the outer surface 22 of the drum 16
and the support
surface 84 at the 6 o'clock position 182. Accordingly, in embodiments, the
spindles 72 (Fig. 1),
174 include friction bearings that resist rotation sufficiently to prevent
overrunning of the coils
74 (Fig. 1), 172 and to provide tension on the sheet 900 against the outer
surface 22 of the drum
16 to retain the hardenable paste 30 in the mold cavities 20.
[0060] Optionally, the embodiment 100 shown in Fig. 7 includes a shield 102
that is attached
to the frame at its lateral ends by arms 104 mounted on the frame 112 (only
one arm 104 is
shown, the other arm being identical thereto). the shield 102 is arcuate in
shape and is curved to
conform to the curvature of the outer surface 22 of the drum 16. In
embodiments, the shield 102
is fixed relative to the drum 16, or optionally adjustable in radial
orientation relative to the drum,
for example by pivoting the arms 104 relative to the frame 112, and positioned
adjacent a
segment of the outer surface 22 of the drum. In embodiments, the shield 102 is
positioned
downstream of the hopper 28. The shield 102 is spaced from the outer surface
22 sufficiently to
retain the paste 30, which has been deposited in the molds 20 from the hopper
28, within the
molds. In embodiments, the shield 102 is made of a rigid material, such as
galvanized steel,
aluminum alloy, an abrasion-resistant polymer, or a combination of the
foregoing. In other
embodiments, the shield 102 is made of a light-duty netting to retain the
hardenable paste 30
within the mold cavities 20. With this embodiment, the sheet 900 is fed from
the coil 172 on the
spindle 174 to cover the mold cavities 20 and the cylindrical outer surface 22
below the shield
102. In embodiments, the sheet 900 is fed from the coil 172 to cover the mold
cavities 20 and
cylindrical outer surface 22 below the 9 o'clock position on the drum 16.
[0061] An exemplary embodiment of the process for making the erosion control
mat 66 shown
in Figs. 1, 5, and 6 is as follows. The cylindrical drum 16 having a plurality
of mold cavities 20
about an outer surface 22 thereof is rotated in the direction of arrow C. In
the embodiments of
Figs. 1 and 7, this rotation is effected by displacing the frame 12, 112 on
which the drum 16 is
rotatably mounted relative to the support surface 84 on which the drum
contacts and is supported
by, which is the direction of arrow A in Figs. 1 and 7. The displacement of
the frame 12, 112 is
17
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
effected by pulling it by the vehicle 14 to which it is attached. In other
embodiments, the frame
12, 112 itself is motorized and self-propelled, thus eliminating the need for
vehicle 14.
[0062] Next, the hardenable paste 30 is deposited into the mold cavities 20.
In embodiments,
the hardenable paste 30 is deposited from the concrete transport truck 34 and
flows through the
chute 32 into the hopper 28, where it is distributed evenly along the width of
the hopper by the
mixing impeller 50, which is rotated by motor 52. The hardenable paste 30
flows downwardly
through the holes 48 of the opening 46 and into the mold cavities 20 to fill
the mold cavities as
the rotation of the drum 16 relative to the hopper 28 causes the mold cavities
to pass adjacent and
align with the holes. In some embodiments, the holes 48 are positioned above
the mold cavities
20. In an embodiment in which the mold cavities 20 are arranged in rows on the
drum 16,
rotation of the drum brings successive rows of mold cavities into alignment
with the holes 48. In
embodiments, the hopper 28 and holes 48 are located at the vertical or 12
o'clock position 86
relative to the circular end 80 of the cylindrical drum 16; in other
embodiments, the hopper and
holes are located upstream or downstream of the 12 o'clock position. Continued
movement of
the frame 12, 112 relative to the support surface 84 causes the drum 16 to
continue to rotate,
thereby moving the mold cavities 20, now filled with hardenable but
unsolidified paste, in a
counterclockwise direction in Figs. 1 and 7.
[0063] If left uncovered, the hardenable paste 30, although somewhat viscous,
would partially
or completely flow out of the mold cavities 20 and over the outer surface 22
of the drum 16 as
the mold cavities rotate from the 12 o'clock position 86 down to the 6 o'clock
position 82, 182.
Thus, the outer surface 22 of the cylindrical drum 12 and outer surfaces 62 of
the hardenable
paste in the mold cavities 20 are covered with the sheet 900 such that the
mesh material retains
the hardenable paste within the mold cavities. At the same time, the three-
dimensional mat of the
sheet 900 projects into and embeds in the hardenable paste 30 in the mold
cavities 20.
[0064] As the drum 16 continues to rotate, the speed of rotation, which
results from movement
of the frame 12, 112, and hence the residence time of the hardenable paste 30
in the mold
cavities 20 covered by the sheet 900, is selected, along with selecting the
cure rate of the
hardenable paste, to allow the hardenable paste to harden in the mold cavities
and securely attach
to the loops 64, thereby forming the erosion control mat 66, which includes
blocks 67 of
18
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
hardened paste attached to the sheet 900 by the three-dimensional mat. In an
embodiment, the
cure rate of the hardenable paste 30 is selected to allow the paste to flow
from the chute 32 in the
hopper 28, be distributed along the length of the hopper, flow through the
slots 48 and into the
mold cavities 20 at the 12 o'clock position 86, and receive and become
embedded by the three-
dimensional mat component of the sheet 900. Further, the paste 30 is cured or
substantially cured
or solidified and dimensionally stable into blocks 67 by the time the drum 16
rotates so that the
blocks 67, which are connected to the drop from the molds 20 at the 6 o'clock
position 82, 182.
[0065] An advantage of this process, in which the hardenable paste 30 hardens
in the mold
cavities 20 to form the blocks 67 of hardened paste connected to the sheet 900
by the mat, is that
the paste hardening process occurs continuously, while the cylindrical drum 16
continues to
rotate in response to movement of the frame 12, 112. Also in an embodiment of
the process, the
blocks 67 of hardened paste are arranged spaced from each other in an array on
the sheet 900, as
shown in Fig. 5. The spacing is determined by the spacing of the mold cavities
20 on the drum
16, and may be selected to allow vegetation to grow upwardly through the mat
160 (Fig. 2B).
[0066] In an exemplary embodiment, release of the cast blocks 67 of hardened
paste
downwardly from the molds 20 is continuous during rotation of the drum 16 and
is effected by
gravity. Continuing to rotate the drum 16 allows the blocks 67 of hardened
paste to fall from the
rows 18 of mold cavities 20 onto the support surface 84, thereby forming the
erosion control mat
66 wherein the sheet 900 is a lowermost layer beneath and attached to a
plurality of the blocks of
hardened paste. In a particular embodiment, the blocks 67 of hardened paste
fall from the rows
18 of mold cavities 20 at the 6 o'clock position 82, 182 relative to a
circular end 80 of the
cylindrical drum 16.
[0067] In embodiments of the system 10, the sheet 900 is payed out from the
roll 74 and is
passed over the idler roll 76 adjacent the cylindrical drum 16 and downwardly
from the idler roll
against the outer surface 22 of the cylindrical drum and the outer surfaces 62
of the hardenable
paste 30 in the molds 20. Passing the sheet 900 over the idler roll 76
includes positioning the
idler roll relative to the cylindrical drum 16 such that the sheet 900
contacts the cylindrical drum
at or above the 9 o'clock position 78 relative to the circular end 80 of the
cylindrical drum 16.
19
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
[0068] In embodiments, covering the outer surface 22 of the cylindrical drum
16 and the outer
surfaces 62 of the hardenable paste 30 in the molds 20 includes bringing the
sheet 900 into
contact with the outer surface of the cylindrical drum and the outer surfaces
of the hardenable
paste. The three-dimensional mat projects upwardly from the surface of the
base. Also in
embodiments of the disclosed process, covering the outer surface 22 of the
cylindrical drum 16
and the outer surfaces 62 of the hardenable paste 30 includes bringing the
sheet 900, which is
made of a weather-resistant material, in particular polypropylene, into
contact with the outer
surface and hardenable paste 30.
[0069] In the embodiment of the system 100 shown in Fig. 7, the disclosed
process includes
positioning the spindle 172 that supports the roll 174 of the coiled sheet 900
on the frame 112
adjacent the drum 16. In embodiments, the roll 174 is positioned such that the
sheet 900 is payed
out from the roll downwardly to begin to contact and cover the outer surface
22 of the drum 16
and the outer surfaces 62 of the hardenable paste 30 in the mold cavities 20
at or above the 9
o'clock position 178 on the end 80 of the drum, and continuously contact and
cover the outer
surface of the drum and the outer surfaces of the hardenable paste until the
outer surface of the
drum and the mold cavities 20 reach the 6 o'clock position 182, at which time
the hardenable
paste 30 has hardened into the blocks 67 attached to the sheet 900. In an
embodiment in which
the mold cavities are arranged on the outer surface 22 of the drum 16 in
successive rows 18 of
the mold cavities 20, the hardenable paste 30 is retained within the
successive rows of the mold
cavities by the sheet 900.
[0070] In sum, with the embodiments 10, 100 depicted in both Fig. 1 and Fig.
7, the process for
making an erosion control mat includes rotating the cylindrical drum 16
supported on a support
surface 84 by displacing the frame 12, 112 on which the cylindrical drum is
rotatably mounted
relative to the support surface. The hardenable paste 30 is deposited into the
hopper 28 above the
cylindrical drum 16 such that the hardenable paste flows downwardly through
the opening 48 in
the hopper into the mold cavities 20 formed in an outer surface 22 of the
cylindrical drum 16 as
the mold cavities align with the opening. The continuous sheet 900 is payed
out from the spindle
72, 172 on the downstream side of the hopper 28 to cover the outer surface 22
of the cylindrical
drum 16 and the outer surfaces 62 of the hardenable paste 30 deposited in the
mold cavities 20,
such that the sheet retains the hardenable paste within the mold cavities, and
the three-
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
dimensional component of the sheet projects into and embed in the hardenable
paste in the mold
cavities.
[0071] The sheet 900 is held against the outer surface 22 of the cylindrical
drum 16 by tension
of the sheet from resistance of the spindle 72, 172 to rotation and a pinch of
the sheet between
the cylindrical drum and the support surface 84, which in embodiments is at,
or is approximately
at, the 6 o'clock position 82, 182. The frame 12, 112 continues to be
displaced by the vehicle 14
relative to the support surface 84 at a rate sufficient to rotate the cylinder
16 at a speed that
enables the hardenable paste 30 to harden or solidify or cure into the blocks
67 in the mold
cavities 20 and attach to the three-dimensional component, thereby forming the
erosion control
mat 66 having blocks 67 of hardened paste attached to the sheet 900. The sheet
900 is selected,
as described in the embodiments of Figs. 2A-2N, to be sufficiently strong to
hold the blocks 67
without need of additional connecting elements, such as a separate geogrid.
Further, the sheet
900 is selected to perform the dual function of interconnecting the blocks 67
into the mat 66 and
retaining the hardenable paste 30 in the molds 20 during the curing process.
[0072] In the embodiment of the system, generally designated 400, shown in
Fig. 8, the drum
16 is rotatably attached to a frame 412 that includes an rigid shield 402 that
is arcuate in shape
and curved to conform to, and extend the entire width of, the outer surface 22
of the drum 16. In
embodiments, the shield 402 is made of a rigid material, such as galvanized
steel, aluminum
alloy, an abrasion-resistant polymer, or a composite of a polymer and steel
and/or aluminum.
The shield 402 is pivotally attached to beams 404 (only one beam 404 being
shown, the other
beam being identical thereto) at lateral ends at its upper end adjacent the
hopper 28, and is held
against the outer surface 22 at its lower end by a transverse tube or bar 406
attached at its ends to
pivot arms 408 (only one pivot arm 408 being shown, the other pivot arm being
identical thereto)
pivotally attached to a remainder of the frame 412. Thus, the weight of the
shield 402 itself urges
the shield against the drum 16.
[0073] In embodiments, the pivot arm 408 may take the form of a chain. In
embodiments, the
attachments at 404 and 406 hold the shield 402 against the outer surface 22 of
the drum 16 from
a position adjacent a downstream side of the wall 36 of hopper 28 downwardly
to a position
adjacent the upstream side of the six o'clock or bottom position 482. In other
embodiments, the
21
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
shield 402 extends from a position adjacent the 10 o'clock or 9 o'clock
positions, or any position
in between the downstream side of the hopper 28 and the 6 o'clock position.
[0074] The sheet of three-dimensional matting 900 is in the form of an
elongate sheet of mesh
material that is placed upon the support surface 84 such that the filaments
64, 264, 370, 870 are
exposed to and/or project upwardly toward the drum 16. The drum 16 is rotated
in the direction
of arrow C directly over the sheet of three-dimensional matting 900, in
embodiments by lateral
displacement of the frame 412 relative to the support surface 84 and the sheet
of three-
dimensional matting in the direction of arrow A, which may be effected by
vehicle 14 (Fig. 1), or
by a self-propelled frame 412. The flowable, hardenable paste 30 is deposited
into the hopper 28
from chute 32, and is deposited into the molds 20 (Figs. 3 and 4) from the
hopper 28. The
hardenable paste 30 is retained in the molds 20 by the force of the shield 402
against the outer
surface 22 of the drum beneath it as the drum 16 rotates the molds from
beneath the hopper 28 in
the direction of arrow C.
[0075] The rotation of the drum 16 progresses the molds 20 downwardly from the
hopper 28
beneath the shield 402 to the six o'clock or bottom position 482. At the
bottom position 482, the
hardenable paste 30 within the molds 20, which is not yet completely
solidified, contacts and is
embedded by the sheet of three-dimensional matting 900 by the compressive
downward force of
the drum 16 over the bottom position against the sheet of three-dimensional
matting and the
support surface 84 beneath it. As the drum 16 continues to roll in the
direction of arrow C, the
hardenable paste 30, now attached to the filaments 64, 264, 370, 870 at the
bottom position 482,
releases from the molds 20 in the form of blocks 67. The blocks 67 become
dimensionally stable
at, or shortly after, the time of release from the molds 20 at the bottom
position 482 and
thereafter solidify with the filaments 64, 264, 370, 870 embedded in them,
which attaches the
blocks to the sheet of three-dimensional matting 900. The blocks 67, together
with the sheet of
three-dimensional matting 900, form the erosion control mat 66.
[0076] As shown in Fig. 9, in still another embodiment of the system,
generally designated
500, the sheet of three-dimensional matting 900 is in the form of a coil 574
rotatably supported
on a spindle 572 that is mounted on the frame 512. The frame 512 rotatably
supports the drum 16
and hopper 28 at the top or twelve o'clock position 586, and supports the
spindle 572 upstream
22
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
of the hopper 28; that is, to the rear of the hopper 28 as the frame 512 moves
in the direction of
arrow A over support surface 84.
[0077] The spindle 572 is spatially oriented relative to the drum 16 and
hopper 28 so that the
sheet of three-dimensional matting 900 pays out from the coil 574, which may
be from the
bottom of the coil as shown in Fig. 9, or from the top of the coil, such that
the filaments 64, 264,
370, 870 face downwardly toward the molds 20 (Figs. 3 and 4) in the drum 16.
The sheet of
three-dimensional matting 900 extends to and engages the drum 16 between the
outer surface 22
and the bottom wall 40 of the hopper 28, entering at the rear wall 38. From
the rear wall 38 the
sheet of three-dimensional matting 900, extends beneath the hopper 28, where
the hardenable
paste 30 from the chute 32 is deposited into the molds 20.
[0078] The openings in the sheet of three-dimensional matting 900 are
sufficiently large to
allow the hardenable paste 30 to flow therethrough from the hopper 28
downwardly into the
molds 20, but sufficiently small to prevent the hardenable paste from flowing
out of the molds as
the molds progress downwardly from the top position 586 to the bottom or six
o'clock position
582, because the paste becomes more viscous as it hardens and therefore
resists flowing out of
the molds. At the top position 586, the filaments 64, 264, 370, 870 embed in
the hardenable
paste 30 in the molds 20 as the molds fill with the hardenable paste and the
sheet of three-
dimensional matting 900 is held against the outer surface 22 of the drum 16.
[0079] This arrangement, in which the sheet of three-dimensional matting 900
is held against
the outer surface 22 of the drum 16, is maintained because of the tension
exerted on the sheet of
three-dimensional matting between the pinch of the drum against the sheet of
three-dimensional
matting at the bottom position 582 and the resistance of the spindle 572 to
rotation of the coil
574 at the upstream end of the sheet of three-dimensional matting. At the
bottom position 582,
the hardenable paste 30 in the molds 20 has hardened sufficiently to adhere to
the filaments 64,
264, 364 so that the blocks 67 fall from the molds 20, forming the mat 66.
[0080] With each of the embodiments of systems 100, 200, 500 described herein,
an elongate
sheet of three-dimensional matting 900 is utilized to serve a dual purpose.
First the sheet of
three-dimensional matting 900 forms an integral part of the erosion control
mat 66, comprised of
the sheet of three-dimensional matting in which blocks 67 of hardened paste 30
are cast and held
23
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
in a predetermined array. Second, and this benefit exists also with the
embodiment of system
400, the sheet of three-dimensional matting 900 is used to retain the
hardenable paste 30 in the
molds 20 of the drum 16 during the process that forms the molded blocks 67. As
the sheet of
three-dimensional matting 900 retains the hardenable paste in the molds 20
while the drum 16
rotates, the sheet of three-dimensional matting contacts the outer surfaces 62
of the hardenable
paste 30 so that the filaments 64, 264, 370, 870 embed in the hardenable
paste, thereby
permanently attaching the blocks 67 to the sheet of three-dimensional matting
to form the
erosion control mat 66.
[0081] In general, the process for making an erosion control mat 10, 100
includes first
depositing a hardenable paste 30 in flowable form into a plurality of molds
20, which may be
formed in the outer surface 22 of the drum 16. The molds 20 are covered with a
sheet 900 of a
geocomposite 260, 360, 860 having a multiplicity of protrusions, which may
take the form of
filaments 64, 264, 370, 870, projecting outwardly therefrom, so that the
multiplicity of
protrusions extends into the hardenable paste 30 in the plurality of molds.
The geocomposite
260, 360, 860 having a multiplicity of protrusions 64, 870 is held against the
molds 20 until the
paste 30 therein hardens sufficiently to form blocks 67 within the molds
attached to the
geocomposite 260, 360, 860 by the multiplicity of protrusions. The
sufficiently hardened blocks
67 are removed from the molds 20 to form the erosion control mat 10, 100
having the
sufficiently hardened blocks interconnected by the geocomposite 260, 360, 860.
[0082] In embodiments, depositing the hardenable paste 30 includes depositing
a hardenable
paste in flowable form downwardly into a plurality of molds 20 opening
upwardly. Further,
removing the solid blocks 67 from the molds in embodiments includes inverting
the molds 20 so
that the sufficiently hardened blocks, interconnected by the geotextile 260,
360, fall out of the
molds. In exemplary embodiments, the geotextile is selected from a loop
matting 260 and a
woven textile having synthetic turf 870.
[0083] While the methods and forms of apparatus disclosed herein constitute
preferred forms
of the disclosed process and system for making an erosion control mat using
loop matting, it is to
be understood that the system and invention are not limited to these precise
forms of apparatus
24
CA 3071175 2020-02-05
Atty. Dkt. No. 079834-00011USCP1
and methods, and that changes may be made therein without departing from the
scope of the
disclosure.
CA 3071175 2020-02-05
