Synthetic ground cover system with binding infill for erosion control.

(54) Title: SYNTHETIC FLOOR COVER SYSTEM WITH ADHESIVE FILLING FOR CONTROL OF EROSION.

(54) Title: SYNTHETIC GROUND COVER SYSTEM WITH BINDING INFILL FOR EROSION CONTROL.

(57) Summary

A synthetic soil cover system for erosion control to be placed on top of the soil, including a synthetic grass which comprises a composite of one or more geo-textiles tufting with synthetic yarns The synthetic floor covering also includes a sand / soil filler ballast applied to the synthetic grass and a binding agent applied to the sand filling / soil to stabilize the sand / soil backfill at high velocity water shear forces.

(57) Abstract

A synthetic ground cover system for erosion control to be placed atop the ground, including a synthetic grass which comprises a composite of one or more geo-textiles tufted with synthetic yarns. The synthetic ground cover also ineludes a sand / soil infill ballast applied to the synthetic grass and a binding agent applied to the sand / soil infill to stabilize the sand / soil infill against high velocity water shear torces.

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Institute

Mexican Property

Industrial i

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PATENT TITLE NO. 337616

Owner (s): WATERSHED GEOSYNTHETICS LLC

Address: 11400 Atlantis Place, Suite 200, Alpharetta; _Qeofgia, 30022, USA

Name: SYNTHETIC FLOOR COVER SYSTEM WITH ADHESIVE FILLING FOR EROSION CONTROL.

Classification: IC.8: E02D17 / 20

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idustrial.

Twenty years that cannot be expended, 'ifa to maintain' lenses the 1st sections III and 7a bis 2 of the Law of 705/1999, 'section V subsection a), 4th and 12th sections I and III of the Regulations of the Mexican Institute of Industrial Property (DOF 12/14/1999, amended on 07/01/2002, 07/15/2004, 07/28/2004 and 09/07/2007); Articles 1, 3, 4, 5, section V, subsection a), 16 sections I and III and 30 of the Organic Statute of the Mexican Institute of Industrial Property (DOF) 12/27/1999, amended on 10/10/2002, 07/29/2004, 08/04/2004 and 09/13/2007); 1, 3 and 5 subsection a) of the Agreement that delegates powers to the Deputy Directors General, Coordinator, Divisional Directors, Holders of the Regional Offices, Divisional Deputy Directors, Departmental Coordinators and other subordinates of the Mexican Institute of Industrial Property. (DOF 12/15/1999, amended on 02/04/2000, 07/29/2004, 08/04/2004 and 09/13/2007).

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Issue Date: March 10, 2016

DIVISIONAL DIRECTOR OF PATENTS

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NAHANNY CANAL REYES

Arenal No. 550, Floor 1 Col. Pueblo Santa María Tepepan, Xochímilco. CP 16020,

Mexico City

Tet (55) 53 34 07 00 www impi gcb.mx srt

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MX / 2016/21103

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SYNTHETIC FLOOR COVER SYSTEM!

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INDiÍSTrJAL

ADHESIVE TO CONTROL THE BRCMfigrUgg ΚΤ

BACKGROUND OF THE INVENTION

The prior art describes systems for erosion protection that usually take the form of a combination of synthetic matting and natural grass. Furthermore, the prior art generally requires multiple anchor points to resist lifting forces and wind erosion on the synthetic mat. Therefore, the industry continues to search for better erosion protection systems that are effective, economical, and comply with the various local, state, and federal environmental laws, rules, and guidelines for these systems.

Artificial grass has been widely used on sports venues (playing fields), as well as along airport runways and in gardening in general.

A primary consideration of artificial grass playing fields is the field's ability to drain. Examples of the prior art in draining synthetic grass are US Patent Nos. 5,876,745; 6,858,272; 6,877,932 and

6,946,181. However, these artificial grasses are generally only suitable for field surfaces - - ___ instituto méxicaw

INDUSTItlAV substantially flat and the ability to improve prior turf technique with slow infiltration of play where the terrain is concern is only with the playing conditions on the field

The use of drainage on man-made primarily treats flat surfaces to prevent field flooding, and such use of drainage generally cannot handle the very large and rapid runoff that would occur on very large and steep slopes of natural or made terrain topography. man-made, such as dumps, reserves, berms, embankments, dikes, drainage channels, mining tailings piles, etc.

SUMMARY OF THE INVENTION

Briefly described, the present invention provides a new and useful system for covering the different types of soil where water and protection against wind erosion are needed. More particularly, in a first exemplary form, the invention comprises a synthetic soil cover system for erosion control to be placed above the ground, including a synthetic grass comprising a compound of one or more geo-textiles with plumes of synthetic threads. The synthetic ground cover also includes a filler ballast that is applied to the synthetic grass and a binder agerite applied to the filler to

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IMPI

INSTITUTO MEXICANO PE LA PROéíEL'AD INDUSTRIAL 'stabilize the sand / soil fill against high speed water shear forces.

Optionally, the binding agent in the synthetic floor covering system for erosion control is cement, grout, lime or the like.

Optionally, the binding agent may comprise a polymer.

Preferably, the binding agent applied to the filler results in a bonded filler having a depth of between about one inch (1.27 cm) and about 2 inches (5.08 cm). Also, preferably, the filler is applied to the synthetic grass in a dry condition and then moistened after curing in a bonded filler.

Preferably, the filler comprises a sand or granular material and the binding agent comprises cement.

sand to cement ratio is between 3: 1 by weight.

synthetic floor covering also seeped from fabric to be placed over, or

twenty. on the ground and an open mesh grill located between the synthetic grass and the fabric filter. Preferably, the at least one filter cloth comprises synthetic non-woven cloth. Also preferably, the open mesh screen comprises a synthetic drainage system. Optionally, the

Preferably the approximately 1: 1

Optionally, it includes at least one

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MEXICAN INSTITUTE OF PROPERTY

INDUSTRIAL

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Synthetic ground cover can include at least one low permeability barrier geomembrane to be placed adjacent to the ground.

Optionally, synthetic grass has a density of between approximately 20 ounces per square yard (0.597 g / m²) and 120 ounces per square yard (3.58 g / m²) .

Preferably, the synthetic grass has fibers with an average length of between about 0.5 and 4 inches (1.27 and 10.16 cm) that act as a reinforcement for the sand / soil filling. Optionally, the synthetic grass has fibers with an average length of between approximately 1.5 and 3 inches (3.81 and 7.62 cm).

Preferably, the filter cloth 1 is positioned to be in direct contact with the ground surface and comprises woven synthetic cloth. Alternatively, the synthetic fabric may be a non-woven material.

In another example form, the invention comprises a method of covering the soil for erosion control. The method includes the steps' of: (a) laying a synthetic grass on top of the ground, synthetic grass having a backing, and synthetic grass blades extending from it; (bj applying a dry fill ballast for synthetic grass, and (c) applying a wetting agent for the dry fill to cure the dry fill in

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INSTITUTO MEXICANO an adherent filler to stabilize the rel ^ eraousT &amp; © n water shear forces at high speed.— ¹ —Optionally, the dry fill ballast includes cement and the wetting agent comprises water.

In another example form, the invention comprises a method of covering the soil for erosion control. The method includes the steps of: (a) placing a synthetic grass on top of the ground, synthetic grass with a backing, and synthetic grass blades extending from it; (b) the application of a dry fill ballast to the synthetic grass, and (c) the. application of a wet binder to the dry fill to bond the dry fill to a tacky fill 'to stabilize the sand / soil fill against high-speed water shear forces.

Optionally, the dry fill ballast includes granular material and the binding agent comprises a polymer. In another form, the binding agent comprises a thick cementitious suspension. Optionally, the dry fill ballast can include sand and / or gravel.

It will be understood that this invention is not limited to the specific devices, methods, conditions, or parameters described and / or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example.

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MEXICAN INSTITUTE. IkS —'Míaffiy OF PROPERTY V »¹-·only. Therefore, the terminology is intended to be broadly interpreted and is not intended to be limiting of the claimed invention. By. Example, as used in the specification including the appended claims, the singular forms one, one, and one include the plural, the term o means and / or, and the reference to a certain value -numeric includes at least that certain value unless the context clearly dictates otherwise. Furthermore, any of the methods described in this document are not intended to be limited to the sequence of steps described, but may be carried out in other sequences, unless expressly stated otherwise in this document.

BRIEF DESCRIPTION OF THE FIGURES

Figure 1 is a schematic sectional view of a synthetic soil cover system for erosion control in accordance with a first example of the present invention.

Figure 2 is a schematic sectional view of a synthetic soil cover system for erosion control according to another example of the present invention, shown with an open mesh screen drain at the bottom of the system.

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Figure 3Ά is a schematic sectional view of a synthetic soil cover system for erosion control in accordance with another example of the present invention.

Figure 3B is a detailed sectional schematic view of the synthetic soil cover system for erosion control of Figure 3A.

Figure 4 is a schematic sectional view of a synthetic soil cover system for erosion control in accordance with another example of the present invention.

Figure 5A is a schematic sectional view of the synthetic soil cover system for erosion control of Figure 1 and is shown installed on multi-slope terrain. .

Figure 5B is a detailed sectional schematic view of the synthetic soil cover system for erosion control of Figure 5A.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides an erosion protection layer for use in retaining walls, levees, ditches, waterways, sloping weirs, dumps and other pronounced topographic ground conditions that

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MEXICAN INSTITUTE OF INDUSTRIAL PROPERTY are exposed to shear water forces and the ———— «MBMiih II ü'iiInT || H&gt; ιΜ · 11 i¹ winds.

In an exemplary form of the present invention, a synthetic grass is used in combination with a bonded / stabilized fill ballast to provide a useful new ground cover system, while also providing a protection system against beneficial erosion that does not require maintenance. This combination (sometimes referred to as a composite material) can be used to cover slopes and line drainage ditches, ditches, and sloping weirs. With the roofing system of this invention, owners and operators can obtain significant cost savings by building a synthetic grass roofing system that does not require vegetative support and does not require a typical topsoil layer. known end cover systems of the prior art.

More particularly, in a first example form, the invention comprises a synthetic soil cover system for erosion control to be placed on the ground, including a synthetic grass comprising a compound of one or more geo-textiles with plumes of synthetic threads. Synthetic ground cover also includes a stabilized / bonded fill ballast applied to grass

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INSTITUTO MEXICANO DE LA PROILEL'FTD INDUSTRIAL Synthetic (stabilized against high speed water shear forces).

Optionally, the filler ballast comprises a sand or earth and is adhered with a binding agent, such as cement, grout, lime, or the like.

With this invention, sloping weirs and ditches can be lined with this system to resist high wind and water shear forces without washing the soil below the system. Artificial grass provides separation of the sand fill from the ground underneath and the grass blades act as structural reinforcement of the sand fill while providing an aesthetically pleasing surface. The sand filler on top is stabilized against remote washing or blowing by a binding agent applied to the sand filler, which generally has the effect of cementing or bonding the sand together. This allows the invention to withstand high wind or water shear forces. In this regard, the bond strength need not be terribly high. In fact, it is not necessary to achieve a structural strength as great as concrete, for example. Instead, it is sufficient that the binding agent simply holds the sand together against the erosive forces of wind and water. In this sense, the

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sand / soil is adhered to the other sand particles and / or to the blades of synthetic grass by the binder.

FIG. 1 is a schematic sectional view of an exemplary synthetic soil cover system 110 for erosion control in accordance with the present invention and showing the soil surface S covered with the present erosion control system from the ground cover. The system includes synthetic grass 140 including a backrest 142 and synthetic grass blades 141 attached to the backrest. A stabilized / bonded sand / soil filler

160 it is placed at the bottom of the synthetic grass 140 above the backrest 142. The floor S may be covered with a sand pit, gravel pit, or intermediate deck before the synthetic floor covering system 110 is placed for the erosion control, · as desired. In this first exemplary embodiment, lawn 140 is placed more or less directly on the ground S. As will be seen later, the system can also be provided with additional elements interposed between the soil S and the grass 140.

Preferably, synthetic grass 140 is used as a major component of the synthetic floor covering system. It can be built using a knitting machine or tuft forming machine that can

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MEXICAN INSTITUTE OF INDUSTRIAL PROPERTY use, for example, more than 1,000 needles to produce a lawn width of about 15 feet (4.57 m).

Preferably, the synthetic turf includes synthetic grass blades 141 comprising polyethylene monofilaments and / or fibrillated and non-fibrillated fibers cut into strips that form tufts and have a blade length of between about 0.5 inches (1.27 mm) and 4 inches ( 10.16 mm). Other polymers can be used for synthetic grass blades as desired. Preferably, synthetic grass blades 141 form tufts to have a blade length of between about 1.5 inches (3.81 cm) and 3 inches (7.62 cm). Most preferably, synthetic grass blades 141 form tufts to have a blade length of about 1.5 inches (3.81 cm).

Optionally, synthetic grass blades 141 form tufts to have a density of between. 20 ounces / square yard. (0.597 g / m²) and about 120 ounces / square yard (3.58 g / m²). Synthetic grass blades preferably have a thickness of at least about

100 oh my.

The synthetic grass blades 141 form tufts in the substrate or backing 142 comprising a synthetic fabric or non-woven fabric. Also, this backing can be a single layer backing or it can be a multi-layer backing,

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as desired. Optionally, a geo-filter can be secured to the substrate to reinforce the substrate and better secure synthetic grass blades.

The chemical composition of synthetic grass components should be selected to resist degradation from exposure to sunlight, which generates heat and contains ultraviolet radiation. Polymer threads should not become brittle when subjected to low temperatures. The selection of the. Synthetic grass color and texture should be aesthetically pleasing.

The actual grass-like components preferably consist of green polyethylene 141 fibers of about 1.5 to about 2.5 inches (3.81 to 6.35 cm) of tuft length inserted into a woven or non-woven geotextile (s). To increase strength on steep slopes, an additional geofilter component backing can be tufted to improve dimensional stability. The polyethylene grass filaments 141 preferably have a long operating life of at least '15 years.

A layer of sand / soil 160 of "about 0.5 to about 2.0 inches (1.27 to 5.08 cm) is placed on top of the synthetic grass as a filler for the ballast material and to protect the system from wind uplift,

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IMPI, INSTITUTO MEXICANO as well as to provide stability * d^LAPRog ^ fe Preferably, the padding is between · about 0 5 and. i inches (1.27 and 2.54 cm). The sand / dirt hood offers additional protection of i.; S geotiext i .us against ultraviolet light. Furthermore, the sand / soil ballast is bonded with cement, mortar, lime, or other binding agent to resist wind and water shear forces on steep slopes, drainage ditches, and sloping dumps. In this sense, the synthetic grass- 140 is first placed on the · ground and then the sand / soil filling is spread on the synthetic grass in dry form. This allows dry filler material to settle easily and efficiently on the underside of synthetic grass. Thereafter, the infill is watered (as by water spray on the lawn) and allowed to cure in a hardened bonded infill layer. In this sense, the sand / soil filler adheres to itself and adheres to the individual sheets of synthetic grass.

Therefore, in the event that the sticky filler does crack in some places, the individual blades of the lawn act as anchors and help keep the sticky filler in place.

The ar.ena / tierra filling. includes real sands (including silica sands, quartz sands, etc.), soils, clays, mixtures thereof, etc. It also includes

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things that are like sand or earth. For example, granular waste from rock quarries could be used (things like marble granules, quartz, granite, etc.). Also, small gravel can be used as sand / soil filler. In this sense, it is preferred that the filler be inorganic in nature, in order to be very stable and long-lasting. But the organic granular material could be used in certain applications. On the other hand, · the binding agent could be inorganic or organic.

Preferably,. the binding agent is inorganic (again, for stability and long life). Cements, grouts, liming agents, etc., fit this application as well. However, other binding agents could be used, such as organic binders. For example, polymer based binders (eg, a urethane product) could be used. In fact, lately a dew binder has come onto the market to bind small gravel on the roads under the brand name Klingstone and sold by Klingstone,

Inc. of Waynesville, North Carolina.

Applicants have found that a recipe of about three parts sand and one part cement works well as a dry filler. Once wetted and cured, this bonded sand filler provides an excellent

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ballast against rising grass .wind,, v ...

It also resists damage or erosion by wind or rain or in high water flows. A recipe for about equal parts sand and cement works well, too, as do the relationships between these two examples. However, for economic reasons, you should choose to use only as much cement as is needed to keep the filler together and the synthetic grass blades, as cement is more expensive than sand in general ... Therefore, more recipes. 3: 1 recipes are generally cheaper but have less strength, while the closest 1: 1 recipes are generally stronger, but more expensive. Furthermore, a 2: 2: 1 recipe for sand / cement / lime also works well. Also, instead of lime you can use fly ash.

Advantageously, the present invention can be used even when high concentration flows are expected (eg, sloping weirs, large drainage ditches). For this purpose, the sand / soil filling is stabilized with a binding agent, such as cement, grout, lime, etc. This creates a sand / soil filler more or less grout or bonded 160 to resist the shear forces of water flow and wind.

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The present invention combines the use of synthetic grass to provide a pleasing visual appearance, erosion protection with minimal maintenance. The invention incorporates a bonded filler that, along with synthetic grass, can handle water runoff very quickly. Thus, the roof system of this invention can be installed on very steep slopes that normally occur on embankments, dams, dams, sloping weirs, dumps and stockpiles. The system can be used as an erosion control material that can withstand high &lt;wind or water lifting forces.

In addition to the modalities described above, the system can take other forms. For example, the system may comprise a membrane with a synthetic turf overlay drainage layer having cemented (stabilized) infill filler using any of the binding agents described herein and the like. In such an embodiment, a bottom layer includes a structured low permeable membrane (optionally textured or spiked on the bottom side and drain bolts on the top side) and a top layer. The top layer may include grass (with, for example, 1.5-inch (3.81 cm) pile height) and a mix of sand, lime, and cement mix. In

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FIG. 2 is a schematic sectional view of a synthetic soil cover system 210 for erosion control in accordance with a second example of the present invention, shown without an open mesh screen at the bottom of the system. As in the exemplary embodiment of Figure 1, the example roof system 210 for erosion control shown in Figure 2 is used to control soil erosion S.

System 210 includes a bottom filter cloth (geofilter) 220, an open grid mesh or geo-net 230, and a synthetic grass 240. Synthetic grass 240 includes a backing 242 and blades 241 are secured to the backing. A stabilized / bonded sand / soil padding 260 is placed at the bottom of the synthetic grass 240 above the backing 242. Soil S may be covered with a sand pit, gravel pit, or intermediate deck before the synthetic floor covering system 210 is placed for erosion control as desired.

Preferably, the bottom filter fabric 220 comprises a woven or non-woven synthetic fabric. In some applications, the bottom filter cloth 220 may be

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replaced with a low permeability barrier geomembrane.

Figures 3A and 3B illustrate a synthetic soil cover system 310 for erosion control in accordance with a third example of the present invention, shown without an open mesh screen at the bottom of the system. As in the exemplary embodiment of Figure 1, the example roofing system 310 for erosion control shown in these figures is used to control soil erosion S. The 310 system includes a 350 waterproof geomembrane and a synthetic grass

340. The waterproof geomembrane 350 is a polymeric sheet with fine spikes on the bottom surface and stud-like or stud-like protrusions on the top surface. For example, see top bumps 351-354 and peaks 357-359. Bottom spikes help anchor the S-ground waterproof geomembrane and top ridges help anchor synthetic turf 340 to 350 waterproof geomembrane. The top ridges also provide a transmitter drainage layer or space in which water can flow through the membrane underneath the synthetic grass. Synthetic grass 340 includes a support 342 and leaves 341 attached to the backrest. A stabilized / bonded sand / soil fill 360

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MEXICAN INSTITUTE OF INDUSTRIAL PROPERTY

T -i, _, INUUJIIUAL - is placed at the bottom of synthetic grass 340 above backrest 342. ^{L 7}**

FIG. 4 is a schematic sectional view of another synthetic floor covering system 410 for erosion control 5 in accordance with the present invention, shown with a reinforcing layer on the backing of the synthetic grass. As in the exemplary modality of the figure

1, the example erosion control deck system 410 shown in Figure 4 is used to control soil erosion S. System 410 includes a synthetic turf 440 that includes a support 442 and attached blades 441 to the back. Backing 442 can be a single layer backing or a multi-layer backing. A urethane barrier 443 is applied to the underside of the backrest 442 and acts both to reinforce the backrest and for the connection between sheets 441 and backing 442. The urethane barrier

443 it also makes backing 442 generally waterproof. A stabilized / bonded sand / soil filler 460 is placed at the bottom of the synthetic turf. 440 above the backrest 442.

Figures 5A and 5B show the exemplary embodiment of Figure 1 applied to terrain with different slopes.

This synthetic 110 floor covering system has the ability to handle high intensity rainfall and

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prevents erosion of sand / soil fill ballast and / or shear forces on grass ranging from 1 pound per square foot (0.4887 g / cm²) more than 25 pounds per square foot (12.22 g / cm²) .

Applicants have found that sand works especially well as the primary ballast agent, although soil works well as well. Even small gravel could be used as the primary ballast agent. Furthermore, applicants have found that the binding agent that works best in most applications is cement, although other binding agents could also work very well. Therefore, while cementitious materials are the preferred binders, other materials may work as well.

There are many advantages to the cover system of this invention. The roofing system reduces construction costs, reduces annual operation and maintenance costs while providing superior and reliable / consistent aesthetics. It also reduces the need for expensive breakwater channels and drainage banks, substantially without erosion or sedimentation problems, even in adverse weather conditions. It is a good option in sensitive areas where soil erosion and sedimentation are: the main concerns, since the

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soil loss is substantially reduced. It also eliminates the need for sedimentation ponds and environmental impacts associated with construction. It allows for steeper slopes as there will be a reduced risk of soil stability problems.

Although the invention has been shown and described in exemplary forms, it will be apparent to those skilled in the art that many modifications, additions, and deletions can be made therein without departing from the spirit and scope of the invention as such. It is defined by the following claims.

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