Patent Publication Number: US-2015086279-A1

Title: Earthwork basket with synthetic turf facing

Description:
TECHNICAL FIELD 
     The present invention relates generally to building, shoring, drainage and flood control structures and, in particular, to these structures having at least one side covered with synthetic turf. 
     BACKGROUND 
     As described in U.S. Pat. No. 5,472,297, certain structures are known by the name “gabions” and comprise essentially wire mesh cages having a block shape, which are filled with rock, stone, rubble and the like. Although such gabions are made up of wire mesh cages filled with stone and other rubble, in effect they often function like solid blocks which can be used for building, for shorings for hillsides, for sea walls and the like, for walls and for other purposes. 
     U.S. Pat. No. 5,472,297 also describes that such gabions can be filled with a much looser particulate as compared to being filled with rock. That patent describes that the filling material can be sand, concrete, ash, soil colliery waste and small particular aggregate. The patent also describes that to use the loose particulate material, the interior of at least some of the gabion is lined with flexible sheet material, and the cage is filled with a particulate of a nature which, but for the lining, would pass through the meshes of the cage. 
     Such prior art arrangements generally suffer from being unsightly due to the exposed flexible sheet material (geotextile or sheet film). They also suffer from having a limited life, as UV radiation tends to break down the flexible sheet material (geotextile or sheet film), leading to premature failure. 
     SUMMARY 
     Generally described, the present invention relates to earthwork basket-like structures utilizing synthetic turf to improve weatherability (longevity in spite of being exposed to wind, rain, and sun) and to improve the visual aesthetics. These earthwork baskets are typically made of wire or mesh cage or a basket and have common industry names of gabion, gabion mattress, gabion basket, reno mattress, or concentainer. These earthwork baskets are typically used for applications involving flood control, flood barriers, retaining walls, walls and barriers, drainage channels, grade control, erosion control, shoreline and coastal protection, and slope reinforcement. 
     In a first example embodiment, the present invention comprises an earthwork basket including a multi-sided wire or mesh cage or basket which optionally can be erected from a flat, folded configuration to an erect, fillable configuration. The earthwork basket also includes a liner for lining at least part of the multi-sided cage. Preferably, the liner is made from a synthetic turf comprising a backing and a plurality of synthetic grass blades tufted into and extending from the backing. In example forms, the backing is comprised of one or more geotextile(s), which optionally may be coated to increase tuft bind. Preferably, the synthetic turf is placed along at least one side of the multi-sided cage. In example embodiments, the synthetic turf is placed along one side or face of the cage, while in other embodiments the synthetic turf is placed along multiple sides or faces of the cage. 
     The earthwork basket can take various shapes, such as cylindrical, cubic, brick, block, triangular, oval, L-shaped, V-shaped, etc. In one form, the multi-sided cage has 2 sides. In a preferred form, the multi-sided cage has 6 sides. 
     Preferably, the synthetic turf faces outwardly from the multi-sided cage and optionally the synthetic turf is positioned along multiple sides of the multi-sided cage. Preferably, the synthetic turf is installed on the inside face(s) of the multi-sided cage and optionally the synthetic turf is installed on the outside face(s) of the multi-sided cage. 
     Optionally, one or more sides of the multi-sided cage can be lined with a geotextile and/or sheet film liner. Thus, the synthetic turf need not be used on every face or side of the cage, although it can be so used if desired. 
     In another example embodiment, the present invention relates to a bundle of earthwork basket-like blocks including a plurality of earthwork basket-like blocks mechanically fastened to one another to form a bundle. Each earthwork basket-like block has a wire or mesh cage or basket structure optionally erectable from a folded configuration to an erect fillable configuration and a liner for containing loose fill material within the earthwork basket-like block. The liner includes a synthetic turf positioned along at least one portion of the earthwork basket-like block, with the synthetic turf including a synthetic backing and a plurality of synthetic blades tufted to and extending from the synthetic backing. Preferably, the synthetic turf is oriented in the earthwork basket-like block so that the synthetic blades extend and face outwardly from the earthwork basket-like block. 
     The specific techniques and structures employed to improve over the drawbacks of the prior devices and accomplish the advantages described herein will become apparent from the following detailed description of example embodiments and the appended drawings and claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an earthwork basket according to a first example embodiment of the present invention, showing synthetic turf along one face portion thereof. 
         FIG. 2  is a plan view of the earthwork basket of  FIG. 1 , showing an optional geotextile liner or film sheet liner along another face portion of the earthwork basket. 
         FIG. 3  is a plan view of another earthwork basket according to another example embodiment of the present invention, showing a synthetic turf liner along four face portions of the earthwork basket. 
         FIG. 4  is a plan view of another earthwork basket according to another example embodiment of the present invention, showing a pair of earthwork baskets according to  FIG. 1  mechanically fastened to one another to form a larger building structure. 
         FIG. 5  is a perspective view of another earthwork basket according to yet another example embodiment of the present invention, showing three earthwork baskets fastened together and a synthetic turf liner along front face portions of the earthwork baskets. 
         FIG. 6  is a perspective view of another earthwork basket according to another example embodiment of the present invention, showing an angular V-shaped earthwork basket and a synthetic turf liner along a front face portion thereof. 
         FIG. 7  is a perspective view of another earthwork basket according to another example embodiment of the present invention, showing an angular L-shaped earthwork basket and a synthetic turf liner along a front face portion thereof. 
         FIG. 8  is a perspective view of another earthwork basket according to another example embodiment of the present invention, showing a block-like triangular prism-shaped earthwork basket and a synthetic turf liner along a front face portion thereof. 
         FIG. 9  is a perspective view of another earthwork basket according to another example embodiment of the present invention, showing an earthwork basket having multiple sections and having a synthetic turf liner along a front face portion thereof. 
         FIG. 10  is a perspective view of another earthwork basket according to another example embodiment of the present invention, showing an earthwork basket having multiple sections and having a synthetic turf liner along a front face portion thereof. 
         FIG. 11  is a perspective view of another earthwork basket according to another example embodiment of the present invention, showing an earthwork basket having multiple sections and having a synthetic turf liner along a front face portion thereof. 
     
    
    
     DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS 
     Generally described, the present invention relates to earthwork basket constructions for preventing erosion on flood control structures, channels, and slopes; for providing reinforcement to walls and slopes; and for creating a barrier.  FIGS. 1-2  show an earthwork basket  10  according to a first example embodiment of the present invention. The earthwork basket  10  generally includes a multi-sided wire or mesh cage or basket  20  and a liner  30  for lining at least a part of the basket  20 . As depicted in  FIG. 1 , the liner  30  is placed on one face of the basket  20 . In one form, the liner  30  is made from a synthetic turf comprising a backing and a plurality of synthetic grass blades tufted into and extending from the backing. U.S. Patent Application No. 2012/0063854, U.S. Patent Application No. 2012/0064262, and U.S. Patent Application No. 2012/0064263 show examples of synthetic turf and are incorporated by reference herein in their entirety. In example forms, the backing of the liner  30  comprises one or more geotextile(s), which may be coated to increase tuft bind. 
     In example embodiments, the earthwork basket  10  is filled with rock, gravel, soil materials, sand, shredded tires, ash, soil colliery waste, small particular aggregate, other loose material, or cementitious material. In one preferred form, the earthwork basket is filled with soil. Preferably, when the earthwork basket  10  is filled with soil, the liner  30  is utilized to contain the soil within the basket  20 . Optionally, an additional secondary liner  40  can be provided along one or more faces of the basket  20  as desired. For example, as depicted in  FIG. 2 , the earthwork basket  10  has a first face comprising the liner  30  (e.g., synthetic turf) and a second face (generally opposite the first face) comprising the secondary liner  40 . In example forms, the secondary liner  40  can be in the form of a geotextile and/or sheet film liner that is preferably UV resistant and substantially durable. Optionally, the secondary liner  40  can be provided in addition to the liner  30  or can be omitted. 
     In example forms, the basket  20  can be constructed from steel, galvanized steel, zinc-coated steel, stainless steel, PVC-coated steel, aluminum, fiberglass, or polymeric material. Generally, the basket  20  has junctions that are welded, fused, single twisted, double twisted, or woven together. In typical forms, the basket is double twisted or welded together. Preferably, the earthwork basket  10  can take various shapes, such as cylindrical, cubic, brick, block, triangular, oval, L-shaped, V-shaped, and various other shapes as desired. Preferably, the basket  20  can be erected from a flat, folded configuration to an erect, fillable configuration. Preferably, the synthetic turf is affixed to the one or more faces of the basket  20  by heat bonding, adhesive bonding, stitching or sewing, mechanical fasteners, or combinations thereof. 
     Preferably, the earthwork basket  10  is modular and is capable of being stacked on top of another earthwork basket  10 . Optionally, the earthwork basket  10  can be placed side-by-side or butted end-to-end with one or more additional earthwork baskets  10 . 
       FIG. 3  shows an earthwork basket  100  according to another example embodiment of the present invention. As depicted, the earthwork basket  100  comprises a mesh basket  120  and a liner  130  (i.e., synthetic turf) affixed to four faces of the basket  120 . Optionally, all six faces can carry the liner  130 . 
       FIG. 4  shows a bundle of earthwork baskets  200  according to another example embodiment of the present invention. As depicted, the bundle  200  comprises two earthwork baskets. Preferably, each earthwork basket comprises a mesh basket  220 , at least one face thereof comprising a liner  230  (i.e., synthetic turf) and at least one face comprising a secondary liner  240 . Preferably, the baskets  220  are affixed to one another with fasteners  250 . The fasteners  250  can be in the form of rings, wire, ties, spiral binders, or other available fasteners. 
       FIG. 5  shows a bundle of earthwork baskets  300  according to another example embodiment of the present invention. As depicted, the bundle  300  is substantially similar to the bundle  200  and comprises three mesh baskets  320 . At least one face of each basket  320  has a liner  330  (i.e., synthetic turf) affixed thereon. Similarly, the baskets  320  are affixed to one another with fasteners. Optionally, one or more additional earthwork baskets can be affixed to the bundle  300  as desired. 
       FIG. 6  shows an earthwork basket  400  according to another example embodiment of the present invention. As depicted, the earthwork basket  400  is in the form of an angular basket that is generally V-shaped. Generally, the earthwork basket  400  comprises a mesh basket  420  (comprising two sides) and a liner  430  (i.e., synthetic turf) affixed to at least one side thereof. As similarly described above, fasteners can be used to affix one or more earthwork baskets  400  together as desired. 
       FIG. 7  shows an earthwork basket  500  according to another example embodiment of the present invention. As depicted, the earthwork basket  500  is in the form of an angular basket that is generally L-shaped. Generally, the earthwork basket  500  comprises a mesh basket  520  (comprising two sides) and a liner  530  (i.e., synthetic turf) affixed to at least one side thereof. As similarly described above, fasteners can be used to affix one or more earthwork baskets  500  together as desired. 
       FIG. 8  shows an earthwork basket  600  according to another example embodiment of the present invention. As depicted, the earthwork basket  600  is in the form of a block-like basket that is shaped similarly to a triangular prism. Generally, the earthwork basket  600  comprises a mesh basket  620  (comprising three sides) and a liner  630  (i.e., synthetic turf) affixed to at least one side thereof. As similarly described above, fasteners can be used to affix one or more earthwork baskets  600  together as desired. 
       FIGS. 9-11  show earthwork baskets  700 ,  800 ,  900  according to additional example embodiments of the present invention. As depicted, each earthwork basket  700 ,  800 ,  900  generally comprises a mesh basket  720 ,  820 ,  920  that is divided into multiple sections and a liner  730 ,  830 ,  930  (i.e., synthetic turf) affixed to at least one side thereof. As similarly described above, fasteners can be used to affix one or more earthwork baskets  700 ,  800 ,  900  together as desired. As depicted in  FIG. 9 , the earthwork basket  700  is divided into five sections. As depicted in  FIG. 10 , the earthwork basket is divided into four sections. As depicted in  FIG. 11 , the earthwork basket is divided into three sections. Optionally, the earthwork baskets  700 ,  800 ,  900  can have fewer than three sections or more than five sections, as desired. 
     Optionally, the synthetic turf comprises synthetic blade-like elements tufted into a synthetic backing. Preferably, the synthetic turf is used as a principal component of the system. It can be constructed using a knitting machine or tufting machine that may use, for example, over 1,000 needles to produce a turf width of about 15 feet. Preferably, the synthetic turf includes synthetic grass blades which comprise polyethylene monofilament and/or slit-film fibrillated and non-fibrillated fibers tufted to have a blade length of between about 0.5 inches and 4 inches. Other polymers can be used for the synthetic grass blades, as desired. Preferably, the synthetic grass blades are tufted to have a blade length of between about 1.5 inches and 3 inches. Most preferably, the synthetic grass blades are tufted to have a blade length of about 1.5 inches. Optionally, the synthetic grass blades are tufted to have a density of between about 20 ounces/square yard and about 120-ounces/square yard. Preferably, the synthetic grass blades have a thickness of at least about 100 microns. 
     The synthetic grass blades are tufted into the substrate or backing comprising a synthetic woven or non-woven fabric. Moreover, this backing can be a single-ply backing or can be a multi-ply backing, as desired. Optionally, the backing fabric may be coated to increase the tuft bind resistance. 
     The chemical composition of the synthetic turf components should be selected to resist degradation by exposure to sunlight, which generates heat and contains ultraviolet radiation. The polymer yarns should not become brittle when subjected to low temperatures. The selection of the synthetic grass color and texture should be aesthetically pleasing. 
     The grass-like components preferably consist of green or tan polyethylene fibers  41  of about 1.5 to about 2.5 inches in length tufted into a woven or non-woven fabric. For added strength, an additional fabric component backing can be tufted for improving dimensional stability. The polyethylene grass filaments  41  preferably have an extended operational life of at least 15 years. 
     Advantageously, the earthwork basket construction according to the present invention provides a good barrier from flooding and other threats, good protection against erosion in flood control and drainage structures, and good reinforcement of walls and slopes. The present earthwork basket construction has good durability, low-cost, excellent erosion control and water control, and a rather natural, pleasant appearance. 
     It is to be understood that this invention is not limited to the specific devices, methods, conditions, or parameters of the example embodiments described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only. Thus, the terminology is intended to be broadly construed and is not intended to be unnecessarily limiting of the claimed invention. For example, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include the plural, the term “or” means “and/or,” and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. In addition, any methods described herein are not intended to be limited to the sequence of steps described but can be carried out in other sequences, unless expressly stated otherwise herein. 
     While the claimed invention has been shown and described in example 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 defined by the following claims.