METHOD OF MANUFACTURING A COMPOSITE NONWOVEN FABRIC SUITABLE FOR GEOTEXTILE USE

Abstract

A composite fabric, suitable for geotextile use, is manufactured by obtaining a web of metal material consisting of a plurality individual strands of metal that are substantially parallel to each other, are substantially unidirectionally oriented, and have not undergone any carding, garneting, lapping, or needle punching processing, and wherein the individual strands of metal have not been cut to any particular length, and obtaining a scrim layer having a porous, open woven configuration. The web of metal material is attached to the scrim layer to form the composite fabric material. The attachment may be by needle punching the web of metal material to the scrim layer.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of pending U.S. application Ser. No. 13/051,318 filed Mar. 18, 2011, which claims the benefit of priority to U.S. Provisional Application 61/351,226, filed Jun. 3, 2010. These related applications are both incorporated herein by reference in their entireties.

FIELD OF THE INVENTION

The field of the invention is geotextiles; more particularly, the present invention relates to certain novel geotextiles and the use thereof in pest control.

BACKGROUND OF THE INVENTION

Geotextiles are permeable fabrics used in association with soil. They have the ability to separate, filter, reinforce, protect, or drain the soil. Geotextile fabrics known in the prior art are typically made from polypropylene, polyester, nylon, or any other like type material and come in three basic forms: woven, felt, or heat bonded fabrics.

Geotextiles are expensive as compared to sheet plastic (black plastic) mulch, photo-degrade (break down in the presence of UV light), usually need mulch cover to slow photo-degradation and improve appearance of fabric-covered areas, and only last approximately 5 years.

There is a need in the art to provide a thicker and heavier geotextile that prevents rodents and pests from burrowing and digging through the geotextile while still allowing grass and small plants to grow through and water to drain to the earth below. Chicken wire and hardware cloth have been used in small areas for this purpose, but they are harder to cut, fasten down, shape around landscaping and will rust away. The embodiments described herein solve these problems as well as provide additional benefits, as set forth herein below.

SUMMARY OF THE INVENTION

The foregoing and other features and advantages of the present invention are defined by the appended claims as construed using this disclosure and including all reasonable equivalents thereof. The following detailed description of exemplary embodiments, read in conjunction with the accompanying drawings, is merely illustrative of possible embodiments rather than limiting the scope defined by the appended claims and equivalents thereof.

The geotextile exclusion fabric and method comprises an interengaged mixture of metal fibers, wherein the metal fibers include barbed projections and a rough outer surface with irregular shape. The interengaged mixture is needle punched to a scrim layer to form a geotextile fabric exclusion material. The method of using said geotextile exclusion fabric includes the excavation of an area of soil, placement and securing of the geotextile exclusion fabric, and covering the geotextile exclusion fabric.

BRIEF DESCRIPTION OF THE FIGURES

The foregoing description of the figures is provided for a more complete understanding of the drawings. It should be understood, however, that the embodiments are not limited to the precise arrangements and configurations shown.

FIG. 1A is a cross section of one embodiment of the geotextile exclusion fabric.

FIG. 1B is a cross section of one embodiment of the geotextile exclusion fabric.

FIG. 2 is enlarged perspective view of the metal fibers.

FIG. 3A is a schematic view of the first step of needle punching machine; and FIG. 3B is schematic view of the second step of the needle punching machine.

FIG. 4 is a schematic view of the needles used in the needle punching machine.

FIG. 5A is a perspective view of installing the geotextile exclusion fabric; and FIG. 5B is a perspective view of geotextile exclusion fabric after installation.

FIG. 6 is a close up view of one embodiment of the geotextile exclusion fabric during installation.

FIG. 7 is a side view of one embodiment of the geotextile exclusion fabric, showing the stainless top first layer, scrim layer, and bottom second layer when rolled up.

FIG. 8 is a perspective view of one embodiment of the geotextile exclusion fabric when unrolling.

FIG. 9 is a perspective view of one embodiment of the geotextile exclusion fabric.

FIG. 10A is a front view of one embodiment of two sheets of geotextile exclusion fabric attached together.

FIG. 10B is a close up view of one embodiment of two sheets of geotextile exclusion fabric attached together.

FIG. 11A is a perspective view of an area of land excavated in preparation for installation of an embodiment of geotextile exclusion fabric.

FIG. 11B is a perspective view of one embodiment of an installation of geotextile exclusion fabric.

FIG. 11C is a perspective view of one embodiment of a structure section of geotextile exclusion fabric.

FIG. 11D is a perspective view of one embodiment of a structure section of geotextile exclusion fabric.

FIG. 11E is a perspective view of an edging.

FIG. 11F is an embodiment of a structure section of geotextile exclusion fabric secured against a structure by an edging.

FIG. 12A is a perspective view of one embodiment of geotextile exclusion fabric configured to be placed around a non-excavatable protrusion.

FIG. 12B is a perspective view of one embodiment of geotextile exclusion fabric configured to be placed around a non-excavatable exclusion, the fabric including a securing member.

DETAILED DESCRIPTION OF THE INVENTION

The methods, apparatuses, and systems can be understood more readily by reference to the following detailed description of the methods, apparatuses, and systems, and the following description of the Figures.

Generally speaking, on one embodiment, as shown in FIG. 1A, a geotextile exclusion fabric 10 generally comprises a layer 12 of an interengaged mixture of a plurality of metal fibers 20 and a scrim layer 14, wherein the layer 12 of metal fibers is needle punched to the scrim layer to form a geotextile exclusion fabric 10.

In another embodiment, the geotextile exclusion fabric 10 comprises an interengaged mixture of a plurality of metal fibers 20, as shown in FIG. 1B. The geotextile exclusion fabric 10 generally comprises a layer 13 of metal fibers, a scrim layer 15 including a first side, for instance, a top side, and a second side, for instance, a bottom side; and a second layer 16 of metal fibers, wherein the first layer 13 of metal fibers is needle punched to the scrim layer on the first, or top, side and the second layer 16 of metal fibers is needle punched to the scrim layer on the second, or bottom, side to form a geotextile exclusion fabric 10.

The metal fibers 20 are interengaged and intertwined to provide for a density and resiliency for excluding pests in any environment. The geotextile exclusion fabric 10 serves as a barrier to protect landscaping and buried assets from damage due to burrowing animals. The geotextile exclusion fabric 10 is designed to be installed similar to carpeting or landscaping material and then covered with soil. Because it installs similar to carpeting, the geotextile exclusion fabric 10 is easy to fit around and attach to surfaces such as structures, trees and other common landscape objects. That the geotextile exclusion fabric 10 includes a form-ability and ease in attaching to objects is important as burrowing animals commonly burrow close to structures and within tree and shrub roots. The geotextile exclusion fabric 10 is permeable, thus water easily penetrates and plant roots grow right through. The geotextile exclusion fabric 10 is optionally made from stainless steel wool so it lasts indefinitely and does not rust or erode.

In another embodiment, the geotextile exclusion fabric 10 comprises at least one layer of a nonwoven metal fabric as disclosed in commonly assigned U.S. Pat. No. 6,583,074, which is hereby incorporated by reference. When nonwoven metal fabric is included, the geotextile exclusion fabric 10 can comprise of a single layer of nonwoven metal fabric with or without a scrim layer attached thereto. Furthermore, when nonwoven metal fabric is included, the geotextile exclusion fabric 10 can comprise a first layer of nonwoven metal fabric attached to a first surface of a scrim layer and a second layer of nonwoven metal fabric attached to a second surface of the scrim layer. Alternatively, multiple layers of nonwoven metal fabric may be attached to a layer of nonwoven metal fabric attached to the first surface, second surface, and/or both. Finally, another embodiment of the geotextile exclusion fabric 10 can include a layer of nonwoven metal fabric, a scrim layer, and a layer of an interengaged mixture of a plurality of metal fibers. The nonwoven metal fabric can be attached to a first side of the scrim layer, and the layer of metal fibers can be attached to a second layer of the scrim layer. The nonwoven metal fabric can be attached to the scrim layer by needle punching, air jet entanglement or any other non-woven fastening methods, or by adhesives, staples, nails, screws, hooks, and the like.

Metal Fiber

In one embodiment, the plurality of metal fibers 20 is shown in FIG. 2. The metal fibers 20 include a random irregular cross-section and rough outer surfaces with barb projections 200 formed on the outer surfaces. The irregular cross-sections vary continuously along the length of the resulting fibers to provide generally curled metal fibers. The curled and barbed nature of the metal fibers allows strong interengagement and intertwining with each other and the scrim layer. In one embodiment, the metal fibers 20 are produced by shaving a metal member with a succession of serrated blades, as disclosed in commonly assigned U.S. Pat. Nos. 6,249,941 and 5,972,814, which are hereby incorporated by reference. The succession of serrated blades has a variety of different serration patterns, so that the resulting individual fibers have barbed projections 200 and irregular cross sections with rough outer surfaces.

Preferably, the metal fibers are shaved from a metal wire. In one embodiment, the metal fibers 20 are produced by shaving a metal member with a succession of serrated blades, as disclosed in commonly assigned U.S. Pat. Nos. 6,249,941 and 5,972,814, which is hereby incorporated by reference. The succession of serrated blades has a variety of different serration patterns, so that the resulting individual fibers have barbed projections 200 and irregular cross sections with rough outer surfaces. A suitable lubricant, such as oil, is preferably applied to the metal member as it is being shaved by the blades in sufficient quantity so that the metal fibers retain on their outer surface a carding-effective amount of the oil or lubricant. “Carding-effective amount” of oil or lubricant means that the metal fibers, when blended with the nonmetal fibers, can be carded without substantial breakage or disintegration. The lubricant optionally may be applied after the metal fibers are formed. The commonly assigned U.S. Pat. No. 5,972,814 discloses the process for shaving a metal bar to produce lubricated metal fibers and the use of such lubricated metal fibers. A carding-effective amount of oil generally may be in the range of about 0.3 wt. % to about 1.0 wt. % oil, more preferably about 0.4 wt. % to about 0.7 wt. %, based on the total weight of the metal fibers, although lesser or greater amounts may be used depending on the type and average cross-sectional length and width of the metal fibers. For example, as the weight percentage of metal fibers is decreased, the quantity of oil or lubricant necessary to provide a carding effective amount may tend to increase. Conversely, as the weight percentage of metal fibers increases, this reduces the quantity of oil needed for carding without breakage of the metal fibers. Thus, a carding-effective amount of oil for carding various combinations and amounts of metal fibers can be determined on a case-by-case basis. Preferably, the metal fibers are made from stainless steel, as to prevent rusting and corrosion of the geotextile exclusion fabric. However, the metal fibers 20 can also be made from bronze, carbon steel, copper, metal alloys, and other suitable metals that can be shaved into suitable metal fibers to suit a variety of pest deterring applications. The metal fibers can have an average cross sectional length, width, or height of between about 25 and about 125 microns.

Preferably the metal fibers are made from stainless steel, as to prevent rusting and corrosion of the geotextile exclusion fabric. However, the metal fibers 20 can also be made from bronze, carbon steel, copper, metal alloys, and other suitable metals that can be shaved into suitable metal fibers to suit a variety of pest deterring applications. The metal fibers can have an average cross sectional length, width, or height of between about 25 and about 125 microns.

Construction of Layers of Metal Fibers

Reels of metal fibers are made from individual strands of metal fibers, which are gathered together. When the metal fibers are shaved with the serrated knives, individual strands of metal fibers are produced. The individual strands of metal fibers from various serrated knives or blades are gathered together and processed through a set of rolls to flatten and form a web of fibers of a certain width and weight. The width of the web of metal fibers can vary from about 1 inch wide to about 12 inches wide depending on the weight of the web of metal fibers desired. The web of metal fibers is then rolled up into a reel that can be further processed. As the strands of metal fibers rolled onto the reel have not undergone any cutting, carding, garneting, needle punching, cutting to any particular length, or any other processing, the web of metal strands placed on the reel are all substantially unidirectional and parallel to each other, and are not substantially entangled. Accordingly, the reels comprise a collection of homogeneous, parallel, unidirectional, unprocessed strands of metal wool, such as, for example, steel wool or stainless steel wool. The standard weight of the web of metal fibers is determined by the weight per 2 foot length of the web of metal fibers. To keep a consistent metal wool reel, the weights of the reel webs stay consistent throughout the length and width of the metal wool reel. The metal wool reels are used to a wider roll of material when lined up side by side. The metal wool reels may have a basis weight between about 500 g/m² to about 2400 g/m².

The metal wool reels 68 are fed, without any prior cutting, carding, garneting, needle punching, cutting of the individual strands to short lengths, or any other processing into a needle punching apparatus 72, as shown in FIG. 3A, to needle-punch the metal wool reels 68 to the scrim layer roll 70 to form the first layer of metal fibers 12 on the top side of the scrim layer 14. The scrim layer roll 70 is provided on the bottom side of the multi-layered web structure 68 and coupled to a guide roll before being introduced to the needle-punch apparatus 72. The needle-punch apparatus 72 comprises a first bed plate 74 having a first needle board of barbed needles 76. The first needle board of barbed needles 76 reciprocates up and down and punches the multi-layered metal fibers 68 from the top side to interengage metal fibers on the down-stroke with the scrim layer 14. The needle-punch apparatus 72 further comprises a second needle board of barbed needles 77 that operates the same as the first needle board of barbed needles 76. After exiting the needle-punch apparatus, the first layer of metal fibers 12 is needle-punched to the scrim layer 14 and exits to a plurality of tension rolls and wrapping rolls to wind up first layer of metal fibers and scrim layer to be facing side up 18.

The scrim layer 14 may be an open woven scrim layer and hence highly porous, a spunbonded adhesive fiber scrim ply, a nylon scrim layer, or a polyester scrim layer, or a nonwoven material. The scrim can be made up of various materials, such as polyester, polypropylene, Nylon, PVC, or any number of other suitable materials that allows for needle punching the metal wool reels on the top and bottom sides. The scrim provides added strength to the geotextile in both the x-direction and the y-direction. Then, with the needle punching of the metal fibers through the top and bottom sides of the scrim layer, the geotextile exclusion fabric will have strength in the z-direction. The basis weight of the scrim layer may vary from about 90 g/m² to about 500 g/m², depending on the type of scrim layer used. The scrim layer in one embodiment may include a basis weight of about 90 g/m². Mechanical bonding of the scrim layer can be hydro-entanglement, air-jet entanglement, needle punching, needle stitching, or by any other mechanical bonding method known in the art that may increase the strength of the scrim layer for z-directional strength during needle punching the top and bottom sides of the scrim layer with metal fibers. In one example, the polyester scrim ply can have a basis weight of about 120 g/m².

Optionally, as shown in FIG. 3B, a second needle-punching apparatus 78 having a second set of a first needle board of barbed needles 80, a second needle board of barbed needles 81, and a second bed plate 82 can be employed. The second layer of metal fibers 16 is provided as stainless wool reels 68 to be unrolled on top of the facing side up 18 first layer metal fibers and the scrim layer is provided facing up. The barbed needles 80 reciprocate up and down and punch the stainless wool reel 68 from the top side to interengage metal fibers with the scrim layer and the bottom layer on the metal fibers 16 on the downstroke. The resulting needle punched geotextile exclusion fabric 10 is formed upon exiting the second needle-punching apparatus 78. The geotextile exclusion fabric 10 exits to a plurality of tension rolls and wrapping rolls to wind up the finished geotextile exclusion fabric 10.

The geotextile exclusion fabric may be needle-punched to a low penetration of a needle per square inch (“PPSI”) so that the puncture density will maintain the resiliency of the geotextile exclusion fabric and compress the metal fibers to a sufficient degree. PPSI is a function of strokes per minute (R), needles per 1 inch width (D) and inches per minute of material traveled (S), where PPSI=(R×D)/S. In one embodiment, the geotextile exclusion fabric is needle punched to a penetration of about 400 PPSI, with a range of about 300 to about 800 needles per square inch. A high penetration of a needle per square inch and a high puncture density decreases the resiliency of the geotextile exclusion fabric, as it would compress the metal fibers to a greater degree with the scrim layer. While pests are prevented from dissembling the geotextile exclusion fabric due the interengagement of the fibers, radial resiliency of the geotextile exclusion fabric maintains an obstruction level for pests. Pests can become entrapped in the interengaged mixture of fibers; alternatively pests are prevented from disassembling the geotextile exclusion fabric due to the interengagement of the fibers.

FIG. 3A shows one embodiment of the needle punched geotextile exclusion fabric 10. The needle punching of the stainless wool reels 68 interengages the metal fibers of respective layers and the scrim layer, giving the resulting geotextile exclusion fabric improved strength, fiber density, and resiliency. The needle punching interengage metal fibers of the top layer with the bottom layer and the bottom layer with the top layer, which provides for increased strength of the geotextile exclusion fabric. The needling process causes the metal fibers 20 and scrim layer 22 to be interengaged in and between the metal layers 12 and 16 (in the “z” direction relative to the layers, as shown in FIG. 3B). The metal fibers 20 of the geotextile exclusion fabric are interengaged in the x and z axes during the needling punching step. The resulting, needle-punched fabric with the scrim layer 14 in the y-direction gives strength to the material. With the fibers interengaged in the x, y, and z directions this forms an isotropically strong, coherent composite structure having desirable properties of resiliency and durability.

The needles of the needling punching apparatus 72 include a gauge, a barb, a point type and a blade shape (i.e., pinch blade, star blade, conical, and the like). The gauge of the needles is defined as the size of the needle blades. In one embodiment, the gauge of the needle may be from about 16 to about 40 gauge with a regular barb. The major components of the needle include the crank, the shank, the intermediate blade, the blade, the barbs, and the point. The crank is the 90 degree bend on the top of the needle and seats the needle when inserted into the punch boards 74 and 78. The shank is the thickest part of the needle. The shank is that part of the needle that fits directly in the needle punch board itself. The intermediate blade is put on fine gauge needles to increase flexibility, which is typically put on 32 gauge needles and finer. The blade is the working part of the needle and is what passes into the stainless wool reels 68 and is where the all barbs are placed. The barbs carry and interlock the metal and nonmetal fibers. The shape and sized of the barbs can dramatically affect the geotextile exclusion fabric 10. The point is the very tip of the needle. In one embodiment, the felting needles are 32 gauge regular barb needles with a pointed end including three sided needles with 3 barbs per blade.

As shown in FIG. 4, are two different types of needles used in the needle punching apparatus. A single reduction needle 90 is used for heavier punching, about 25 gauge and heavier. A double reduction needle 92 is used for the finer blade gauges about 25 gauge and finer. The single reduction needle includes a crank, a shank, and a blade portion. The double reduction needle includes a crank, a shank, an intermediate blade, and a blade. Both the single reduction needle and the double reduction needle include a kick-up, which is the projection of the barb above the edge of the needle. The amount of kick-up is desirable for the amount at which when combined with other barb dimensions will yield the needled product with the required qualities of appearance, strength, etc. As the amount of kick-up decreased, the fabric appearance and strength will both improve. The fiber type, fabric weight, and the model needle-loom may preclude using small kick-up levels. “K” barb kick-up types are most common on about 25 gauge and heavier needles. “N. K.” barb kick-up types are most common on about 25 gauge and finer needles. And “B” barb kick-up types are available on about 32 gauge and finer needles.

In one embodiment, the needle gauge is 32, which is flexible enough to slide past a thicker and heavier fiber and not break in the needle punching process. In one embodiment, the 32 gauge needle includes a barb on the right side as to not carry too many metal fibers that would change the density of the final end product, and while a coarser needle would shred the fiber and reduce the strength of the geotextile exclusion fabric.

As the punch boards 78 and 80 move up and down, the blades of the needles penetrate the stainless wool reels 68, as shown in FIGS. 3A and 3B. Barbs on the blade of the needles 76 pick up the metal fibers on the downward movement and carry these fibers through the depth of the penetration. The draw roll (pull-out roll) pulls the multi-layered structure 68 through the needle punching apparatus 72, as the needles reorient the metal fibers. Generally speaking, the more the needles 76 and 80 penetrate the multi-layered structure 68, the denser and more resilient the geotextile exclusion fabric 10 becomes; however, beyond some point, damage may result to the metal fibers from excessive needle penetration and decreased resiliency.

The needle punching apparatus 72 includes machine variables of the depth of penetration and puncture density. The travel of the metal fibers through the geotextile exclusion fabric depends on the depth of penetration of the needles 76 and 80. The maximum penetration is fixed by the needles 76 and 80 of the needle punching apparatus 72 and depends on the length of the three sided shank, the distance between the needle plates, and the stroke of the punch. The greater the depth of penetration, the greater the entanglement of fibers is within the multi-layered structure 68, because more barbs are employed per penetration. In one embodiment, the penetration depth may be between about ⅜ of an inch to about ¾ of an inch.

The punch density is determined by the number of punches on the surface of the feed in the web. The punch density is a complex factor and depends on the density of needles in the needle board (Nb), the rate of material feed (V), the frequency of punching (F or RPM), the effective width of the needle board (W), and the number of runs. The punch density per run Ed_pass=[n*F]/[V*W], where, n=number of needles within the punch boards, F or RPM=frequency of punching, V=rate of material feed, and W=effective width of the needle board. The puncture density in the needled fabric Ed_NV depends on the number of runs N_pass; Ed_NV=Ed_pass*N_pass. The frequency of punching is formulated in the PPSI formula, where the penetrations per square inch may be determined from P=RD/S, where P is the number of needles penetrations per square inch, R is the machine speed in strokes per minute, D is the number of needles per inch of machine width, and S is the web speed in inches per minute. In one embodiment, R is about 300 strokes per minute, D is 96 needles per inch of the machine width, and S is about 72 web speed inches per minute, thereby resulting in about P or PPSI of about 400. In another embodiment R is between about 200 to about 600, D is between about 54 to about 96, S is between about 48 to about 144, and PPSI is between about 75 to about 1200.

The thickness, basis weight, density and air permeability provide information about compactness of geotextile exclusion fabric and are influenced by a number of factors. If the basis weight of the geotextile exclusion fabric and punch density and depth are increased, the geotextile exclusion fabric density increases and air permeability is reduced. Preferably, the basis weight of the geotextile exclusion fabric, punch density, and penetration depth are maintained to result in a resilient material. In one embodiment, the needles per inch width are 96 needles and the resiliency of the geotextile exclusion fabric is about 90%. In one embodiment, the resiliency is between about 50% to about 95%, which depends on what material is placed on top of the geotextile exclusion, such as rocks, mulch, and the like.

As far as the strength of the geotextile exclusion fabric, the situation is similar to that for compactness, namely that finer needles, finer and longer fibers, greater geotextile exclusion fabric basis weight and greater punch depth and density, result in increased strength and resiliency of the geotextile exclusion fabric. However, once a certain critical puncture depth or density has been reached, the rise in strength and resiliency may be reversed. If the depth of the barb is decreased or the distance between the barbs is increased, the dimensional stability is decreased during needling, and the web density, resiliency, and maximum tensile strength in relation to basis weight will be lower. The resiliency of the geotextile exclusion fabric is determined from the penetrations per square inch (“PPSI”), the needle penetration depth, and the type of needles that are being used. The frequency of needle punching is part of the equation for figuring out the PPSI, as indicated above. Alternative punching apparatuses include different needle densities and different needle patterns, which affect the tightness or resiliency of the geotextile exclusion fabric.

The weight of the metal fibers can be as high as about 2500 g/m². By needle punching the geotextile exclusion fabric 10, the required density for the desired pest exclusion operation can be obtained. The required density can also be obtained by optionally using a geotextile fabric 10 with metal fibers on either both the top and bottom of the scrim or only on the top of the scrim. For the large pests, a higher weight product of between about 1400 g/m² and about 2500 g/m² may be used. Then for smaller pests, a lighter geotextile exclusion can be used in the range of about 500 g/m² to about 1400 g/m². A gradient weight variance allowed form the geotextile exclusion fabric to include high density areas where pests are most likely to be located and then areas of lower density, where pests are not likely to be located and where greater flow through of water and foliage may be desired.

In one embodiment, a method for making a geotextile exclusion fabric includes providing an interengaged mixture of metal fibers, wherein the metal fibers include a plurality of barbed projections and a rough barbed outer surface with irregular shaped cross-sections varied along the lengths of the metal fibers; and needle-punching the interengaged mixture of metal fibers to the scrim layer to form a layer of metal fibers. In one embodiment, the metal fibers are needlepunched to interengage adjacent metal fibers. Alternatively, the step of needle-punching the interengaged mixture of metal fibers is performed on a first side of the scrim layer, further comprising the step of needle-punching the interengaged mixture of metal fibers to the scrim layer to form a second layer of metal fibers is performed on a second side of the scrim layer.

In one embodiment, a method of pest exclusion comprises excavating an area of land; placing a geotextile exclusion fabric in the excavated area; driving a plurality of sod staples through the geotextile exclusion fabric; and covering the geotextile exclusion fabric with landscaping material. The area of excavated land is adjacent a structure, further comprises configuring a structure section of geotextile exclusion fabric to conform to the interface between the structure and the excavation area; placing the structure section of geotextile exclusion fabric such that it conforms to the interface between the structure and the excavation area; and securing the structure section of geotextile exclusion fabric against the structure. The step of attaching the structure section of geotextile exclusion fabric against the structure is accomplished using an attachment mechanism selected from the group consisting of stakes, screws, bolts, nails, adhesives, staples, hooks, tapes, and welds.

In an alternative embodiment, the step of configuring the structure section of geotextile exclusion fabric comprises providing a section of geotextile exclusion fabric having a first section and a second section; and configuring the first section and second section to form an interface angle therebetween. The interface angle may be greater than about 0.degree. and less than about 360.degree.. Alternatively, the interface angle is about 90.degree.. The step of securing the structure section of geotextile exclusion fabric comprises providing an edging, the edging comprising a body strip and at least one securing tab, the securing tab comprising at least one via; disposing the edging such that the body strip abuts the second section of the structure section and the at least one securing tab abuts the first section of the structure section; and disposing a fastener through the at least one via, penetrating through the geotextile exclusion fabric.

In one embodiment, the step of placing the geotextile exclusion fabric in an excavated area comprises placing a first sheet of geotextile exclusion fabric in the excavated area; and placing a second sheet of geotextile exclusion fabric in the excavated area, wherein the first sheet of geotextile exclusion fabric and the second sheet of geotextile exclusion fabric overlap each other. The first sheet of geotextile exclusion fabric and the second sheet of geotextile exclusion fabric overlap each other with a width of overlap between 0.01 inches to the whole length of one of the first sheet of geotextile exclusion fabric and the second sheet of geotextile exclusion fabric. The width of overlap between the first sheet of geotextile exclusion fabric and the second sheet of geotextile exclusion fabric is from about three inches to about six inches. The sod staples comprising the plurality of sod staples are separated from one another by at least about one inch. Alternatively, the sod staples are separated from one another by about two feet. The at least one of the sod staples comprising the plurality of sod staples is driven through the area of overlap between a first sheet of geotextile exclusion fabric and a second sheet of geotextile exclusion fabric. The excavation area is made to a depth of at least 0.01 inches. Alternatively, the excavation area is made to a depth of about three inches. The landscaping material is selected from the group consisting of mulch, soil, loam soil, sod, sand, gravel, rocks, or bricks.

In one embodiment, the excavation area includes a non-excavatable protrusion, further comprising providing a second geotextile exclusion fabric substantially as presented in claim 3; and disposing the second geotextile exclusion fabric about the non-excavatable protrusion. Alternatively, the excavation area includes a non-excavatable protrusion, further comprising providing a second geotextile exclusion fabric disposing the second geotextile exclusion fabric about the non-excavatable protrusion; and engaging the securing member to the second flap.

EXAMPLES

The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how the articles, devices, systems, and/or methods claimed herein are made and evaluated, and are intended to be purely exemplary and are not intended to limit the scope of articles, systems, and/or methods. Efforts have been made to ensure accuracy with respect to numbers (e.g., amounts, temperature, etc.), but some errors and deviations should be accounted for.

In one example and as shown in FIGS. 7 and 8, the basis weight for geotextile exclusion fabric is about 1400 g/m² to about 2500 g/m², preferably about 1800 g/m². In another example, the geotextile exclusion fabric includes a thickness between about ¼ to about ¾ inch, preferably about ½ inch. In another example, the geotextile exclusion fabric will compress to between about ⅛ to about ½ inch under the weight of dirt or stones, preferably about ¼ inch under the weight of dirt or stones. Alternative installments may be with mulch on top of the geotextile exclusion fabric, which will cause less compression of the geotextile exclusion fabric. In one example, the geotextile exclusion fabric is about 6 feet in width and about 100 feet in length. On larger punching equipment this geotextile fabric could be made up to 15 feet wide and to a wide variety of lengths.

Compression Test

A compression test determines behavior of materials under crushing loads. The specimen is compressed and deformation at various loads is recorded. Compression stress and strain are calculated and plotted as a stress-strain diagram which is used to determine elastic limit, proportional limit, yield point, yield strength and, for some materials, compressive strength.

The ASM Handbook®, Volume 8, Mechanical Testing and Evaluation states: Axial compression testing is a useful procedure for measuring the plastic flow behavior and ductile fracture limits of a material. Measuring the plastic flow behavior requires frictionless (homogenous compression) test conditions, while measuring ductile fracture limits takes advantage of the barrel formation and controlled stress and strain conditions at the equator of the barreled surface when compression is carried out with friction. Variations of the strains during a compression test. Axial compression testing is also useful for measurement of elastic and compressive fracture properties of brittle materials or low-ductility materials. In any case, the use of specimens having large L/D ratios should be avoided to prevent buckling and shearing modes of deformation.

If desired, the geotextile exclusion fabric may optionally include various additives, such as insect repellents and animal repellents, which may enhance the performance of the composite as a deterrent agent. Additionally, the geotextile exclusion fabric 10 may molded and adhered to various structures by any desirable fashion. For example, the geotextile exclusion fabric 10 may be formed to slopes, walls, mountains, river banks, and the like, as shown in FIG. 9.

The geotextile exclusion fabric may optionally be cut, fabricated, or otherwise formed to any geometric shape, such as a rectangle, a circle, an ellipse, a triangle, a polygon, a rhomboid, any other regular or non-regular shape, or symmetrical or asymmetrical shape, and the like. Additionally, the geotextile exclusion fabric may be configured to form three-dimensional shapes, either by varying the vertical thickness of the web or the scrim, or by arranging a number of sheets of geotextile exclusion fabric to form the three-dimensional shape. Such three-dimensional shapes include polygons, cubical shapes, cylindrical shapes, prismatoids, regular platonics, pyramids, cones, ellipsoids, and the like.

Landscaping Deployment

One application and method of use for the geotextile exclusion fabric is to prevent burrowing rodents and pests from digging beneath a certain depth underground. To accomplish this, the geotextile fabric can be deployed to form a continuous layer of fabric across an area. Such a deployment is depicted in FIG. 10A. In the depiction, a first sheet 1002 of geotextile exclusion fabric 10 is placed or overlaid. A second sheet 1004 of geotextile fabric 10 is then placed adjacent the first sheet 1002 of geotextile fabric such that there is an area of overlap 1006 between the first sheet 1002 and the second sheet 1004. The area of overlap 1006 is more clearly shown in FIG. 10B. The width 1008 of the area of overlap 1006 can vary between 0.01 inches and the entire width of either the first sheet 1002 or second sheet 1004, or both. A potential width 1008 of the area of overlap 1006 is from about three inches to about twelve inches. Alternatively, the area of the overlap can be selected according to the particular landscape or area being excluded or the particular pest being excluded. A greater area of overlap may be used for landscapes or areas with high traffic, steeper slopes, and the like. As shown in FIG. 5A, shows the installation of the geotextile exclusion fabric along a sloping river bank.

Alternatively, a greater area of overlap may be used for larger rodents or pests. The shape of the area of overlap 1006 may be rectangular, square, polygonal, circular, elliptical, rhomboidsal, and the like, or selected for the particular underground deployed for use of the geotextile fabric.

Once placed, the geotextile exclusion fabric 10 can be secured in place by driving a plurality of sod staples or stakes 1010 through the geotextile exclusion fabric 10 and into the soil beneath. Alternatively, various securing devices may be used to secure the geotextile exclusion fabric 10, such as rods, nails, clips, and the like. The sod staples/stakes can be placed anywhere on the geotextile exclusion fabric 10 as to secure the fabric to a particular area. In one embodiment, FIG. 10A shows the sod staples/stakes 1010 being placed along the edges or periphery of the sheets of geotextile exclusion fabric 10 as well as in the area of overlap 1006 between the sheets of geotextile exclusion fabric 10. A sod staple 1010 preferably placed in the area of overlap 1006 can be more clearly seen in FIG. 10B. The sod staples/stakes 1010 can be spaced as is required by the environment, with the staples having at least one inch between them. A standard but not necessarily required spacing between sod staples/stakes 1010 is about two feet, alternatively between about 1 foot to about 10 feet. A greater number of sod staples/stakes 1010 may be used for larger rodents or areas of high traffic, steeper slopes, and the like.

In landscaping deployment, the geotextile exclusion fabric can be deployed in an area of soil excavated to a certain depth beneath the ground surface 1108, as shown in FIG. 11A. An excavation area 1100 includes a width 1102 and depth 1104 beneath the ground surface 1108, which is excavated adjacent to a structure 1106. The width 1102 and depth 1104 of the excavation can be changed to meet the requirements of the deployment. Alternatively, the excavation area 1100 may be circular, elliptical, and like including a perimeter. The establishment of surface-rooted plants, such as grass, may assist in the holding and stationing of the geotextile exclusion fabric in the soil, whereby the roots of the plants are able to grow through the geotextile fabric for stationing. An excavation depth of at least 3 inches will accommodate the establishment of surface-rooted plants. However, excavation depths of about 0.01 inches to about 3 inches are also employed, as there will not always be a need to accommodate surface-rooted plants. Alternatively, excavation depths of greater than 3 inches may be employed to exclude rodents structures located at deeper depths. Alternative deployment requirements may be included considering the type of structure, rodent, erosion of soil, and the like.

Once the excavation area 1100 is completed, a layer of geotextile excluder fabric 10 can be placed in the excavation area 1100, as shown in FIG. 11B. With reference to FIG. 5B, the post-installation includes a layer of soil and grass on top of the geotextile exclusion fabric to prevent any pests from burrowing into the river bank. In one embodiment, a continuous layer of geotextile exclusion fabric 10, with adjacent sheets of geotextile exclusion fabric 10 overlapping each other, is preferable. In other embodiments, a discontinuous layer of geotextile exclusion fabric 10 may be used, where additional structures, plants, and the like may be employed between such discontinuities in the exclusion fabric 10.

When the excavation is made adjacent to a structure 1110, a structure section 1108 of the geotextile excluder fabric 10 can be secured against the structure 1110 to improve pest exclusion near the structure 1110. Structure section 1108 can be configured to be either contiguous with the geotextile exclusion fabric 10 covering the excavation area 1100 or a separate piece of geotextile exclusion fabric 10 overlapping with the geotextile exclusion fabric 10 covering the excavation area. If a separate piece of geotextile exclusion fabric 10 is used, a sufficient area of overlap and staples/stakes may be used to secure the separate piece adjacent to the ground fabric 10 and the structure 1110.

When the structure section 1108 is a separate piece of geotextile exclusion fabric, it can be configured to conform to the interface between structure 1110 and excavation area 1100. In FIG. 11B, because structure 1110 is perpendicular to the excavation area 1100, the structure section 1108 would be L-shaped, as shown in FIG. 11C. Alternative structure sections 1108 may be employed for non-perpendicular structures 1110, such as to complement the non-perpendicular structure 1110 and form a coherent seal. The structure section 1108 can comprise a first section 1112 and a second section 1114 that are configured to form an interface angle 1116. In the present embodiment the interface angle 1116 is about 90.degree. In other embodiments, interface angle 1116 can be greater than 90.degree. but less than 180.degree., greater than or equal to 180.degree. but less than 360.degree., or less than 90.degree. but greater than 0.degree. for non-perpendicular structures 1110. In order to prevent movement of the structure section 1108, it can be secured to structure 1110 by any appropriate fastener, such as a screw, bolt, nail, spike, staple, hook, adhesive, tape, edging material, or weld. Preferably, the interface angle 1116 provides continuous coverage by the geotextile exclusion fabric 10 between the structure 1110 and the excavated area 1100.

One method of securing the structure section 1108 against the structure 1110 includes the use of an edging 1118. An example of edging 1118 is shown in FIG. 11E. Edging 1118 generally comprises a body strip 1120 and at least one securing tab 1122. The at least one securing tab 1122 projects from one end of the body strip 1120. When there are two or more securing tabs 1122, the tabs 1122 can optionally project from the body strip 1120 at the same angle, or may project at different angles. In one embodiment, the angle formed between the body strip 1120 and the at least one securing tab 1122 is about 90.degree. The angle formed between the body strip 1120 and the securing tab 1122 can be about equal to the interface angle between the first and second sections of the structure section; thus, the angle may also be non-perpendicular such as greater than 90.degree. but less than 180.degree., greater than or equal to 180.degree. but less than 360.degree., or less than 90.degree. but greater than 0.degree.. Each securing tab 1122 can include one or more vias 1124 through which fasteners can be disposed. Such fasteners include screws, nails, bolts, nails, spikes, stakes, staples, and any other appropriate device.

An embodiment of a method of securing the structure section 1108 is shown in FIG. 11F. Structure section 1108 is provided substantially as shown in FIG. 11C. The structure section 1108 is positioned according to the method previously describe, abutting the structure section against the ground and a structure 1110. An edging component 1118, such as the one shown in FIG. 11E, is placed such that the body strip 1120 abuts the second section 1114 of the structure section 1108 and that the at least one securing tab 1122 abuts the first section 1112 of the structure section 1108, making the edging component 1118 flush with the structure section 1108. In one embodiment, the edging component 1118 includes the body strip 1120 that is substantially flat or planar. Alternatively, the body strip 1120 may be curvilinear, angled, and the like, such as to complement the structure section 1108 exterior surface and maintain a flush and coherent securement. After the edging component 1118 is placed, a stake 1124 is driven through via 1124 of the at least one securing tabs 1122. Alternatively, the stake 1124 may be any securing device or tool to secure the edging component 1118 and the structure section 1108 with the geotextile exclusion fabric. The stake 1124 penetrates through the securing tab 1122, through the second section 1112 of the structure section 1108, and into the ground, in one embodiment.

In one embodiment, configuring the structure section 1108 to have the desired interface angle 1116 can be accomplished by fabricating a single piece of geotextile exclusion fabric having the interface angle 1116, as shown in FIG. 11C. Alternatively, the interface angle 1116 may also be accomplished by joining two separate pieces of geotextile exclusion fabric, as shown in FIG. 11D. Joining two separate pieces of geotextile exclusion fabric could be accomplished by sewing, adhesives, staples, welding, hooks, and the like. Optionally, the separate pieces of geotextile exclusion fabric could be mitered or the separate pieces may be overlapped and adjoined in the overlapped regions.

Once all desired geotextile exclusion fabric 10 has been placed and secured in the excavation area 1100, the geotextile exclusion fabric 10 can be covered by any material. Typically, the geotextile exclusion fabric will be covered by a material commonly known and used in landscaping, such as mulch, soil, loam soil, sod, sand, gravel, rocks, or bricks. These landscaping materials are provided for example only and do not limit the scope of materials that can cover geotextile exclusion fabric 10.

In an alternative embodiment, the geotextile exclusion fabric 10 is first formed into a circle, as shown in FIG. 12A. The disclosed embodiment of the geotextile exclusion fabric 10 comprises a first layer 1202 of metal fibers, a scrim 1204, and a second layer 1206 of metal fibers, similar to the embodiment shown in FIG. 1B. In this embodiment, the layers comprising the geotextile exclusion fabric 10 are configured to have approximately the same perimeter and are arranged to be coterminous and define an external boundary 1210. A void 1212 can be made through the first layer 1202, scrim 1204, and second layer 1206 such that the void does not extend to the external boundary 1210 of the geotextile exclusion fabric 10. In this embodiment, the first cut 1212 was made approximately about the center of the geotextile exclusion fabric. Alternatively, the void may be made off center in the fabric. A slit 1208 can then be made through the first layer 1202 of metal fibers, the scrim 1204, and the second layer 1206 of metal fibers, with the slit 1208 extending from at least a portion of the external boundary 1210 to the void 1212. This embodiment allows the geotextile exclusion fabric to be more easily formed to non-excavatable protrusions, such as plants, poles, posts, or any other outcropping by configuring void 1212 to be large enough to allow the protrusion to pass therethrough. Void 1212 can be of any shape, preferably one that conforms to the shape of the protrusion it will be placed about. Such shapes include circles, ellipses, squares, rectangles, triangles, crosses, and all other regular and non-regular polygons. Alternatively, the void 1212 may be smaller than the non-excavatable protrusion, such that the fabric must be pulled over the protrusion and forms a tight fit against the protrusion. In another alternative, the void 1212 may be larger than the non-excavatable protrusion, such that the fabric must be overlapped to form a fit against the protrusion.

It is understood that the embodiment of FIG. 12A is exemplary only. All other shapes and arrangements of the first layer 1202 of metal fibers, scrim 1204, and second layer 1206 of metal fibers that conform with geometric requirements of the protrusion about which the geotextile exclusion fabric 10 is placed about are included in the embodiments disclosed herein. Alternatively, only a single layer of metal fibers can be included in the geotextile exclusion fabric, attached to the top of the scrim. Furthermore, the geotextile exclusion fabric 10 could comprise a layer of nonwoven metal fabric as described above.

In an alternative embodiment, a slit is made from the external boundary 1210 to an inside point of the geotextile exclusion fabric 10 that is not on the external boundary 1210, for instance, the center. In this embodiment, no void is formed in the geotextile exclusion fabric 10. This embodiment is quicker and easier to form, requiring only a single cut, but does not conform as well to the protrusion. This embodiment is preferable when more precise conformation to the protrusion is less valuable than the time required to improve conformation.

In another embodiment, depicted in FIG. 12B, void 1212 is made and partitions a first flap 1214 and a second flap 1216. At least one securing member 1218 is then associated to either first flap 1214 or second flap 1216. Securing member 1218 projects from the flap to which it is attached such that it can fixedly engage with the other flap. Securing member comprises an engagement layer capable of fixedly engaging with the metal fibers of first flap 1214. In this embodiment, the engagement layer comprises a hook-and-loop fabric with stainless steel fibers on the back side of the hook material, and stakes, sod staples, or any other type fastener can be used. When deployed around a non-excavatable protrusion, securing member 1218 fixedly engages with first flap 1214, thereby positioning second flap 1216 to overlap first flap 1214. This arrangement prevents any gap between first flap 1214 and second flap 1216 through which burrowing pests could pass through.

Securing member 1218 can optionally have a layer 1220 of geotextile exclusion fabric attached to the side opposite that engages with first flap 1214 or second flap 1216, protecting securing member 1218 from burrowing pests.

It is understood that the embodiment depicted in FIG. 12B is exemplary only. Securing member 1218 can take any shape that provides sufficient area to engage with the fabric. Securing member 1218 can also project any distance from the flap to which it is attached. Securing member 1218 can also project such that it engages with fabric other than first flap 1214 or second flap 1216, such as fabric adjacent thereto. Furthermore, securing member 1218 can employ means other than hook-and-loop to engage with the fabric, including staples, nails, and stakes.

It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the scope or spirit of the embodiments described herein. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the embodiments disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the embodiments being indicated by the following claims.

Claims

1. A method of manufacturing a composite fabric material, comprising the steps of:

obtaining a first web of metal material consisting of a plurality individual strands of metal that are substantially parallel to each other, are substantially unidirectionally oriented, and have not undergone any carding, garneting, lapping, or needle punching processing, and wherein the individual strands of metal have not been cut to any particular length;

obtaining a scrim layer having a first side, an opposing second side, and a porous, open woven configuration; and

attaching the first web of metal material to the first side of the scrim layer to form the composite fabric material.

2. The method according to claim 1, wherein the scrim layer is water permeable.

3. The method according to claim 1, wherein the first web of metal material comprises steel.

4. The method according to claim 1, wherein the first web of metal material comprises stainless steel.

5. The method according to claim 1, wherein the step of attaching the first web of metal material to the first side of the scrim layer comprises entangling at least a portion of the first web of metal material with the scrim layer.

6. The method according to claim 1, wherein the step of attaching the first web of metal material to the first side of the scrim layer comprises needle punching at least a portion of the first web of metal material to the scrim layer.

7. The method according to claim 1, further comprising the steps of:

obtaining a second web of metal material consisting of a plurality individual strands of metal that are substantially parallel to each other, are substantially unidirectionally oriented, and have not undergone any carding, garneting, lapping, or needle punching processing, and wherein the individual strands of metal have not been cut to any particular length; and

attaching the second web of metal material to the second side of the scrim layer.

8. The method according to claim 7, wherein the steps of attaching the first web of metal material to the first side of the scrim layer and attaching the second web of metal material to the second side of the scrim layer are performed substantially simultaneously.

9. The method according to claim 7, wherein the scrim layer is interlocked between the first web of metal material and the second web of metal material.

10. The method according to claim 1, wherein the composite fabric material is a geotextile material, and wherein the scrim layer includes a plurality of openings extending therethrough and created by the open woven configuration, the openings being sized to permit plant roots to grow therethrough.