High-strength, wear-resistant, and weather-resistant geotextile fabrics

Abstract

A high-strength, abrasion-resistant, and weather-resistant geotextile fabric comprises a plurality of warp units and a plurality of weft units interwoven with the warp units. Each warp unit includes at least one warp monofilament fiber. Each weft unit includes at least one weft monofilament fiber. The high-strength, abrasion-resistant, and weather-resistant geotextile fabric has a warp density of 20 to 600 warp monofilament fibers per inch, with each warp monofilament fiber having a fineness between 501 and 3000 denier. The weft density has a weft density of 150 to 2000 weft monofilament fibers per inch, with each weft monofilament fiber having a fineness between 50 and 1000 denier. Therefore, this geotextile fabric can improve abrasion and weather resistance, and while maintaining strength and good water permeability, it can also maintain small average pore size, achieving a good filtration effect.

Description

[Technical Field]

[0001] This invention relates to a geotextile, and more particularly to a high-strength, wear-resistant, and weather-resistant geotextile. [Previous Technology]

[0002] The main functions of geotextiles include reinforcement, isolation, and filtration. Their strength, permeability, and characteristic pore size are key factors determining product performance. These fundamental properties not only affect the stability and durability of geotextiles in engineering projects but also directly relate to their ability to perform their designed functions under different environmental conditions. In practical applications, the performance of geotextiles may be affected by abrasion during construction or long-term exposure to ultraviolet radiation from sunlight; therefore, their abrasion resistance and weather resistance are equally crucial. For example, heavy equipment during construction may damage the surface of geotextiles, while prolonged exposure to sunlight can lead to material aging and performance degradation.

[0003] Especially when geotextiles are made into bag-type products such as geotextile sandbags, their application scenarios and functional requirements become more complex. Geotextile sandbags not only need to perform the dual functions of filling and filtering, but also need to maintain a stable filtration effect while withstanding high load pressure. Therefore, these products have higher requirements for the strength, permeability, and filtration capacity of geotextiles.

[0004] Furthermore, in some applications, these products may be exposed to harsh outdoor environments for extended periods, such as in coastal, riverine, or wetland engineering projects. They must withstand not only strong water currents and impacts from floating debris, but also extreme weather and sun exposure. Therefore, improving the abrasion resistance and weather resistance of geotextiles is particularly important. In summary, the design of geotextiles needs to be adjusted according to specific application requirements. In addition to meeting basic reinforcement, isolation, and filtration functions, they must also achieve higher standards in durability and resistance to environmental impacts to ensure their reliability and long-term stability under different environmental conditions.

[0005] The existing industry commonly uses fiber monofilaments (such as round yarn, flat yarn, sliced ​​yarn), fine fiber (fine denier) multifilaments, and split film yarns to improve the abrasion resistance of fabrics by combining woven and non-woven fabrics into composite fabrics by needle punching, adhesive bonding or sewing. However, non-woven fibers are extremely fine and are more easily worn and sacrificed into plastic debris.

[0006] Existing geotextiles and geotextile sandbags are used in river or coastal protection projects and are frequently exposed to direct sunlight during use. When using single fibers, fibers with low denier, or thin structures, photo-oxidation easily occurs, causing molecular bonds to break, which in turn weakens the material strength and damages the geotextile sandbag material, leading to the loss of filler. In addition, when water flow and waves repeatedly beat against the geotextile sandbag, they often carry mud, sand, garbage, and debris, causing abrasion on the surface of the geotextile sandbag. This can range from minor abrasion and fraying to severe fiber breakage, causing the bag to break and resulting in the loss of filler. [Summary of the Invention]

[0007] Therefore, the object of the present invention is to provide a high-strength, abrasion-resistant, and weather-resistant geotextile that can improve upon at least one of the aforementioned disadvantages.

[0008] Therefore, the high-strength, abrasion-resistant, and weather-resistant geotextile fabric of the present invention comprises a plurality of warp units and a plurality of weft units interwoven with the warp units. Each warp unit comprises at least one warp monofilament fiber. Each weft unit comprises at least one weft monofilament fiber. The high-strength, abrasion-resistant, and weather-resistant geotextile fabric has a warp density of 20 to 600 warp monofilament fibers per inch, and the fineness of each warp monofilament fiber is between 501 and 3000 denier. The weft density has a weft density of 150 to 2000 weft monofilament fibers per inch, and the fineness of each weft monofilament fiber is between 50 and 1000 denier.

[0009] The advantages of the present invention are as follows: by interweaving the warp monofilament fibers with a fineness between 501 and 3000 denier and the weft monofilament fibers with a fineness between 50 and 1000 denier, the warp density contains 20 to 600 warp monofilament fibers per inch and the weft density contains 150 to 2000 weft monofilament fibers per inch, thereby improving wear resistance, weather resistance and sun protection, reducing material wear and aging problems, and maintaining small average pore size while taking into account strength and good water permeability, thus achieving a good filtration effect.

Implementation Method

[0010] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0011] Before the present invention is described in detail, it should be noted that similar elements are represented by the same numbers in the following description.

[0012] Referring to Figures 1 to 3, a first embodiment of the high-strength, abrasion-resistant, and weather-resistant geotextile fabric of the present invention includes a plurality of warp yarn units 1 and a plurality of weft yarn units 2 interwoven with the warp yarn units 1. Figure 1 shows a weave cycle of the first embodiment. The portion of each warp yarn unit 1 that floats above each weft yarn unit 2 is defined as a warp weave point 31, and the portion of each weft yarn unit 2 that floats above each warp yarn unit 1 is defined as a weft weave point 32.

[0013] Referring to Figure 4, which is a weave diagram of the weave cycle, it contains 64 squares in an 8x8 array. Each colored square represents a weft weave point 32, and each white square represents a warp weave point 31. The side where the warp monofilaments 11 are concentrated in the fabric is defined as a first side surface, and the other side where the weft monofilaments 21 are concentrated is defined as a second side surface. The ratio of the number of warp weave points 31 to the total number of weave points (the sum of warp weave points 31 and weft weave points 32) in the first side surface of the weave cycle is defined as the coverage rate. The ratio of the number of warp weave points 31 to the total number of weave points is greater than 70%. Specifically, the total number of weave points is 64, and the number of warp weave points 31 is 56. Therefore, the coverage rate in this embodiment is 56 divided by 64, which is 87.5%.

[0014] In this embodiment, the warp yarn units 1 and the weft yarn units 2 are interwoven to form a p-count satin weave structure. That is, each weft yarn unit 2 passes under (p-1) warp yarn units 1 and then passes over one warp yarn unit 1. In the p-count satin weave, the coverage rate is (p-1) / p. If the coverage rate needs to be greater than 70%, then p needs to be greater than 10 / 3. In this embodiment, p is greater than or equal to 5. Specifically, p equals 8. The warp yarn units 1 and the weft yarn units 2 are interwoven to form an 8-count 3-fly satin weave structure. The 3-fly represents the interval of two weft yarn units 2 between the adjacent weft weave points 32 on the two adjacent warp yarn units 1.

[0015] Referring again to Figures 1 to 3, each warp unit 1 includes two warp monofilament fibers 11. Each weft unit 2 is broad and flat and includes a plurality of weft monofilament fibers 21. The coverage of this embodiment is greater than 70%, meaning that the ratio of the area of ​​the warp monofilament fibers 11 on the first side to the overall area of ​​the weft loop is greater than 70%, and the warp monofilament fibers 11 cover most of the weft monofilament fibers 21.

[0016] The warp density of the fabric includes 20 to 600 warp monofilaments 11 per inch, and the fineness of each warp monofilament 11 is between 501 and 3000 deniers. The weft density of the fabric includes 150 to 2000 weft monofilaments 21 per inch, and the fineness of each weft monofilament 21 is between 50 and 1000 deniers. In one embodiment, the warp density of the fabric includes 40 to 600 warp monofilaments 11 per inch, and the fineness of each weft monofilament 21 is between 50 and 500 deniers. Specifically, each warp monofilament 11 and each weft monofilament 21 is a polymer, such as polypropylene (PP), polyethylene terephthalate (PET), or polyethylene (PE), etc.

[0017] This geotextile can be made into a geotextile sandbag (not shown), with the first side located on the outer side and the second side located on the inner side. Because the warp monofilaments 11 have a large diameter (high denier) and an arc-shaped surface, and cover a high proportion of the weft monofilaments 21, the total exposed surface area of ​​the weft monofilaments 21 is small, resulting in less exposure to sunlight and thus better durability. Furthermore, the finer weft monofilaments 21 are concentrated on the inner side, preventing them from coming into contact with and wearing down external objects. When this geotextile sandbag is filled with filler and used in river or coastal protection projects, it can withstand long-term sun exposure. When subjected to long-term scouring and beating by water currents or waves, it also reduces wear caused by silt, garbage, or debris in the water, preventing the sandbag from breaking and causing the internal filler to leak out. Therefore, the local textile or sandbag has excellent wear resistance and weather resistance.

[0018] Furthermore, by interlacing the warp monofilaments 11 with high denier and the weft monofilaments 21 with low denier, the fabric can maintain small average pore size while taking into account both strength and good water permeability, thus achieving a good filtration effect.

[0019] In this embodiment, the tensile strength of the geotextile is between 100 kN / m and 400 kN / m (measured according to test standards ISO 10319 or ASTM D4595), specifically, the tensile strength of the geotextile is 120 kN / m. The abrasion resistance of the geotextile is greater than 85% (measured according to test standard ASTM D4886), the UV resistance after 500 hours is greater than 98% (measured according to test standard ASTM D4355), the UV resistance after 6000 hours is greater than 90% (measured according to test standard ASTM D4355), and the water permeability is greater than 40 L / m² / s (measured according to test standard ISO 11058). The characteristic pore size of the geotextile is between 0.075 mm and 0.4 mm (measured according to test standard ISO 12956). In one embodiment, the characteristic aperture of the geotextile is between 0.2 mm and 0.4 mm. Specifically, the characteristic aperture of the geotextile is 0.25 mm.

[0020] Existing geotextile fabrics have an abrasion resistance of approximately 70% to 80%, a UV resistance of approximately 70% to 90% after 500 hours of exposure, and a water permeability of approximately 12.5 to 25 L / m² / s. Therefore, this embodiment exhibits superior abrasion resistance, UV resistance, and water permeability compared to existing geotextile fabrics.

[0021] It should be noted that the high-strength, wear-resistant, and weather-resistant geotextile of the present invention does not limit the number of warp monofilament fibers 11 in each warp unit 1, nor the number of weft monofilament fibers 21 in each weft unit 2. In other variations of this embodiment, each warp unit 1 may also include one or more warp monofilament fibers 11, and each weft unit 2 may also include one or a different number of weft monofilament fibers 21.

[0022] To facilitate the subsequent explanation of other variations of this embodiment, the weaving structure of the warp unit 1 and the weft unit 2 in this embodiment is further defined as an 8-ply 3-ply / 2-warp-1-weft structure. This means that each warp unit 1 includes two warp monofilament fibers 11, and each weft unit 2 includes one or a bundle of weft monofilament fibers 21.

[0023] Referring to Figures 5 to 7, a second embodiment of the high-strength, wear-resistant, and weather-resistant geotextile of the present invention is shown. The weave diagram of the second embodiment (not shown) is the same as that of the first embodiment (see Figure 4), which is also an 8-ply, 3-fly structure. The difference between the second embodiment and the first embodiment is that the weft yarn units 2 are divided into a plurality of first fiber bundles 2' and a plurality of second fiber bundles 2" and the first fiber bundles 2' and the second fiber bundles 2" are alternately arranged along the warp direction. Each first fiber bundle 2' has a plurality of weft monofilament fibers 21, each second fiber bundle 2" has a plurality of weft monofilament fibers 21, and the number of weft monofilament fibers 21 in each second fiber bundle 2" is twice the number of weft monofilament fibers 21 in each first fiber bundle 2'. The second embodiment is hereby defined as an 8-ply, 3-fly / 2 warp (1+2) weft structure.

[0024] Since the second embodiment has the same weave diagram as the first embodiment, the coverage of the second embodiment is also 87.5%. In other variations of this embodiment, the number of weft monofilament fibers 21 in each first fiber bundle 2' and each second fiber bundle 2" can also be set to different numbers as needed. Another variation of this embodiment can also be an 8-ply 3-ply / 2-warp 2-weft structure, that is, the weave diagram of this variation is the same as that in Figure 4, and each warp unit 1 includes two warp monofilament fibers 11 (not shown), each weft unit 2 includes two fiber bundles (not shown), and each fiber bundle has the same number of weft monofilament fibers 21.

[0025] Referring to Figures 8 to 11, these are weave diagrams of a weave cycle in a third to a sixth embodiment of the high-strength, wear-resistant, and weather-resistant geotextile of the present invention. The difference between the third to sixth embodiments and the first embodiment lies in the weaving method. The warp units 1 and the weft units 2 are woven using an m / n twill weave (refer to Figure 1 for the warp units 1 and weft units 2, the difference being in the weaving structure). This means that a weft unit 2 passes under m warp units 1 and then over n warp units 1, and each weft weave point 32 has a shift of one weave point in each column to form a twill pattern. In the twill weave, the coverage is m / (m+n). If the coverage needs to be greater than 70%, then the ratio of m to n needs to be greater than 7 / 3. In the third to sixth embodiments, the ratio of m to n is greater than or equal to 3. It should be noted that in the third to sixth embodiments and other variations (i.e., different twill structures), the number of warp monofilament fibers 11 in each warp unit 1 and the number of weft monofilament fibers 21 in each weft unit 2 are not limited.

[0026] Referring again to Figure 8, in this third embodiment, the warp units 1 and the weft units 2 are woven using a 7 / 1 twill weave, where m is 7, n is 1, the ratio of m to n is 7, the total number of weave points is 64, the number of warp weave points 31 is 56, and the coverage rate is 56 / 64, which is 87.5%. Each warp unit 1 contains two warp monofilament fibers 11 (not shown), and each weft unit 2 contains two fiber bundles (not shown) each containing a plurality of weft monofilament fibers 21. This embodiment is defined as a 7 / 1 twill / 2 warp 2 weft structure. A variation of this embodiment can be a 7 / 1 twill / 2 warp (1+2) weft structure. The difference between this variation and the 7 / 1 twill / 2 warp 2 weft structure is the same as the variation logic described in the first embodiment and the second embodiment, so it will not be repeated here.

[0027] Referring again to Figure 9, in this fourth embodiment, the warp units 1 and the weft units 2 are woven using a 5 / 1 twill weave, the ratio of m to n is 5, the total number of weave points is 36, the number of warp weave points 31 is 30, and the coverage rate is 30 / 36, which is approximately 83.33%. This embodiment can be a 5 / 1 twill / 1 warp 2 weft structure or a 5 / 1 twill / 1 warp (1+2) weft structure.

[0028] Referring again to Figure 10, in this fifth embodiment, the warp units 1 and the weft units 2 are woven using a 6 / 2 twill weave, the ratio of m to n is 3, the total number of weave points is 64, the number of warp weave points 31 is 48, and the coverage rate is 48 / 64, which is 75%. This embodiment can be a 6 / 2 twill / 2 warp 1 weft structure or a 6 / 2 twill / 2 warp 2 weft structure.

[0029] Referring again to Figure 11, in this sixth embodiment, the warp units 1 and the weft units 2 are woven using a 3 / 1 twill weave, the ratio of m to n is 3, the total number of weave points is 16, the number of warp weave points 31 is 12, and the coverage rate is 12 / 16, which is 75%. This embodiment is a 3 / 1 twill / 1 warp 1 weft structure.

[0030] As can be seen from the foregoing description, the coverage of the third to sixth embodiments is all greater than 70%. Therefore, the third to sixth embodiments also have the technical feature that the warp monofilaments 11 with large diameter (high denier) are concentrated on one side of the fabric, so that the total exposed surface area of ​​the weft monofilaments 21 is small, avoiding sun exposure and external force wear, and has better resistance. Therefore, it can also improve the wear resistance and weather resistance of the fabric.

[0031] In summary, the high-strength, wear-resistant, and weather-resistant geotextile of the present invention is achieved by interweaving warp monofilament fibers 11 with a fineness between 501 and 3000 denier and weft monofilament fibers 21 with a fineness between 50 and 1000 denier, such that the warp density contains 20 to 600 warp monofilament fibers 11 per inch and the weft density contains 150 to 2000 weft monofilament fibers 21 per inch. This improves wear resistance, weather resistance, and sun protection, reduces material wear and aging, and maintains small average pore size while ensuring strength and good water permeability, thus achieving a good filtration effect. Therefore, the present invention can indeed achieve its objectives.

[0032] However, the above description is only an embodiment of the present invention and should not be construed as limiting the scope of the present invention. Any simple equivalent changes and modifications made in accordance with the scope of the patent application and the contents of the patent specification of the present invention shall still fall within the scope of the patent of the present invention. [Simplified Explanation of the Diagram]

[0033] Other features and effects of the present invention will be clearly presented in the embodiments with reference to the drawings, wherein: Figure 1 is a plan view of a first embodiment of the high-strength, abrasion-resistant, and weather-resistant geotextile of the present invention; Figure 2 is a cross-sectional view taken along line II-II in Figure 1; Figure 3 is a cross-sectional view taken along line III-III in Figure 1; Figure 4 is a schematic diagram of a weave cycle of the first embodiment; Figure 5 is a plan view of a second embodiment of the high-strength, abrasion-resistant, and weather-resistant geotextile of the present invention; Figure 6 is a cross-sectional view taken along line VI-VI in Figure 5; Figure 7 is a cross-sectional view taken along line VII-VII in Figure 5; Figure 8 is a schematic diagram of a weave cycle of a third embodiment of the high-strength, abrasion-resistant, and weather-resistant geotextile of the present invention; Figure 9 is a schematic diagram of a weave cycle of a fourth embodiment of the high-strength, abrasion-resistant, and weather-resistant geotextile of the present invention; Figure 10 is a schematic diagram of a weave cycle of a fifth embodiment of the high-strength, abrasion-resistant, and weather-resistant geotextile of the present invention; and Figure 11 is a schematic diagram of a weave cycle of a sixth embodiment of the high-strength, abrasion-resistant, and weather-resistant geotextile of the present invention.

Claims

1. A high-strength, abrasion-resistant, and weather-resistant geotextile fabric comprising: a plurality of warp units, each warp unit including at least one warp monofilament fiber; and a plurality of weft units interwoven with the warp units, each weft unit including at least one weft monofilament fiber, wherein the high-strength, abrasion-resistant, and weather-resistant geotextile fabric has a warp density of 20 to 600 warp monofilament fibers per inch, and each warp monofilament fiber having a fineness between 501 and 3000 denier, and a weft density of 150 to 2000 weft monofilament fibers per inch, and each weft monofilament fiber having a fineness between 50 and 1000 denier, wherein in one weave cycle, the ratio of the number of warp weave points to the total number of weave points is greater than 70%.

2. The high-strength, abrasion-resistant, and weather-resistant geotextile fabric as claimed in claim 1, wherein the density is further selected to contain 40 to 600 warp monofilaments per inch, and the fineness of each weft monofilament is further selected to be between 50 and 500 deniers.

3. The high-strength, abrasion-resistant, and weather-resistant geotextile fabric as described in claim 1, wherein the warp units and the weft units are interwoven into an m / n twill structure, and the ratio of m to n is greater than or equal to 3.

4. The high-strength, abrasion-resistant, and weather-resistant geotextile fabric as described in claim 1, with a water permeability greater than 40 L / m² / s (measured according to test standard ISO 11058).

5. The high-strength, abrasion-resistant, and weather-resistant geotextile fabric as described in claim 1, with a tensile strength between 100 kN / m and 400 kN / m (measured in accordance with test standards ISO 10319 or ASTM D4595).

6. A high-strength, abrasion-resistant, and weather-resistant geotextile fabric, comprising: a plurality of warp units and a plurality of weft units, each warp unit comprising at least one warp monofilament fiber, the weft units being interwoven with the warp units, each weft unit comprising at least one weft monofilament fiber, the high-strength, abrasion-resistant, and weather-resistant geotextile fabric having a warp density of 20 to 600 warp monofilament fibers per inch, and each warp monofilament fiber having a fineness between 501 and 3000 denier, and a weft density of 150 to 2000 weft monofilament fibers per inch, and each weft monofilament fiber having a fineness between 50 and 1000 denier, the warp units and the weft units being interwoven to form a p-p satin weave structure, where p is greater than or equal to 5.

7. A high-strength, abrasion-resistant, and weather-resistant geotextile fabric comprising: a plurality of warp units and a plurality of weft units, each warp unit comprising at least one warp monofilament fiber, the weft units being interwoven with the warp units, each weft unit comprising at least one weft monofilament fiber, the high-strength, abrasion-resistant, and weather-resistant geotextile fabric having a warp density of 20 to 600 warp monofilament fibers per inch, and each warp monofilament fiber having a fineness between 501 and 3000 denier, a weft density of 150 to 2000 weft monofilament fibers per inch, and each weft monofilament fiber having a fineness between 50 and 1000 denier, the characteristic aperture of the high-strength, abrasion-resistant, and weather-resistant geotextile fabric being between 0.075 mm and 0.4 mm (measured according to test standard ISO 12956).

8. A high-strength, abrasion-resistant, and weather-resistant geotextile fabric comprising: a plurality of warp units and a plurality of weft units, each warp unit comprising at least one warp monofilament fiber, the weft units being interwoven with the warp units, each weft unit comprising at least one weft monofilament fiber, the high-strength, abrasion-resistant, and weather-resistant geotextile fabric having a warp density of 20 to 600 warp monofilament fibers per inch, and each warp monofilament fiber having a fineness between 501 and 3000 denier, and a weft density of 150 to 2000 weft monofilament fibers per inch, and each weft monofilament fiber having a fineness between 50 and 1000 denier, the high-strength, abrasion-resistant, and weather-resistant geotextile fabric having an abrasion resistance greater than 90% (measured according to test standard ASTM D4886).

9. A high-strength, abrasion-resistant, and weather-resistant geotextile fabric, comprising: a plurality of warp units and a plurality of weft units, each warp unit comprising at least one warp monofilament fiber, the weft units being interwoven with the warp units, each weft unit comprising at least one weft monofilament fiber, the high-strength, abrasion-resistant, and weather-resistant geotextile fabric having a warp density of 20 to 600 warp monofilament fibers per inch, and each warp monofilament fiber having a fineness between 501 and 3000 denier, and a weft density of 150 to 2000 weft monofilament fibers per inch, and each weft monofilament fiber having a fineness between 50 and 1000 denier, the high-strength, abrasion-resistant, and weather-resistant geotextile fabric having a UV resistance intensity greater than 98% after 500 hours (measured according to test standard ASTM D4355) and a UV resistance intensity greater than 90% after 6000 hours (measured according to test standard ASTM D4355).

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