Note: Descriptions are shown in the official language in which they were submitted.
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WOVEN FABRIC WITH COMPARABLE TENSILE STRENGTH IN WARP AND
WEFT DIRECTIONS
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This present application claims benefit of U.S. Patent Application
Serial No.
17/022,422, which is related to U.S. Application Serial No. 16/091,297, filed
October 4, 2018,
which is U.S. national stage entry of PCT Application Serial No.
PCT/U52017/026511, filed
April 7, 2017, which claims benefit of U.S. Patent Application Serial No.
62/319,481 filed
April 7, 2016.
BACKGROUND
[0002] In traditional weaving of a material, crimp is introduced into the yams
woven
in the machine direction (i.e., warp yams). As a result of the warp yarn
interlacing with the
weft yarns, the warp yam contains inherent crimp. This warp crimp causes a
significant
reduction in the tensile strength at low strain rates in the machine direction
(MD) when
compared to the tensile strength in the cross-machine direction (CD).
[0003] During a tensile test, there are two main contributors to tensile
strength
(modulus): 1) warp crimp and 2) tensile strength of the yarn. In the initial
portion of the
stress/strain curve, at low strain values (e.g., 1%-5% strain), the warp crimp
in the material is
removed. This crimp removal typically requires very small tensile loads
resulting in lower
tensile values at these lower strains (i.e., 1%-5% strain). It is therefore
desirable to minimize
warp crimp as much as possible in order to maximize the MD tensile strength in
the fabric.
Many geosynthetic applications have a clause written in that describe the
product in its
weakest principle direction. However, in many applications the stresses and
strains of the
application cannot be dictated or predicted as to which direction will receive
more of the
principle load. In addition, seaming geotextile panels will naturally cause
weaker tensile
properties at respective joints.
[0004] Accordingly, there is a need for a modulus balanced, woven geosynthetic
fabric in which the effect of warp crimp is minimized while maintaining other
properties
desirable for civil applications, such as relatively high water flow rates and
particle retention.
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BRIEF DESCRIPTION
[0004a] Disclosed herein is a woven geosynthetic fabric having a weft
direction and a
warp direction. The weft yarns are woven in the weft direction and the warp
yarns woven in
the warp direction interweave the weft yarns to form a fabric. In one aspect,
the fabric has a
tensile strength of at least 100 pounds/inch (1b/in) at 2% strain in both the
warp and weft
directions as respectively measured in accordance with ASTM International
Standard D4595.
In another aspect, the fabric has a tensile strength of at least 200 lb/in at
5% strain in both the
warp and weft directions as respectively measured in accordance with ASTM
International
Standard ASTM International Standard D4595. Yet, in another aspect, the fabric
has a
repeating pattern of a first shed comprising one or more yarns having a total
denier between
about 200 denier to about 1000 denier and a second shed comprising one or more
yarns
having a total denier between about 400 denier to about 15,000 denier, the
total denier of the
second shed is at least 50% greater than the total denier of the first shed,
and the first shed is
adjacent the second shed. Still, in another aspect, the fabric has a repeating
pattern of at least
one yarn disposed in a first shed and at least two yarns disposed in a second
shed with the
first shed being adjacent the second shed, and the fabric has a tensile
strength in the warp
direction in a range of about 80% to about 120% of the tensile strength in the
weft direction
as respectively measured in accordance with ASTM International Standard D4595
at 5%
strain. As disclosed herein, the fabric can have an apparent opening size
(AOS) of at least 30
as measured in accordance with ASTM International Standard D475. Further, the
fabric can
have a water flow rate of at least 75 gpm/ft2 as measured in accordance with
ASTM
International Standard D449.
[0004b] In one embodiment, there is provided a woven geosynthetic fabric
having a
weft direction and a warp direction. The woven geosynthetic fabric comprises:
weft yarns
woven in the weft direction and warp yams woven in the warp direction
interweaving the
weft yarns in a plain weave pattern or a twill weave pattern; and a repeating
pattern of at least
one first weft yarn disposed in a first shed and at least one second weft yarn
in a second shed,
the at least one first weft yarn and the at least one second weft yarn being
different, and the
second shed being taller than the first shed, the first shed having a
thickness of about 50 mils
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to about 150 mils, and the second shed having a thickness of about 10 mils to
about 70 mils,
the first shed and the second shed differing in thickness by about 15% to
about 55%. The
woven geosynthetic fabric has an apparent opening size (AOS) of at least 30 as
measured in
accordance with ASTM International Standard D4751 and a water flow rate of at
least 75
gpm/ft2 as measured in accordance with ASTM International Standard D4491. The
woven
geosynthetic fabric has a tensile strength of at least 100 lb/in at 2% strain
in both the warp
and weft directions as respectively measured in accordance with ASTM
International
Standard D4595.
[0004c] In another embodiment, there is provided a woven geosynthetic fabric
having
a weft direction and a warp direction. The woven geosynthetic fabric
comprises: weft yarns
woven in the weft direction and warp yarns woven in the warp direction
interweaving the
weft yarns in a plain weave pattern or a twill weave pattern; and a repeating
pattern of at least
one first weft yarn disposed in a first shed and at least one second weft yarn
in a second shed,
the at least one first weft yarn and the at least one second weft yarn having
different surface
areas, and the second shed being taller than the first shed, the first shed
having a thickness of
about 50 mils to about 150 mils, and the second shed having a thickness of
about 10 mils to
about 70 mils, the first shed and the second shed differing in thickness by
about 15% to about
55%. The woven geosynthetic fabric has an apparent opening size (AOS) of at
least 30 as
measured in accordance with ASTM International Standard D4751 and a water flow
rate of
at least 75 gpm/ft2 as measured in accordance with ASTM International Standard
D4491. The
woven geosynthetic fabric has a tensile strength of at least 100 lb/in at 2%
strain in both the
warp and weft directions as respectively measured in accordance with ASTM
International
Standard D4595.
[0004d] In another embodiment, there is provided a method of making a woven
geosynthetic fabric having a weft direction and a warp direction. The method
comprises
weaving weft yarns in the weft direction and warp yarns in the warp direction
such that the
warp yarns interweave the weft yarns in a plain weave pattern or a twill weave
pattern, the
woven geosynthetic fabric including a repeating pattern of at least one first
weft yarn
disposed in a first shed and at least one second weft yarn in a second shed,
the at least one
first weft yarn and the at least one second weft yarn being different, and the
second shed
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being taller than the first shed, the first shed having a thickness of about
50 mils to about 150
mils, and the second shed having a thickness of about 10 mils to about 70
mils, the first shed
and the second shed differing in thickness by about 15% to about 55%. The
woven
geosynthetic fabric has an apparent opening size (AOS) of at least 30 as
measured in
accordance with ASTM International Standard D4751 and a water flow rate of at
least 75
gpm/ft2 as measured in accordance with ASTM International Standard D4491; and
wherein
the woven geosynthetic fabric has a tensile strength of at least 100 lb/in at
2% strain in both
the warp and weft directions as respectively measured in accordance with ASTM
International Standard D4595.
[0005] The above described and other features are exemplified by the following
figures
and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The following figures are exemplary embodiments wherein the like
elements
are numbered alike.
[0007] FIG. 1 is a cross-sectional view of an embodiment of a woven
geosynthetic
fabric.
[0008] FIG. 2 is a cross-sectional view of another embodiment of the woven
geosynthetic fabric.
[0009] FIG. 3 is a top view of the woven geosynthetic fabric utilizing a 2/2
twill
weave.
DETAILED DESCRIPTION
[0010] Disclosed herein are geosynthetic fabrics having comparable modulus
tensile
properties. That is, the woven fabric has comparable tensile strength values
in both the warp
(machine) direction and the weft (cross machine) direction at specified
elongation values that
are relevant to civil engineering specifications. Tensile strength is measured
in accordance
with American Society for Testing and Materials International Standard (ASTM)
D4595. In
addition, the fabric can have an apparent opening size (AOS) of at least 30 as
measured in
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accordance with ASTM D4751. Further, the fabric can have a waterflow of
greater than 75
gallons per minute square feet (gpm/ft2) as measured in accordance with ASTM
D4491.
[0011] For example, the woven geosynthetic fabric has weft yarns woven in the
weft
direction and warp yarns woven in the warp direction interweaving the weft
yarns to form the
fabric. The fabric has an AOS of at least 30 and a water flow rate of at least
75 gpm/ft2.
Further, the fabric has respective tensile strengths of at least 100 lb/in at
2% strain in both the
warp and weft directions. In another aspect, the fabric has respective tensile
strengths of at
least 125 lb/in at 2% strain in both the warp and weft directions. Yet, in
another aspect, the
fabric has respective tensile strengths of at least 130 lb/in at 2% strain in
both the warp and
weft directions.
[0012] In another aspect, the woven geosynthetic fabric has weft yarns woven
in the
weft direction and warp yarns woven in the warp direction interweaving the
weft yarns to
form the fabric. The fabric has an AOS of at least 30 and a water flow rate of
at least 75
gpm/ft2. Further, the fabric has respective tensile strengths of at least 200
lb/in at 5% strain in
both the warp and weft directions. In another aspect, the fabric has
respective tensile
strengths of at least 250 lb/in at 5% strain in both the warp and weft
directions. Yet, in
another aspect, the fabric has respective tensile strengths of at least 300
lb/in at 5% strain in
both the warp and weft directions. Still, in another aspect, the fabric has
respective tensile
strengths of at least 350 lb/in at 5% strain in both the warp and weft
directions. Yet still, in
another aspect, the fabric has respective tensile strengths of at least 400
lb/in at 5% strain in
both the warp and weft directions.
[0013] Yet, in another aspect, the woven geosynthetic fabric has weft yarns
woven in
the weft direction and warp yarns woven in the warp direction interweaving the
weft yarns to
form the fabric. The fabric has an AOS of at least 30 and a repeating pattern
of a first shed
comprising one or more yarns having a total denier between about 200 denier to
about 1000
denier and a second shed comprising one or more yarns having a total denier
between about
400 denier to about 15,000 denier, and the total denier of the second shed
being at least 50%
greater than the total denier of the first shed, the first shed being adjacent
the second shed. In
another aspect, the total denier of the second shed is at least 100% greater
than the total
denier of the first shed. Yet, in another aspect, the total denier of the
second shed is at least
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150% greater than the total denier of the first shed. Still, in another
aspect, the total denier of
the second shed is at least 200% greater than the total denier of the first
shed. The term "total
denier" means the sum of denier of the respective yarns disposed in a specific
shed. For
example, the total denier of a 1,000 denier yam and a 1,500 denier yam
disposed in the same
shed is 2,500 denier.
[0014] Still, in another aspect, the woven geosynthetic fabric has weft yams
woven
in the weft direction and warp yams woven in the warp direction interweaving
the weft yarns
to form the fabric. The fabric has an AOS of at least 30 and a repeating
pattern of at least
one yarn disposed in a first shed and at least two yams disposed in a second
shed, the first
shed being adjacent the second shed. Further, the fabric has a tensile
strength in the warp
direction in a range of about 80% to about 120% of the tensile strength in the
weft direction
as respectively measured at 5% strain. In another aspect, the fabric has a
tensile strength in
the warp direction in a range of about 85% to about 115% of the tensile
strength in the weft
direction as respectively measured at 5% strain. Further, in another aspect,
the fabric has a
tensile strength in the warp direction in a range of about 90% to about 110%
of the tensile
strength in the weft direction as respectively measured at 5% strain. Yet, in
another aspect,
the fabric has a tensile strength in the warp direction in a range of about
95% to about 105%
of the tensile strength in the weft direction as respectively measured at 5%
strain.
[0015] Moreover, in another aspect, the fabric has one yam disposed in the
first shed
and two yarns disposed in the second shed, the yams of the second shed being
the same or
different, and the yam of the first shed being the same as or different from
the yams of the
second shed. Further, in another aspect, the fabric has one yarn disposed in
the first shed and
three yams disposed in the second shed, the yams of the second shed being the
same or
different, and the yarn of the first shed being the same as or different from
the yams of the
second shed. Still, in another aspect, the fabric has two yams disposed in the
first shed and
two yarns disposed in the second shed, the yarns of the first shed being the
same or different,
the yams of the second shed being the same or different, and the yarns of the
first shed being
the same as or different from the yams of the second shed. Yet still, the
fabric has two yarns
disposed in the first shed and three yams disposed in the second shed, the
yams of the first
shed being the same or different, the yams of the second shed being the same
or different,
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and the yarns of the first shed being the same as or different from the yarns
of the second
shed.
[0016] In some aspects, the one or more yarns in the first shed are a
monofilament
yarn, a fibrillated tape, or any combination thereof; the one or more yarns in
the second shed
are a monofilament yarn, a fibrillated tape, or any combination thereof; and
the yarns
respectively disposed in the first and second sheds can be the same or
different. For
example, the one or more yarns in the first shed can comprise a monofilament
yarn and the
one or more yarns in the second shed can comprise fibrillated tape. Moreover,
the one or
more yarns in the first shed can comprise a monofilament yarn, and the one or
more yarns in
the second shed can comprise a combination of monofilament yarn and
fibrillated tape.
[0017] As indicated above, the geosynthetic fabric comprises a repeating
pattern of
two specialized fabric sheds. The first shed is a "high tensile/high modulus"
shed whereby
the warp yarn is floating over a large denier weft yarn, causing the warp yarn
to have a low
level of weaving crimp. The second shed is a "high flow/high AOS" shed,
whereby the warp
yarn is floating over a monofilament weft yarn, resulting in a slightly higher
level of weaving
crimp in the warp yam. These two specialized sheds create a taller (thicker)
shed and a
smaller (thinner) shed, that is, sheds having varying warp crimp amplitude.
The taller shed
has a greater thickness than the smaller shed. The result is a rougher surface
on the geotextile
which is beneficial in civil applications where it is desired to have
sufficient shear face
interaction with the soil and/or aggregate material which is in intimate
contact with the
geotextile. The greater the shear angle between the two surfaces, the more
difficult it is to
push or pull the geotextile out of the in situ system. The alternating shed
pattern also
produces a synergy in the product that allows comparable tensile strength
properties in the
warp and weft directions and "hydraulic" properties (AOS, water flow,
strength, etc.) to be
met in a single warp woven fabric.
[0018] In some aspects, the first shed (the high tensile/high modulus shed)
has a
thickness of about 50 mils to about 150 mils, and the second shed (the high
flow/high AOS
shed) has a thickness of about 10 mils to about 70 mils. In other aspects, the
first shed and
the second shed differ in height (thickness) by about 10% to about 60 %. In
other aspects, the
first shed and the second shed differ in height (thickness) by about 15% to
about 55%, about
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20 to about 50%, about 25% to about 45%, or about 30% to about 40%. Yet, in
some aspects,
the first shed and the second shed differ in height (thickness) by an amount
about or in any
range between about 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, and 60%.
[0019] Reference is made to FIGS. 1 ¨ 3, wherein like reference numerals
indicate
like parts throughout the figures. FIGS. 1 ¨3 illustrate respective
embodiments of a woven
geosynthetic fabric 10 with comparable tensile strength in the warp and weft
directions
utilizing a 2/2 twill weave pattern. As illustrated in FIG. 1 and FIG. 3, the
fabric 10 includes
in the weft (fill) direction a first weft yarn 20, and a second weft yarn 30.
The first and
second weft yarns 20, 30 are interwoven with warp yarns 40. The first weft
yarns 20 are in a
first shed 50 and the second weft yarns are in a second shed 60 adjacent to
the first shed 50.
The first shed 50 and second shed 60 form a repeating pattern of alternating
sheds in the
fabric weave. Specifically, in FIG. 1, the fabric 10 has one monofilament in
the first shed and
one fibrillated tape in the second shed.
[0020] FIG. 2 illustrates the fabric having one monofilament (first yarn 20)
in the first
shed and two fibrillated tapes (second yarns 30 and 32) in the second shed.
While second
yarns 30 and 32 are illustrated as being fibrillated tape, it is not required
for second yarns 30
and 32 to be the same.
[0021] In one aspect, the woven fabric 10 comprises a repeating pattern of two
or
more first weft yarns 20 in the first shed 50 and a second weft yarn 30 in the
second shed 60.
In one aspect, the woven fabric 10 comprises a repeating pattern of two first
weft yarns 20 in
the first shed 50 and a second weft yarn 30 in the second shed 60. In yet
another aspect, the
woven fabric 10 comprises three first weft yarns 20 in the first shed 50 and a
second weft
yarn 30 in the second shed 60.
[0022] The first and second weft yarns 20, 30 can be the same or they can be
different. In one aspect, first weft yarns 20 and second weft yarns 30 are
different and
comprise two types of yarns of differing cross-sectional shapes. In some
aspects, first weft
yarn 20 is a fibrillated tape yarn having a rectilinear cross-section with a
width greater than
its thickness. The first weft yarns 20 comprise fibrillated tape of about 500
to about 6500
Denier. In one aspect, the first weft yarn 20 comprises a fibrillated tape of
about 3000 to
about 6500 Denier. In another aspect, the first weft yarns 20 comprise a
fibrillated tape of
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about 3600 to about 6200 Denier, and in yet another aspect, the first weft
yarns 20 comprise a
fibrillated tape of about 4600 to about 5600 Denier. In one aspect, the first
weft yams 20
comprise a fibrillated tape of about 4600 Denier.
[0023] In various aspects, the first weft yarn 20 is a high modulus
fibrillated tape yam
having a tenacity of at least 0.75 g/denier at 1% strain, at least 1.5
g/denier at 2% strain, and
at least 3.75 g/denier at 5% strain. Tenacity, a referenced herein, is
determined in accordance
with ASTM D2256. Second weft yarn 30 is a monofilament yarn having a different
geometrically shaped cross-section from that of the first weft yarn. In one
aspect, the second
weft yarn 30 has a substantially rounded cross-sectional shape, i.e., a
substantially circular
cross-sectional shape. In one aspect, the second weft yam 30 is a monofilament
yam of about
400 to about 1600 Denier. In another aspect, the second weft yam 30 is a
monofilament yam
of about 400 to about 925 Denier, and in yet another aspect, the second weft
yarn 30 is a
monofilament yarn of about 425 to about 565 Denier.
[0024] Fibrillated tapes have a non-round cross-sectional shape that can be
irregular
bundles and packs into a shed to provide a different cross sectional shape,
for example when
used in combination with a round monofilament in another shed, based on the
number of
warp yarns, warp tension, size of warp yarn, etc. The shape of the fibrillated
tape will affect
the AOS and water flow of the fabric, but not modulus or tensile.
[0025] In another aspect, first weft yarn 20, the second weft yam 30, or both,
has a
cross-sectional shape that is non-round. For example, the first weft yam 20
and/or the second
weft yarn 30 has a cross-sectional shape that is oval.
[0026] Yet, in another aspect, the first weft yarn 20, the second weft yarn
30, or both,
has a cross-sectional shape that is multi-lobal. Non-limiting examples of
multi-lobal cross-
sectional shapes include multi-channel, tri-lobal, and pillow cross-sectional
shapes.
[0027] The first and second weft yarns 20, 30 are woven together with a warp
yam
40. In some aspects, the warp yams 40 comprise a high modulus monofilament
yarn of about
1000 to about 1500 Denier. In one aspect, the warp yarns 40 comprise a high
modulus
monofilament yam of about 1200 to about 1400 Denier. In yet another aspect,
the warp
yams 40 comprise a high modulus monofilament yam of about 1360 Denier. In
various
aspects, the warp yarns 40 are high modulus monofilament yarns having a
tenacity of at least
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0.75 g/denier at 1% strain, at least 1.5 g/denier at 2% strain, and at least
3.75 g/denier at 5%
strain.
[0028] The monofilament, yarn, or tape yarns employed herein, collectively
referred
to herein as "yarn or yams," include yams comprising, in some aspects,
polypropylene, yarns
comprising an admixture of polypropylene and a polypropylene/ethylene
copolymer, or yarns
comprising an admixture of polypropylene and polyethylene, or any combination
of such
yams. Warp and weft yams can be the same or different.
[0029] As mentioned above, yarns disposed in the first or second sheds can be
the
same or different. For example, the yarns disposed in the first and second
sheds can have
different cross-sectional shapes, be formed of different polymers, and/or have
different
surface areas. Although, the differences between the yams in the first and
second sheds are
not limited to these differences and can have different properties than those
in the foregoing
list. Still further, yams disposed is a given shed can be the same or
different.
[0030] In one aspect, the yarns (warp and/or weft yarns) can comprise a
polypropylene composition comprising a melt blended admixture of about 94 to
about 95%
by weight of polypropylene and at least about 5% by weight of a
polypropylene/ethylene
copolymer or polymer blend. In another aspect, the yarns can comprise an
admixture of about
90% by weight of polypropylene and about 10% by weight of a
polypropylene/ethylene
copolymer of polymer blend. Further, the polypropylene/ethylene copolymer has
an ethylene
content of about 5% to about 20% by weight of the copolymer. In one aspect,
the
polypropylene/ethylene copolymer has an ethylene content of about 16% by
weight of
copolymer. In another aspect, aspect the polypropylene/ethylene copolymer has
an ethylene
content of about 5% to about 17% by weight of copolymer. In yet another
aspect, aspect the
polypropylene/ethylene copolymer has an ethylene content of about 5%, about
6%, about
7%, about 8%, about 9%, about 10%, about 11%, about 12%, about 13%, about 14%,
about
15%, about 16%, about 17%, about 18%, about 19%, or about 20%, or any range
therebetween, by weight of copolymer. Still, in another aspect, the
polypropylene/ethylene
copolymer has an ethylene content of about 16% by weight of copolymer. Such an
admixture is referred to herein as "high modulus" yam. The high modulus yarn
is described
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in U.S. Patent Application Serial No. 13/085,165, to Jones et al. entitled
"Polypropylene
Yarn Having Increased Young's Modulus and Method of Making Same," ("Jones et
al.").
[0031] As described by Jones et al., in some aspects, the monofilament, yarn,
or tape
of the warp and/or weft yarns has an improved Young's modulus as compared to
monofilament, yarn, tape, or staple fiber made from neat polypropylene
homopolymer.
Young's modulus (E), also known as the modulus of elasticity, is a measure of
the stiffness
of an isotropic elastic material. It is defined as the ratio of the uniaxial
stress over the
uniaxial strain in the range of stress in which Hooke's Law holds. This can be
experimentally determined from the slope of a stress-strain curve created
during tensile tests
conducted on a sample of the material. See International Union of Pure and
Applied
Chemistry, "Modulus of Elasticity (Young's modulus), E", Compendium of
Chemical
Terminology, Internet edition.
[0032] In one or more aspects, the monofilament, yarn, tape, or staple fiber
has a
Young's modulus greater than 3.5. Young's modulus, as referenced herein, is
determined in
accordance with ASTM D2256. In another aspect, the monofilament, yarn, tape,
or staple
fiber of the present invention has a Young's modulus of at least 4 GigaPascal
(GPa), at least
4.5 GPa, at least 5 GPa, at least 5.5 GPa, at least 6 GPa, at least 6.5 GPa,
or at least 6.9 GPa.
[0033] Furthermore, in various aspects, the monofilament, yarn, or tape each
has a
tenacity of at least 0.75 g/Denier at 1% strain, at least 1.5 g/Denier at 2%
strain, and at least
3.75 g/Denier at 5% strain. In another aspect such monofilament, yarn, tape,
or staple fiber
respectively has a tenacity of at least 0.9 g/Denier at 1% strain, at least
1.75 g/Denier at 2%
strain, and at least 4 g/Denier at 5% strain. Still, in another aspect such
monofilament, yarn,
tape, or staple fiber respectively has a tenacity of about 1 g/Denier at 1%
strain, about 1.95
g/Denier at 2% strain, and about 4.6 g/Denier at 5% strain.
[0034] In some aspects, the weft yarns and/or warp yarns are, independently,
made
from an acrylic acid polymer, an aramid polymer, a fluoropolymer, a high
density
polyetheylene, a low density polyethylene, a linear low density polyethylene,
a
polyacrylonitrile, a polyamide, a polybutylene terephthalate, a polycarbonate,
a
polyetherimide, a polyether ether ketone, a polyethylene copolymer, a
polyethylene
terephthalate, a polytetrafluoroethylene, a polyimide, a polylactic acid, a
polyolefin, a
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polyphenylene, a polyphenylene oxide, a polyphenylene sulfide, a polyolefin, a
polypropylene, a polypropylene/ethylene copolymer, a polystyrene, a
polyurethane, an ultra-
high molecular-weight polyethylene, a vinyl polymer, or any combination
thereof.
[0035] In other aspects, the yarns disposed in the first and second sheds have
different surface areas. In some non-limiting examples, at least one first
weft yarn in the first
shed and/or at least one second weft yam in the second shed is a texturized
yarn, a
continuous filament yarn, a staple yarn, a spun yarn, a twisted yam, an air
tacking yarn, or
any combination thereof.
[0036] A woven fabric typically has two principle directions, one being the
warp
direction and the other being the weft direction. The weft direction is also
referred to as the
fill direction. The warp direction is the length wise, or machine direction
(MD) of the fabric.
The fill or weft direction is the direction across the fabric, from edge to
edge, or the direction
traversing the width of the weaving machine (i.e., the cross machine
direction, CD). Thus,
the warp and fill directions are generally perpendicular to each other. The
set of yarns,
threads, or monofilaments running in each direction are referred to as the
warp yams and the
fill yams, respectively.
[0037] A woven fabric can be produced with varying densities. This is usually
specified in terms of number of the ends per inch in each direction (i.e., the
warp direction
and the weft direction). The higher this value is, the more ends there are per
inch and thus the
fabric density is greater or higher.
[0038] The woven fabric is constructed so that the number of ends in the warp
is in
the range from about 20 per inch to about 55 per inch. In another aspect the
number of ends
in the warp is about 35 per inch to about 50 per inch. Still, in another
aspect, the number of
ends in the warp is about, or in the range of, 35, 36, 37, 38, 39, 40, 41, 42,
43, 44, 45, 46, 47,
48, 49, and 50 per inch. In yet another aspect, the woven fabric is
constructed with 45 ends
per inch.
[0039] It is desirable to keep the pick/inch value as low as possible in order
to
minimize warp crimp and thus increase machine direction modulus. The weft of
the woven
fabric typically has a number of picks in the range from about 6 per inch to
about 20 per inch.
In another aspect the number of picks is in the range from about 8 per inch to
about 15 per
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inch to provide sufficient compaction to limit air flow through the fabric. In
yet another
aspect the fabric has about 10 to 14 picks per inch. Still, in another aspect
the number of
picks in the weft is about or in the range of 10, 10.5, 11, 11.5, 12, 12.5,
13, 13.5, and 14 per
inch.
[0040] The term "shed" is derived from the temporary separation between upper
and
lower warp yarns through which the fill yarns are woven during the weaving
process. The
shed allows the fill yarns to interlace into the warp to create the woven
fabric. By separating
some of the warp yarns from the others, a shuttle can carry the fill yarns
through the shed, for
example, perpendicularly to the warp yarns. As known in weaving, the warp
yarns which are
raised and the warp yarns which are lowered respectively become the lowered
warp yarns
and the raised warp yarns after each pass of the shuttle. During the weaving
process, the shed
is raised; the shuttle carries the weft yarns through the shed; the shed is
closed; and the fill
yarns are pressed into place. Accordingly, as used herein with respect to the
woven fabric,
the term "shed" means a respective fill set which is bracketed by warp yarns.
[0041] The weave pattern of fabric construction is the pattern in which the
warp yarns
are interlaced with the fill yarns. A woven fabric is characterized by an
interlacing of these
yarns. For example, plain weave is characterized by a repeating pattern where
each warp
yarn is woven over one fill yarn and then woven under the next fill yarn.
There are many
variations of weave patterns commonly employed in the textile industry, and
those of
ordinary skill in the art are familiar with most of the basic patterns. While
it is beyond the
scope of the present application to include a disclosure of this multitude of
weave patterns,
the basic plain and twill weave patterns can be employed with the present
invention.
However, such patterns are only illustrative, and the invention is not limited
to such patterns.
It should be understood that those of ordinary skill in the art will readily
be able to determine
how a given weave pattern could be employed in practicing the present
invention in light of
the parameters herein disclosed.
[0042] A twill weave, relative to the plain weave, has fewer interlacings in a
given
area. The twill is a basic type of weave, and there are a multitude of
different twill weaves.
A twill weave is named by the number of fill yarns which a single warp yarn
goes over and
then under. For example, in a 2/2 twill weave, a single warp end weaves over
two fill yarns
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and then under two fill yarns. In a 3/1 twill weave, a single warp end weaves
over three fill
yams and then under one fill yam. For fabrics being constructed from the same
type and size
of yarn, with the same thread or monofilament densities, a twill weave has
fewer interlacings
per area than a corresponding plain weave fabric.
[0043] In one aspect, in the woven fabric, the warp yams interweave the weft
yams to
form a weave comprising one or more of a plain weave, a 2/1 twill weave, a 2/2
twill weave,
and a 3/1 twill weave. In another aspect, the warp yams interweave the weft
yarns to form a
twill weave comprising a repeating pattern of two or more first weft yams
comprising a high
modulus fibrillated tape yarn in the first shed and a second weft yarn
comprising a
monofilament yam in the second shed. FIG. 1 is an illustration of a cross-
sectional view of a
2/2 twill weave having a construction comprising a repeating pattern of
fibrillated tape yarns
in a first shed and a monofilament yarn in a second shed. FIG. 3 is a top view
of a 2/2 twill
weave comprising a repeating pattern of two fibrillated tape yarns in a first
shed and a
monofilament yam in a second shed.
[0044] The woven geosynthetic fabric has comparable tensile strength. That is,
the
fabric has similar tensile strength values in both the warp (machine)
direction and the weft
(cross machine) direction at a specified elongation values. As discussed
above, in one aspect,
the woven fabric has a tensile strength in the warp direction of at least 100
pounds per inch
(1b/in) at 2% strain and a tensile strength in the weft direction of at least
100 lb/in at 2%
strain. In another aspect, the woven fabric has a tensile strength in the warp
direction of at
least 125 lb/in at 2% strain and a tensile strength in the weft direction of
125 lb/in at 2%
strain. Still, in another aspect, the woven fabric has a tensile strength in
the warp direction of
at least 130 lb/in at 2% strain and a tensile strength in the weft direction
of 130 lb/in at 2%
strain. In other aspects, the woven fabric has a tensile strength in the warp
direction of at
least 200 lb/in at 5% strain and a tensile strength in the weft direction of
at least 200 lb/in at
5% strain. In yet another aspect, the woven fabric has a tensile strength in
the warp direction
of at least 250 lb/in at 5% strain and a tensile strength in the weft
direction of at least 250
lb/in at 5% strain. Still, in another aspect, the woven fabric has a tensile
strength in the warp
direction of at least 300 lb/in at 5% strain and a tensile strength in the
weft direction of at
least 300 lb/in at 5% strain. Still further, in another aspect, the woven
fabric has a tensile
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strength in the warp direction of at least 350 lb/in at 5% strain and a
tensile strength in the
weft direction of at least 350 lb/in at 5% strain. Yet still, in another
aspect, the woven fabric
has a tensile strength in the warp direction of at least 400 lb/in at 5%
strain and a tensile
strength in the weft direction of at least 400 lb/in at 5% strain.
[0045] In some aspects, the woven fabric has a tensile strength in the warp
direction
of at least 100 lb/in at 2% strain and at least 200 lb/in at 5% strain, and a
tensile strength in
the weft direction of at least 100 lb/in at 2% strain and at least 200 lb/in
at 5% strain, as
measured in accordance with ASTM D4595. In other aspects, the woven fabric has
a tensile
strength in the warp direction of at least 125 lb/in at 2% strain and at least
250 lb/in at 5%
strain, and a tensile strength in the weft direction of at least 125 lb/in at
2% strain and at least
250 lb/in at 5% strain, as measured in accordance with ASTM D4595.
[0046] The woven fabric has open channels through the fabric for water flow.
With a
woven fabric comprising a repeating pattern of two or more first weft yarns in
a same first
shed and one second weft yarn in a second shed, water is able to flow at a
rate between about
and about 195 gallons per square foot per minute (gpm/ft2) through the fabric.
Water flow
rate, as referenced herein, is measured in accordance with ASTM D4491. In
another aspect,
the woven fabric has a water flow rate between about 30 and about 150 gpm/ft2
through the
fabric. In another aspect, the woven fabric has a water flow rate of at least
about 75 gpm/ft2.
In yet another aspect, the woven fabric has a water flow rate of at least
about 80 gpm/ft2, at
least about 85 gpm/ft2, at least about 90 gpm/ft2, at least about 95 gpm/ft2,
or at least about
100 gpm/ft2.
[0047] The woven fabric comprising a repeating pattern of two or more first
weft
yarns in a same first shed and one second weft yarn in a second shed has an
apparent opening
size (AOS) of at least 30. In one aspect, the woven fabric has an AOS of at
least 35. And, in
another aspect, the woven fabric has an AOS of at least 40.
[0048] Thus, the woven geosynthetic fabric has comparable tensile strength in
combination with a pore size of at least 30 AOS and high wateiflow. AOS, as
referenced
herein, is determined in accordance with ASTM International Standard D4751. In
comparison, when only a monofilament weft (fill) yarn is used in the first and
second shed, a
fabric is produced with very high wateiflow (e.g., 200 gpm/ft2 or more), but
with a very low
Date Recue/Date Received 2023-03-15
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AOS value, (e.g., 20 AOS or less). Further, when only multiple fibrillated
taped yarns are
placed in a single shed, the waterflow is very low, and when multiple
monofilaments are
placed in a single shed, the warp crimp is not reduced enough to allow for the
desired
combination of comparable tensile strength, at least 30 AOS, and waterflow of
at least 75
gpm/ft2.
[0049] The process for making fabrics, to include the above described woven
geosynthetic fabric, is well known in the art. Thus, the weaving process
employed can be
performed on any conventional textile handling equipment suitable for
producing the woven
fabric. In weaving the woven geosynthetic fabric, the raised warp yarns are
raised, and the
lowered warp yarns are lowered, respectively, by the loom to open the shed. In
one aspect,
high modulus monofilament yarns are employed as the warp yarns, while high
modulus
fibrillated tape yarns and monofilament yarns are employed as the weft yarns.
In some
aspects, a method of making a woven geosynthetic fabric having a weft
direction and a warp
direction includes weaving weft yarns in the weft direction and warp yarns in
the warp
direction such that the warp yarns interweave the weft yarns in a plain weave
pattern or a
twill weave pattern. The woven geosynthetic fabric includes a repeating
pattern of at least
one first weft yarn disposed in a first shed and at least one second weft yarn
in a second shed.
The at least one first weft yarn and the at least one second weft yarn are
different, and the
second shed is taller than the first shed.
[0050] This disclosure is further illustrated by the following examples, which
are
non-limiting.
EXAMPLES
[0051] A number of different fabric samples were prepared and their properties
were
compared. The fabric samples were identified by AOS, waterflow, tensile
strength,
threads/inch, weave, warp yarns, and fill yarns.
[0052] The properties of the woven fabric were measured using standardized
American Society for Testing and Materials International (ASTM International)
test methods
set forth in Table 1 below in effect at the time of filing of the instant
application. The target
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tensile is directed to a theoretical commercial embodiment and should not be
considered as
limiting the scope of the description of the invention herein.
Table 1
Property Test Method* Units Target
Tensile,
MD x CD
Wide Width (WW) tensile strength ASTM D4595 lb/in 125 x
125
@2% Strain
Wide Width (WW) tensile strength ASTM D4595 lb/in 250 x
250
@5% Strain
Apparent opening size (AOS) ASTM D4751 U.S. Sieve No. 30 ¨ 40
Waterflow ASTM D4491 gal/min=ft2 75
* The recited Test Method is the identified ASTM International Standard.
Examples 1-9
[0053] Examples 1-9 were used to provide a beginning, baseline set of data.
The
construction of and results for Examples 1-9 are provided in Table 2 below.
Table 2
Property Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5
Ex. 6 Ex. 7 Ex. 8 Ex. 9
Construction 45x13.2 45x12.2 45x11.2 45x13.2 45x12.2 45x11.2 45x13.2
45x12.2 45x11.2
Weave Pattern 2/2 Twill 2/2 Twill 2/2 Twill 3/1 3/1 3/1 3/3
3/3 3/3
Special Special Special Herring- Herring- Herring-
bone bone bone
Warp Yam 1011 1011 1011 1011 1011 1011 1011 1011
1011
Fill Yam (tape) 4602 4602 4602 4602 4602 4602 4602
4602 4602
Fill Yarn (mono) 925 925 925 925 925 925 925
925 925
WW Tens@,2% 63x171 84x154 80x141 74x163 n/a
103x148 85x162 n/a 112x139
WW Tens g5% 177x352 154x216 141x220 163x226 n/a 148x278 162x250
n/a 139x292
AOS 40 40 40 Fail 40 n/a Fail 40
Fail 40 n/a Fail 40
Waterflow 111 101 107 ¨ 162 n/a 179 124
n/a 146
[0054] Examples 5 and 8 were not tested since neither of the adjacent examples
passed all specifications. As shown in Table 2, for each example, the tensile
strengths in the
2% and 5% warp direction (machine direction, MD) were significantly below the
desired
tensile strengths of 125 and 250 lb/in respectively.
Examples 10-14
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[0055] A variety of concepts were tested in Examples 10-14 as set forth in
Table 3
below. Examples 10 and 11 are a 2/2 twill weave pattern of a monofilament
having a 565
denier twisted together with fibrillated tape having a 4602 denier to make a
single composite
yarn for the fill, in the weft direction. Examples 12 and 13 are a special 3/1
twill pattern
having a 3602 denier tape fill yarn in the weft direction in order to reduce
some of the crimp
in the MD yarns and maintain the CD tensile strength. Example 14 used the
double layer
weave pattern described in U.S. Patent No. 8,598,054 to King el al.
Table 3
Property Ex. 10 Ex. 11 Ex. 12 Ex. 13
Ex. 14
Construction 45x6 45x8 45x7.8 45x8.4
45x13
Weave Pattern 2/2 Twill 2/2 Twill 3/1 Special 3/1 Special
Double Layer
Warp Yarn 1011 1011 1011 1011
1011
Fill Yarn (tape) 565 mono & 4602 565 mono &
4602 3602 3602 3602
Fill Yarn (mono) tape twisted tape twisted none
none 565
together together
WW Tensg2% n/a 85x130 137x114 135x120
93x150
WW Tens (0% n/a 233x316 327x252 320x267
253x334
AOS n/a Fail 40 Fail 40 Fail 40
Fail 40/Pass 30
Waterflow n/a 322 60 52 72
(gpm/ft2)
[0056] As shown in Table 3, the fabric of Examples 10 and 11, having a
monofilament and fibrillated tape twisted together, had a low 2% MD tensile
strength, failed
for 40 AOS and had very high waterflow (322 gpm/ft2). For Examples 12 and 13,
the CD 2%
and 5% tensile values of the fabrics were borderline to low, failed 40 AOS,
and had low
waterflow. With regard to Example 14, the fabric had excessive warp crimp,
resulting in low
2% MD tensile values, and failed 40 AOS and low waterflow.
Examples 15-20
[0057] The materials, construction and test results for the fabrics of
Examples 15-20,
are shown in Table 4.
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Table 4
Property Ex. 15 Ex. 16 Ex. 17 Ex. 18 Ex. 19
Ex. 20
Construction 45x7.5 45x8.5 45x9 45x10 45x7
45x9
Weave Pattern 3/1 3/1 2/2 Twill ¨ alt 2/2 Twill ¨
2/2 Twill ¨ 2/2 Twill ¨
Special Special tape & mono
alt tape & mono alt tape/tape/mono alt tape/tape/mono
Warp Yarn 1011 1011 1011 1011 1011
1011
Fill Yarn (tape) 3602 3602 _ 5602 5602 4602
4602
Fill Yarn (mono) None none 925 925 925
925
WW Tensg2% n/a n/a 111x136 101 x 128 121x90
101x132
WW Tens gs% n/a n/a 276x281 258x298 300x212
265x287
AOS n/a n/a Fail 40 Fail 40 Fail 40
Fail 40
Waterflow n/a n/a 132 128 124
115
[0058] As shown in Table 4, Examples 15 and 16 were a broken 3/1 twill weave,
Examples 17 and 18 were a 2/2 twill weave pattern of an alternating single
tape yarn and a
single monofilament yarn in the weft (fill) direction. Examples 19 and 20 were
a 2/2 twill
weave pattern alternating a single tape yarn, single tape yarn, and single
monofilament yarn
in a weft direction. Examples 17 and 18 were directed toward increasing the 2%
MD value
by decreasing warp crimp and fabric interlacings, but were not successful. In
addition, all of
the examples failed 40 AOS.
Examples 21-26
[0059] The materials, construction and test results for Examples 21-26 are
shown in
Table 5 below. Examples 21 & 22 used a double layer weave pattern with two
stuffer picks
adjacent to one another (e.g. as described in King et al). Examples 23 and 24
used the weave
pattern of earlier samples, 2/2 twill with alternating tape & monofilament
fill yarns, and
Examples 26 used a special 3/2 twill weave with alternating tape &
monofilament fill yarns
in order to further reduce warp crimp.
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Table 5
Property Ex. 21 Ex. 22 Ex. 21A Ex. 22A Ex. 23 Ex. 24
Ex. 25 Ex. 26
Construction 45x10 45x12 45x10 45x12 45x9 45x10
45x9 45x10
Weave Pattern Dbl Dbl Dbl Dbl
2/2 Twill ¨ 2/2 Twill Special 3/2 Special 3/2
Layer-2 Layer- 2 Layer-2
Layer¨ 2 alt tape & ¨ alt tape Twill ¨ alt Twill ¨ alt
Stuffer Stuffer Stuffer Stuffer mono
& mono tape & tape &
Pks Pks Pks Pks mono
mono
Warp Yarn 1011 1011 1011 1011 1011 1011 1011
1011
Fill Yarn (tape) 4602 4602 4602 4602 5602 5602
5602 5602
Fill Yarn 565 565 925 925 695 695 695
695
(mono)
WW Tens(0,2% 106x157 109x175 n/a n/a 106x128 100x151
n/a 115x148
WW Tens co% 332x535 368x535 n/a n/a 273x518 312x508
n/a 302x311
AOS Fail 40 Fail 40 n/a n/a Fail 40
Fail 40 n/a Fail 40
Waterflow 109 95 n/a n/a 129 128 n/a
130
[0060] Examples 21A and 22A were not tested because the double layer 2 stuffer
pick weave pattern produced holes in the fabric and would not pass 40 AOS. As
shown in
Table 5, Examples 21 and 22 both had low 2% MD values due to the relative high
level of
warp crimp in this weave pattern. Both also failed for 40 AOS. Examples 23 and
24 both had
low 2% MD values and failed 40 AOS. Example 26 had low 2% MD and failed 40
AOS.
Examples 27-31
[0061] The materials and construction of Examples 27-31 are shown below in
Table
6. Examples 27, 27A, and 28 used a double layer weave pattern with two stuffer
picks
adjacent to one another. Examples 29 - 30 used a different weave pattern,
consisting of two
sections of different pick counts. It consisted of a section of monofilament
picks at a higher
density (for flow/AOS) and a section of fibrillated tape yarns at a lower
density (for
strength). Example 31 used a 865 denier nylon continuous filament yarn instead
of a
monofilament.
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Table 6
Property Ex. 27 Ex. 27A Ex. 28 Ex. 29 Ex. 30
Ex. 31
Construction 45x7 45x10 45x9 45x16/6.8 45x16/6.5
45x116/6.8
Weave Pattern Dbl Layer ¨ Dbl Layer ¨2 Dbl Layer ¨2 Special ¨2 pk Special
¨2 pk Special ¨2 pk
2 Stuffer Pks Stuffer Pks Stuffer Pks counts
counts counts
Warp Yarn 1011 1011 1011 1011 1011 1011
Fill Yarn (tape) 5602 5602 5602 5602 5602 5602
Fill Yarn (mono) 925 925 925 925 925 865*
WW Tens@2% n/a n/a 132x175 79x160 122x145
86x101
WW Tens @5% n/a n/a 318x368 230x325 305x288
244x227
AOS n/a n/a Fail 40 Fail 40 Fail 40
Fail 40
Waterflow n/a n/a 160 137 140 99
[0062] Examples 27 and 27A were not tested. Example 28 had marginal 2% MD
values due to the relative high level of warp crimp inherent in this weave
pattern. It also
failed for 40 AOS. Examples 29-30 did not meet the 2% MD value and failed 40
AOS, while
Example 31 offered no improvement in physical properties.
[0063] This concluded this series of prototypes. It was determined that the
1011
denier warp yarn needed to be heavier in order to increase the 2% and 5% MD
tensile
strength.
Examples 32-59: PC-1C-14-304-01B
[0064] A 1362 Denier high modulus, high tensile warp yarn was used in the
following series of examples for PC-1C-14-304-01B.
Examples 32-37
[0065] Examples 32-37 are provided in Table 7 below. As shown in Table 7,
Examples 32, 34, 35, and 37 were low (do not make 125 lb/in tensile strength)
on 2% CD,
while Examples 33, 34, 36, and 37 were low or marginally low (do not make 125
lb/in
MARV) on 2% MD.
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Table 7
Property Ex. 32 Ex. 33 Ex. 34 Ex. 35 Ex. 36
Ex. 37
(Trial 1) (Trial 2) _ (Trial 3) _ (Trial 4)
_ (Trial 5) _ (Trial 6)
Construction 45x9 45x10 45x11 45x9 45x10
45x11
Weave Pattern 2/2 Twill ¨ alt 2/2 Twill ¨ alt
2/2 Twill ¨ alt 2/2 Twill ¨ alt 2/2 Twill ¨ alt 2/2 Twill ¨ alt
tape & mono tape & mono tape & mono
tape & mono tape & mono tape & mono
Warp Yarn 1362 1362 1362 1362 1362 ,
1362
Fill Yarn (tape) _ 5602 5602 5602 5602
5602 5602
Fill Yarn (mono) 565 565 565 695 695
695
WW Tens@2% 150x118 136x150 122x89 151x95 123x142
110x69
WW Tens g5% 389x247 349x295 306x192 368x199 315x303
283x345
AOS Fail 40/Pass 30 _ Fail 40/Pass 30 Fail
40 , Fail 40 Fail 40 , Fail 40
Waterflow 115 110 121 130 121
111
Examples 38-45
[0066] Examples 38, 39, 40, 41, and 42 used a smaller monofilament fill yarn
(425
denier) than previous trials, in an attempt to improve the MD modulus by
reducing warp
crimp (Table 8). A new weave pattern was created in Examples 43 and 44 using a
2/2 twill
based, but with alternating 2 tape yarns in the same shed, with one
monofilament yarn in the
next (adjacent) shed. This was done in an effort to decrease the warp crimp
and fabric
interlacings to increase MD modulus. Example 45 once again used the double
layer weave
pattern (with the 1362 Denier warp yarn).
Table 8
Property Ex. 38 Ex. 39 Ex. 40 Ex. 41 Ex. 42
Ex. 43 Ex. 44 Ex. 45
(Trial 7) (Trial 8) (Trial 9) (Trial 9A) (Trial 10) (Trial 11)
(Trial 12) (Trial 13)
Construction . 45x9 45x11 45x10 45x11 45x12 45x10
45x12 45x14
Weave Pattern 2/2 Twill 2/2 Twill ¨ 2/2 Twill 2/2 Twill ¨
2/2 Twill ¨ 2/2 Twill ¨ 2/2 Twill ¨ Double
¨ alt tape alt tape & ¨ alt tape alt tape & alt tape &
alt 2 tape in alt 2 tape in Layer
& mono mono & mono mono
mono 1 shed & 1 1 shed & 1
mono shed mono shed
Warp Yarn 1362 1362 1362 1362 1362 1362 1362
1362
Fill Yarn (tape) 5602 5602 4602 4602 4602 4602
4602 5602
Fill Yarn 425 425 425 425 425 565 565
565
(mono)
WW Tens@2% 151x141 111x154 144x115 105x156 110x138
231x156 196x192 107x139
WW Tens @5% 387x262 302x328 366x248 296x329 288x296
508x318 457x369 309x320
AOS Fail 40 / Fail 40 Fail 40 Fail 40 Pass 40
Fail 30 Fail 40/ Fail 40
Pass30 Pass 30
Waterflow 108 109 120 113 97 109 102
102
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[0067] Examples 38-42 were only marginally successful in improving the MD
modulus by reducing warp crimp, as Examples 39, 41, and 42 were less than 125
lb/in at 2%
MD, and Examples 38 and 40 were acceptable. For Examples 43 and 44, the 2% MD
values
were very good (231 and 196 lb/in, respectively), however, the AOS failed at
30 for Example
43 and failed at 40 for Example 44. While Example 45 used the double layer
weave pattern
described in U.S. Patent No. 8,589,054 to King et al., it again failed to
reach the target tensile
strength at 2% MD and 40 AOS. However, it did successfully provide 30 AOS and
tensile
strength in the warp and weft directions as measured at 2% strain of at least
100 lb/in.
[0068] The following examples were targeted at 30 AOS, a waterflow of 75
gpm/ft2,
and tensile strength values of 125x125 at 2% strain and 250x250 at 5% strain.
Smaller AOS,
such as 40 AOS, can be achieved by employing a small denier tape or
monofilament in the
range of about 350 denier to about 2,000 denier in the first shed and/or two
monofilaments
respectively being in the range of about 1,600 denier to about 6,500 denier in
the second
shed.
Examples 46-53
[0069] Examples 46-53 were a 2/2 twill weave alternating two fill yarns in the
same
first shed, with one monofilament fill yarn in the second (adjacent) shed
(Table 9). Examples
46, 47, 48, and 49 used a 4000 denier (continuous filament) polyester yarn
substituted for the
fibrillated PP tapes previously used. Examples 50-53 used a 3602 denier tape
polypropylene
yarn in fill direction with either a 565 or 425 denier monofilament.
23
Date Recue/Date Received 2023-03-15
CA 03195559 2023-03-15
Table 9
Property Ex. 46 Ex. 47 Ex. 48 Ex. 49 Ex. 50 Ex. 51
Ex. 52 Ex. 53
Trial 11A Trial 12A Trial 13A Trial 14 Trial 15
Trial 16 Trial 17 Trial 18
Construction 45x11 45x13 45x11 45x13 45x12 45x14
45x12 45x14
Weave Pattern 2/2 Twill 2/2 Twill 2/2 Twill ¨ 2/2 Twill
2/2 Twill 2/2 Twill 2/2 Twill 2/2 Twill
¨ alt cont. ¨ alt cont. alt cont. fil ¨ alt cont. ¨
alt tape ¨ alt tape ¨ alt tape ¨ alt tape
fil & fil & & mono fil & & mono & mono & mono
& mono
mono mono mono
Warp Yarn 1362 1362 1362 1362 1362 1362 1362
1362
Fill Yarn (tape) 4000 4000 4000 4000 3602 3602 3602
3602
Fill Yarn 565 565 425 425 565 565 425
425
(mono)
WW Tens@2% 129x75 97x89 116x74 94x85 100x94 74x109
99x89 77x100
WW Tens @5% 340x198 255x241 322x196 256x229
280x206 202x238 277x198 225x222
AOS Fail 40 Fail 40 Fail 40 Fail 40 Pass 40
Pass 40 Pass 40 Pass 40
Waterflow 165 160 155 148 108 95 103
82
[0070] For Examples 46-53, using the 4000 denier (continuous filament)
polyester
yam, it was thought the higher yarn modulus of the polyester yarn would carry
over into the
fabric CD, allowing for the use of lower pick density, and therefore lower
warp crimp and
higher MD modulus. However, as shown in Table 9, none of these trials passed
the 2% CD
specification. Also, the pick density and interlacings were too high,
resulting in low 2% MD
values. Examples 50-53 all passed for 40 AOS, however, all were low on the 2%
MD values,
due to the high warp crimp resulting from the single picks in each shed and
relatively high
pick densities of 12-14 ppi.
Examples 54-59
[0071] A variety of concepts were tested in Examples 54-59 as set forth in
Table 10
below.
24
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CA 03195559 2023-03-15
Table 10
Property Ex. 54 Ex. 55 Ex. 56 Ex. 57 Ex.
58 -- Ex. 59
(Trial 19) (Trial 20) (Trial 20A) _ (Trial 21)
(Trial 22) (Trial 23)
Construction 45x9 45x14 45x12 45x13 45x12.5 45x12
Weave Pattern 2/2 Twill ¨ .. 2/2 Twill ¨ alt 2/2 Twill ¨alt 2/2 Twill ¨alt
2/2 Twill ¨ alt 2/2 Twill ¨ alt
alt tape & 2 tape in 1 2 tape in 1 2
tape in 1 2 tape in 1 3 tape in 1
mono shed & 1 shed & 1 shed & 1 shed
& 1 shed & 1
mono shed mono shed mono shed
mono shed mono shed
Warp Yarn 1362 1362 1362 1362 1362 1362
Fill Yarn (tape) 5602 4602 4602 4602 4602 4602
Fill Yarn (mono) 525* 565 565 565 565 565
WW Tens@2% 165x127 123x201 139x177 142x193
136x205 171x211
WW Tens (0% 418x265 336x433 377x378 365x410
365x431 433x437
AOS Pass 30 Pass 30 Pass 30 Pass 30 Pass
30 Fail 30
Fail40 Fail 40 Fail 40 Fail 40 Fail 40
Waterflow 97 89 96 91 97 100
[0072] Example 54 used an oval shaped 525 denier monofilament in fill (rather
than
round shapes used in all other trials). No improvement in properties was
noticed for
Example 54.
[0073] Examples 55 and 56 were very similar to previous Example 44 and results
were also very similar, providing a preliminary small scale validation of the
construction.
Example 57 was then run at 13 picks per inch to optimize the construction. A
100 LYD roll
of Example 57 was run, and the Tensile Strength values of 2% MD averaged above
125 lb/in.
(See Table 10 above)
[0074] Then Examples 58 and 59 were run. The data for Example 58 looked good.
Example 59 used yet another different weave pattern in which 3 picks of tape
yarn were put
into a single shed, rather than 2 picks in a shed. This resulted in greatly
improved 2% MD
values due to the reduction in interlacings, however, the pores in the fabric
were much larger,
and as a result, the fabric failed 30 AOS.
[0075] Table 11 below shows detailed results of the 100 yard (yd) roll of
Example 57,
with the original prototype sample included for comparison.
Date Recue/Date Received 2023-03-15
CA 03195559 2023-03-15
Table 11
Property Ex. 57 100 yd roll; 100 yd roll; 100 yd roll; 100
yd roll; 100 yd roll; 100 yd roll; AVG
(Trial 21) sample #1 sample #2 sample #3 .. sample #4
.. sample #5 .. sample #6
prototype
WW 142x193 124x192 125x193 121x200 123x198 134x200 135x198 129x196
Tens@2%
WW Tens 365x410 336x407 338x410 336x416 338x415
361x421 358x414 347x413
@5%
AOS Pass 30 Pass 30 Pass 30 Pass 30 Pass 30
Pass 30 Pass 30 Pass 30
Waterflow 91 97 98 97 112 94 105 99
[0076] Table 12 below shows detailed results of the 100 yard (yd) roll of
Example 58,
with the original prototype sample included for comparison.
26
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CA 03195559 2023-03-15
Table 12
Ex. 58
ASTM Test NEW 1st sample Sample Sample Sample Sample
Method SPECS (prototype #1 Sample #2 #3
#4 #5 AVG
)
Grab, MD D4632 905 943 985 1026 995 989
974
Grab, CD D4632 , 505 533 , 507 483 _ 508
517 , 509
Grab Elong MD D4632 15.0 16.8 16.5 17.8 17.2
17.6 16.8
Grab Elong CD D4632 8.0 8.1 7.5 7.8 7.9 8.3
7.9
WW lilt (1b/in)
MD _ D4595 400 813 776 _ 806 799 _ 775
796 , 794
WW Ult (1b/in) CD D4595 400 470 474 429 425 441 475
452
WW Elong MD D4595 11.6 10.4 11.3 10.7 10.3
11.3 10.9
WW Elong CD D4595 5.8 6.2 , 5.8 5.4 5.6 6.4
5.9
WW 2% MD D4595 125 136 142 141 155 _ 149
149 145
WW 2% CD D4595 125 205 196 188 202 214 193
200
WW 5% MD _ D4595 , 250 365 382 , 378 395 392
381 382
WW 5% CD D4595 250 431 422 _ 396 372 374 409
401
WW 10% MD D4595 736 759 749 770 740 742
749
WW 10% CD , D4595 , --- --- --- --- --- ---
---
WW Seam _ D4595 --- --- --- --- --- ---
---
CBR (lb) --- 2765 2531 2805 2839
2714 2731
Trap Tear, MD D6241 , 363 373 391 365 , 411
386 , 382
Trap Tear, CD D4533 233 299 _ 230 235 257 246
250
P30(1.8% P30(1.6 P30(2.8 P30(2.0
P30(0.0
)
%) P30(0.4%) %) %) %)
AOS D4533 30
P30
F40(93%) F40(95% F40(46%) F40(92% F40(93 F40(64
) . ) . %)
%)
Opening Size D4751 0.600 --- 0.594 0.581 0.595 0.594
0.586 0.590
Permitivitty D4751 1.317 1.664 1.230 1.587 1.472
1.392 1.444
Permeability 0.226 0.266 , 0.204 0.258 0.227 0.223
0.234
,
Flow Rate D4491 75 97 123 91 117 108 103
107
Weight D4491 13.9 13.7 13.7 13.4 13.8
13.7 13.7
Thickness D4491 68 63 _ 65 63 61 63
64 .
27
Date Regue/Date Received 2023-03-15
CA 03195559 2023-03-15
[0077] In order to show the benefits of mixing monofilament and tape fill
yarns, the
following Examples were run (Table 13). Trials PA14 & PA 15 were made with 12
picks/inch, while PA18 and PA19 were made with 13 picks/inch.
[0078] Trials PA14 and PA18 used only 565 denier round monofilament in fill
direction, while Trials PAIS and PA19 used ONLY 4602 denier fibrillated tape
in fill
direction. The weave patterns on all PA14, PA15, PA18 and PA19 were same as
Examples
57 and 58 detailed above
Table 13
Property Trial PA14 Trial PAIS Trial PA18 Trial PA19
Construction 45x12 45x12 45x13 45x13
Weave Pattern 2/2
Twill ¨ alt 2/2 Twill ¨ alt 2/2 Twill ¨ alt 2/2 Twill ¨ alt
2 mono in 1 2 tape in 1 2 mono in 1 3 tape in 1
shed & 1 shed & 1 tape shed & 1 shed &
1 tape
mono shed shed mono shed shed
Warp Yarn 1362 1362 1362 1362
Fill Yarn (tape) NONE 4602 NONE 4602
Fill Yarn (mono) 565 NONE 565 NONE
WW Tensg2% 167x13 130x271 164x15 105x285
WW Tens @5% 404x32 355x568 410x35 310x598
AOS Fail 30 Pass 30 Pass 30 Pass 30
Waterflow 210 46 211 45
[0079] As shown in Table 13, when using only 565 denier monofilament in fill,
2%
and 5% MD values are very low (i.e. <50 lb/in), waterflow is very high (<200
gpm/ft2), and
AOS is passed at 30 AOS. When using only the 4602 denier fibrillated tape in
fill, all tensile
values are very high, AOS values pass for 30 AOS, and waterflow is low (<50
gpm/ft2).
[0080] A comparison of Example 57 with Trials PA18 and PA19 is provided in
Table
14 below.
28
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CA 03195559 2023-03-15
Table 14
Test Trial 21 Trial PA18 Trial PA19
Method
Warp Yarn Denier 1360 1360 1360
Warp Yarn Ends/Inch 45 45 45
Fill Yarn Denier Monofilament 565 565 None
Fill Yarn Picks/Inch Monofilament 4.3 13 None
Fill Yarn Denier Fibrillated Tape --- 4600 None 4600
Fill Yarn Picks/Inch Fibrillated --- 8.7 None 13
Tape
Total Fill Picks/Inch 13 13 13
Weave Pattern 2/2 Twill- 2/2 Twill- 2/2 Twill-
alternating 1 alternating 1 alternating
pk/shed & 2 pk/shed & 2 1 pk/shed
pks/shed pks/shed & 2
pks/shed
Wide Width Tensile @ 2% Strain, ASTM 142 x 193 164 x 15 105 x 285
lb/in (MDxCD) D4595
Wide Width Tensile @ 5% Strain, ASTM 365 x 410 410 x 35 310 x 598
lb/in (MDxCD) D4595
Waterflow, gpm/ft2 ASTM 91 211 45
D4491
AOS, U.S. Sieve ASTM 30 30 30
D4751
[0081] As show in Table 14, when two different fill yarns are used in a single
material, in the prescribed fashion, all of the desired properties can be
obtained in one single
material (Ref Example 57), e.g., comparable tensile strength of 125 x 125
lb/in @2% strain,
250 x 250 lb/in @5% stain, 30 AOS, and 75 gpm/ft2 flow rate.
[0082] Alternatively, if a single fill yarn is used, the desired properties
cannot be
obtained in a single material (refer to Trial PA19). Trial PA18 was produced
with the same
weave pattern and pick density as Example 57, only using the 565 denier
monofilament in
the fill direction. No tape yarn was used in the fill direction. Trial PA18
did achieve the high
flow (211 gpm/ft2) and 30 AOS, but the CD tensile strength values were very
low (15 lb/in
@2% strain, and 35 lb/in @5% strain).
[0083] Trial PA19 was produced with same weave pattern and pick density as
Example 57 but used a 4600 denier fibrillated tape yarn in the fill direction
(i.e., no
monofilament yarn was used in the fill direction). Trial PA19 did achieve the
desired tensile
29
Date Recue/Date Received 2023-03-15
CA 03195559 2023-03-15
strength values in the CD and 30 AOS, however, the waterflow of 46 gpm/ft2 was
below the
desired level of 75 gpm/ft2.
[0084] As shown in Table 15, the differences in heights between the first and
second
sheds in 2/2 twill weave fabrics were measured. The Peak (P) height of the
first shed and the
Valley (V) height of the second shed were measured, and the % difference was
calculated
((P-V/P). In each fabric, the first shed (fill yarn 1) included a tape, and
the second shed (fill
yam 2) included a round monofilament. The % difference in heights
(thicknesses) of the
sheds ranged from 21% to 52%.
Table 15
Construction Weave Warp Fill Fill Peak Valley %
pattern Yarn Yarn 1 Yarn 2 (P) (V)
Difference
(mils) (mils) (P-V)/P
45 x 13.2 2/2 Twill 1011 den 4600 den 925 den 51 36 29%
oval monofil tape round mono
45 x 12.2 2/2 Twill 1011 den 4600 den 925 den 52 32 38%
oval monofil tape round mono
45 x 11.2 2/2 Twill 1011 den 4600 den 925 den 50 31 38%
oval monofil tape round mono
45 x 9 2/2 Twill 1011 den 5600 den 925 den 49 32 35%
oval monofil tape round mono
45 x 10 2/2 Twill 1011 den 5600 den 925 den 51 38 25%
oval monofil tape round mono
45 x 9 2/2 Twill 1011 den 5600 den 695 den 49 34 31%
oval monofil tape round mono
45 x 10 2/2 Twill 1011 den 5600 den 695 den 48 33 31%
oval monofil tape round mono
45 x 9 2/2 Twill 1362 den 5600 den 565 den 54 36 33%
oval monofil tape round mono
45 x 10 2/2 Twill 1362 den 5600 den 565 den 56 36 36%
oval monofil tape round mono
45 x 11 2/2 Twill 1362 den 5600 den 565 den 53 39 26%
oval monofil tape round mono
45 x 9 2/2 Twill 1362 den 5600 den 695 den 54 38 30%
oval monofil tape round mono
45 x 10 2/2 Twill 1362 den 5600 den 695 den 55 37 33%
oval monofil tape round mono
Date Regue/Date Received 2023-03-15
CA 03195559 2023-03-15
45 x 11 2/2 Twill 1362 den 5600 den 695 den 58 38 34%
oval monofil tape round mono
45 x 9 2/2 Twill 1362 den 5600 den 425 den 57 34 40%
oval monofil tape round mono
45 x 11 2/2 Twill 1362 den 5600 den 425 den 53 35 34%
oval monofil tape round mono
45 x 10 2/2 Twill 1362 den 4600 den 425 den 54 33 39%
oval monofil tape round mono
45 x 11 2/2 Twill 1362 den 4600 den 425 den 54 34 37%
oval monofil tape round mono
45 x 12 2/2 Twill 1362 den 4600 den 425 den 59 37 37%
oval monofil tape round mono
45 x 13 2/2 Twill 1362 den 4000 den 425 den 48 38 21%
oval monofil multifil round mono
45 x 12 2/2 Twill 1362 den 3600 den 565 den 48 37 23%
oval monofil tape round mono
45 x 14 2/2 Twill 1362 den 3600 den 565 den 51 36 29%
oval monofil tape round mono
45 x 12 2/2 Twill 1362 den 3600 den 425 den 50 34 32%
oval monofil tape round mono
45 x 14 2/2 Twill 1362 den 3600 den 425 den 49 33 33%
oval monofil tape round mono
45 x 14 2/2 1362 den 4600 den 565 den 75 49 35%
Twill- oval monofil tape round mono
1&2/shed
45 x 12 2/2 1362 den 4600 den 565 den 66 44 33%
Twill- oval monofil tape round mono
1&2/shed
45 x 13 2/2 1362 den 4600 den 565 den 64 45 30%
Twill- oval monofil tape round mono
1&2/shed
45 x 12.5 2/2 1362 den 4600 den 565 den 61 36 41%
Twill- oval monofil tape round mono
1&2/shed
45 x 12 2/2 1362 den 4600 den 565 den 82 39 52%
Twill- oval monofil tape round mono
1&3/shed
57x 11.5 2/2 1011 den 4600 den 565 den 58 46 21%
Twill- oval monofil tape round mono
1&2/shed
31
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CA 03195559 2023-03-15
[0085] The compositions, methods, and articles can alternatively comprise,
consist of,
or consist essentially of, any appropriate components or steps herein
disclosed. The
compositions, methods, and articles can additionally, or alternatively, be
formulated so as to
be devoid, or substantially free, of any steps, components, materials,
ingredients, adjuvants,
or species that are otherwise not necessary to the achievement of the function
or objectives of
the compositions, methods, and articles.
[0086] All ranges disclosed herein are inclusive of the endpoints, and the
endpoints
are independently combinable with each other. "Combinations" is inclusive of
blends,
mixtures, alloys, reaction products, and the like. The terms "first,"
"second," and the like, do
not denote any order, quantity, or importance, but rather are used to
distinguish one element
from another. The terms "a" and "an" and "the" do not denote a limitation of
quantity, and
are to be construed to cover both the singular and the plural, unless
otherwise indicated
herein or clearly contradicted by context. "Or" means "and/or" unless clearly
stated
otherwise.
[0087] Reference throughout the specification to "one aspect", "another
aspect", and
so forth, means that a particular element (e.g., feature, structure, and/or
characteristic)
described in connection with the aspect is included in at least one aspect
described herein,
and may or may not be present in other aspects. In addition, it is to be
understood that the
described elements may be combined in any suitable manner in the various
aspects.
[0088] In general, the compositions or methods may alternatively comprise,
consist
of, or consist essentially of, any appropriate components or steps herein
disclosed. The
invention may additionally, or alternatively, be formulated so as to be
devoid, or substantially
free, of any components, materials, ingredients, adjuvants, or species, or
steps used in the
prior art compositions or that are otherwise not necessary to the achievement
of the function
and/or objectives of the present invention.
[0089] The terms "first," "second," and the like, "primary," "secondary," and
the like,
as used herein do not denote any order, quantity, or importance, but rather
are used to
distinguish one element from another. The terms "front," "back," "bottom,"
and/or "top" are
used herein, unless otherwise noted, merely for convenience of description,
and are not
limited to any one position or spatial orientation.
32
Date Recue/Date Received 2023-03-15
CA 03195559 2023-03-15
[0090] The modifier "about" used in connection with a quantity is inclusive of
the
stated value and has the meaning dictated by the context (e.g., includes the
degree of error
associated with measurement of the particular quantity).
[0091] Unless defined otherwise, technical and scientific terms used herein
have the
same meaning as is commonly understood by one of skill in the art to which
this application
belongs. If a term in the present application contradicts or conflicts with a
term in related
patents or patent applications mentioned in the present application, the term
from the present
application takes precedence.
[0092] While particular embodiments have been described, alternatives,
modifications, variations, improvements, and substantial equivalents that are
or may be
presently unforeseen may arise to applicants or others skilled in the art.
Accordingly, this
present application as filed and as it may be amended is intended to embrace
all such
alternatives, modifications variations, improvements, and substantial
equivalents.
33
Date Recue/Date Received 2023-03-15
