Integral polyethylene terephthalate grids, the method of manufacture, and uses thereof

Abstract

An integral polymer grid with a plurality of interconnected, oriented polyethylene terephthalate strands and an array of openings therein is made from a polyethylene terephthalate sheet-like starting material having holes or depressions therein that form the openings when the sheet-like material is uniaxially or biaxially stretched. The grid has a higher tensile strength to weight ratio and a higher creep reduced strength to weight ratio than corresponding ratios associated with a grid made from a non-polyethylene terephthalate starting material.

Claims

1. A polymer mesh structure comprising a substantially uniplanar integral geogrid having a plurality of highly oriented strands interconnected by partially oriented junctions forming an array of openings in said geogrid, said integral geogrid formed of polyethylene terephthalate and having (a) a tensile strength per unit of cross-sectional area of from approximately 63N/mm.sup.2 to approximately 384N/mm.sup.2 and (b) a creep strain at 60% loading which starts out at about 0.75% and does not exceed about 1.00% after 10,000 hours loading.

2. The polymer mesh structure according to claim 1, wherein the highly oriented polyethylene terephthalate strands have been uniaxially or biaxially stretched.

3. The polymer mesh structure according to claim 1, wherein the polyethylene terephthalate is a homopolymer or a copolymer.

4. The polymer mesh. structure according to claim 1, wherein the polyethylene terephthalate is selected from the group consisting of amorphous polyethylene terephthalate, crystalline polyethylene terephthalate, and polyethylene terephthalate glycol.

5. The polymer mesh structure according to claim 1, wherein the plurality of highly oriented polyethylene terephthalate strands includes oriented transverse strands and oriented longitudinal strands interconnected by partially oriented polyethylene terephthalate junctions.

6. The polymer mesh structure according to claim 1, wherein the integral geogrid is configured for structural or construction reinforcement purposes.

7. The polymer mesh structure according to claim 1, wherein the plurality of highly oriented polyethylene terephthalate strands are aligned in a longitudinal array by unilateral stretching and each aligned pair of the highly oriented strands are interconnected by a partially oriented polyethylene terephthalate junction aligned in a transverse bar.

8. The polymer mesh structure according to claim 1, wherein the polyethylene terephthalate has a creep strain at 70% loading which starts out at about 0.75% and does not exceed about 1.50% after 10,000 hours loading.

9. A starting material for making an integral polymer geogrid comprising a homogeneous polyethylene terephthalate substantially uniplanar material having holes or depressions therein that provide highly oriented polyethylene terephthalate strands interconnected by partially oriented junctions forming an array of grid openings, when the substantially uniplanar material is uniaxially or biaxially stretched, said integral polymer geogrid having (a) a tensile strength to weight ratio of from approximately 63N/mm.sup.2 to approximately 384N/mm.sup.2 and (b) a creep strain at 60% loading which starts out at about 0.75% and does not exceed about 1.00% after 10,000 hours loading.

10. The starting material according to claim 9, wherein the polyethylene terephthalate is crystalline polyethylene terephthalate.

11. The starting material according to claim 9, wherein the substantially uniplanar starting material has an initial thickness of at least 1.4 mm.

12. The starting material according to claim 11, wherein the substantially uniplanar starting material has an initial thickness of at least 3 mm.

13. The starting material according to claim 12, wherein the stretched substantially uniplanar starting material exhibits a substantially linear relationship between a stretch ratio and a specific tensile strength.

14. The starting material according to claim 9, wherein the polyethylene terephthalate has a creep strain at 70% loading which starts out at about 0.75% and does not exceed about 1.50% after 10,000 hours loading.

15. A soil construction comprising a mass of particulate material strengthened by embedding therein a polymer mesh structure as claimed in claim 1.

16. A method of strengthening a mass of particulate material, comprising embedding in the mass of particulate material a polymer mesh structure as claimed in claim 1.

17. A method of making a polymer mesh structure, comprising orienting a substantially uniplanar homogeneous polyethylene terephthalate starting material having holes or depressions therein into an integral geogrid having a plurality of highly oriented.[...]. polyethylene terephthalate strands interconnected by partially oriented junctions to configure the holes or depressions as mesh openings, said integral geogrid having (a) a tensile strength per unit of cross-sectional area of from approximately 63N/mm.sup.2 to approximately 384N/mm.sup.2 and (b) a creep strain at 60% loading which starts out at about 0.75% and does not exceed about 1.00% after 10,000 hours loading.

18. The method according to claim 17, wherein the substantially uniplanar polyethylene terephthalate starting material is oriented by uniaxial or biaxial stretching.

19. The method according to claim 17, wherein the polyethylene terephthalate is crystalline polyethylene terephthalate.

20. The method according to claim 19, wherein the substantially uniplanar polyethylene terephthalate starting material has an initial thickness of at least 3 mm.

21. The method according to claim 17, further comprising a step of manipulating a variable associated with the polyethylene terephthalate to improve resistance of the integral .[.geocrid.]. .Iadd.geogrid .Iaddend.to hydrolysis, the variable being selected from the group consisting of carboxyl end group, molecular weight, crystallinity, orientation, surface area, temperature, pH, and cation presence.

22. The method according to claim 17, wherein the polyethylene terephthalate has a creep strain at 70% loading which starts out at about 0.75% and does not exceed about 1.50% after 10,000 hours loading.

23. A method of providing a stabilized soil construction, comprising: .[.uniazially.]. .Iadd.uniaxially .Iaddend.or biaxially stretching a crystalline polyethylene terephthalate substantially uniplanar starting material having holes or depressions therein to form an integral geogrid having a plurality of highly oriented polyethylene terephthalate strands interconnected by partially oriented junctions which define a plurality of grid openings, said integral polymer geogrid having (a) a tensile strength per unit of cross-sectional area of from approximately 63N/mm.sup.2 to approximately 384N/mm.sup.2 and (b) a creep strain at 60% loading which starts out at about 0.75% and does not exceed about 1.00% after 10,000 hours loading; and embedding the integral geogrid in a mass of particulate material.

24. The method according to claim 23, wherein the polyethylene terephthalate has a creep strain at 70% loading which starts out at about 0.75% and does not exceed about 1.50% after 10,000 hours loading.

.Iadd.25. A substantially uniplanar integral geogrid formed by uniaxially or biaxially stretching and orienting a substantially uniplanar sheet-like material having an array of perforations or indentations, said substantially uniplanar integral geogrid comprising: a plurality of interconnected, oriented strands and partially oriented junctions having an array of openings therebetween, with the substantially uniplanar sheet-like material and the substantially uniplanar integral geogrid being made of polyethylene terephthalate..Iaddend.

.Iadd.26. The substantially uniplanar integral geogrid according to claim 25, wherein the polyethylene terephthalate substantially uniplanar sheet-like material is biaxially stretched and oriented to form the polyethylene terephthalate substantially uniplanar integral geogrid having molecularly oriented longitudinal strands and molecularly oriented transverse strands interconnected by the partially oriented junctions which define generally square or rectangular grid openings..Iaddend.

.Iadd.27. The substantially uniplanar integral geogrid according to claim 25, wherein the polyethylene terephthalate is a homopolymer or a copolymer..Iaddend.

.Iadd.28. The substantially uniplanar integral geogrid according to claim 25, wherein the polyethylene terephthalate is selected from the group consisting of amorphous polyethylene terephthalate, crystalline polyethylene terephthalate, and polyethylene terephthalate glycol..Iaddend.

.Iadd.29. The substantially uniplanar integral geogrid according to claim 25, wherein the polyethylene terephthalate substantially uniplanar sheet-like material is uniaxially stretched and oriented to form a generally square or rectangular grid of substantially parallel oriented strands and a set of substantially parallel bars generally at right angles to the strands, wherein an end of each of the strands is oriented into adjacent ones of said parallel bars. .Iaddend.

.Iadd.30. The substantially uniplanar integral geogrid according to claim 25, wherein the polyethylene terephthalate substantially uniplanar sheet-like material has an initial thickness of at least about 1.4 mm. .Iaddend.

.Iadd.31. The substantially uniplanar integral geogrid according to claim 25, wherein the polyethylene terephthalate strands include substantially transversely oriented strands interconnected by substantially longitudinally oriented strands..Iaddend.

.Iadd.32. A starting material for making a substantially uniplanar integral geogrid, said starting material comprising: a substantially uniplanar sheet-like material having holes or depressions therein that provides a plurality of interconnected, oriented strands and partially oriented junctions having an array of openings therebetween when the substantially uniplanar sheet-like material is uniaxially or biaxially stretched, with the substantially uniplanar sheet-like material being made of polyethylene terephthalate..Iaddend.

.Iadd.33. The starting material according to claim 32, wherein the stretched polyethylene terephthalate substantially uniplanar sheet-like material exhibits a substantially linear relationship between a stretch ratio and a specific tensile strength..Iaddend.

.Iadd.34. A method of making a substantially uniplanar integral geogrid, said method comprising: stretching and orienting a substantially uniplanar sheet-like material having holes or depressions therein to provide a plurality of interconnected, oriented strands and partially oriented junctions, and to configure the holes or depressions as geogrid openings, with the substantially uniplanar sheet-like material and the substantially uniplanar integral geogrid being made of polyethylene terephthalate..Iaddend.

.Iadd.35. The method according to claim 34, wherein the polyethylene terephthalate substantially uniplanar sheet-like starting material is oriented by uniaxial or biaxial stretching..Iaddend.

.Iadd.36. The method according to claim 34, wherein the polyethylene terephthalate is crystalline polyethylene terephthalate..Iaddend.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 illustrates a sample of a crystalline polyethylene terephthalate (CPET) grid according to one embodiment of the present invention in which the starting sheet was uniaxially stretched to a stretch ratio of 3.1:1.

(2) FIG. 2 is a creep test chart showing a creep curve for a CPET sample, initially 3 mm thick, which is uniaxially stretched to a stretch ratio of 5.3:1 and suspended under 60% loading.

(3) FIG. 3 is a creep test chart showing a creep curve for a CPET sample, also initially 3 mm thick, which is uniaxially stretched to a stretch ratio of 5.3:1, but suspended under 70% loading.

(4) FIG. 4 is a graph illustrating comparative creep curves for various polymeric geotextile materials under loading of 40% ultimate strength.

(5) FIG. 5 is a graph illustrating representative creep curves for filaments of various polymers.

(6) FIG. 6 is a table summarizing the tensile test results of the various polymeric samples tested.

(7) FIG. 7 is a chart illustrating the specific strength of the samples shown in FIG. 6.

(8) FIG. 8 is a table summarizing the specific strength of certain representative samples shown in FIG. 7.

(9) FIG. 9 is a chart summarizing the specific strength of the representative samples shown in FIG. 8.

(10) FIG. 10 is a table summarizing the effect of the stretch ratio on the specific strength of a PET sample.

(11) FIG. 11 is a graph depicting the effect of the stretch ratio on the specific strength summarized in FIG. 10.

(12) FIG. 12 is a creep test chart showing a creep curve for a CPET sample, initially 1.4 mm thick, which is stretched to a stretch ratio of 4.25:1 and suspended under 60% loading.

(13) FIG. 13 is a table summarizing basic properties of various polymers typically used to produce staple fibers, continuous filaments, and oriented tapes.

(14) FIG. 14 is a table summarizing the relative chemical resistance of various fiber-forming polymers used in geotextiles.

(15) FIG. 15 is a table summarizing the effect of pH on the tensile strength of various geotextile polymers.

(16) FIG. 16 illustrates a substantially uniplanar biaxial integral geogrid as shown for a composite of FIGS. 3 and 5 of U.S. Pat. No. 4,374,798.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(17) Although only preferred embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its scope to the details of construction and arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways.

(18) Also, in describing the preferred embodiments, terminology will be resorted to for the sake of clarity. It is intended that each term contemplates its broadest meaning as understood by those skilled in the art, and includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.

(19) In order to understand the behavior and properties of the PET material, and to establish the parameters of using PET to make integral grids, instead of HDPE, standard commercially available extruded sheets of PET were procured. Three types of PET sheets were used: amorphous PET (“APET”), crystalline PET (“CPET”), and PET glycol (“PETG”).

(20) Punched samples for each of the three types of PET sheet were prepared with standard sheet punches such as those used to manufacture HDPE UX products sold by the Tensar International Corporation, Inc. (hereinafter “Tensar”) (Atlanta, Ga.), the assignee of the instant provisional application for patent. For example, FIG. 1 shows a CPET starting sheet sample prepared using a punch (1.53″×0.375″) and uniaxially stretched to a stretch ratio of 3.1:1.

(21) The punched sheet uniaxial stretching was performed on a Tensar laboratory stretcher. Tensar carried out initial laboratory work in accordance with the present invention by stretching narrow strips, i.e., from 2 mm to 4 mm wide, of PET and HDPE to establish the temperature and stretch ratio conditions under which the testing would be conducted. The temperature range was established to be between 100° C. and 240° C., and the stretch ratio range to be between 2:1 and 10:1. These temperature and stretch ratio conditions were then used during stretching of the approximately 8″×10″ punched samples.

(22) For high temperature stretching, i.e., above 160° C., an Instron “Hot-Box” was installed on an Instron Model 1125 tensile testing machine. Standard “dog bone”-shaped samples of CPET, having an initial thickness of 3 mm, were heated to, and then conditioned at, 180° C. for 15 minutes. The heat-conditioned samples were then uniaxially stretched in the lab stretcher in accordance with standard stretching protocols used by Tensar. The samples were stretched to the maximum stretch ratio that was allowed by the size of the Hot-Box, i.e., a ratio of 5.3:1. These 5.3:1 samples were then tested for both tensile and creep properties.

(23) The unstretched and stretched strips and ribs from the 8″×10″ samples were tested for tensile properties on an Instron Model 1125 tensile testing machine using serrated pneumatic grips. The testing grips were padded with cardboard and/or sandpaper to prevent slippage and edge break. The tensile data was normalized for the difference in sheet thickness between the HDPE and the PET by dividing the tensile results by the initial cross-sectional area of the test specimen (i.e., the resultant tensile data has the units of N/mm.sup.2). This normalization enabled a material-to-material comparison without the need to standardize the physical dimensions of the test specimens.

(24) Finally, a strength to basis weight comparison was made between standard Tensar HDPE UX products and the 8″×10″ PET punched and stretched samples.

(25) For creep testing, the 5.3:1 stretch ratio samples were suspended under a load at room temperature in a quality control laboratory. One sample was suspended under a load corresponding to 60% of ultimate tensile strength (FIG. 2), and a second sample was suspended under a load corresponding to 70% of ultimate tensile strength (FIG. 3).

(26) Tensile strength test data associated with the aforementioned 5.3:1 stretch ratio samples is presented in FIGS. 6 and 7. A summary of representative data from FIGS. 6 and 7 is presented in FIGS. 8 and 9. FIG. 8 presents representative specific strength values for each type of polymer at unstretched and maximum stretch ratio conditions.

(27) Since the 3 mm thick CPET starting sheet provided the maximum specific strength among the samples summarized in FIGS. 6-8, samples of the 3 mm CPET starting sheet were uniaxially stretched at various ratios of from 3.1:1 to 5.3:1. These results are shown in FIGS. 10 and 11. From this data it is evident that for the 3 mm CPET starting sheet there exists a substantially linear relationship between stretch ratio and specific tensile strength (see FIG. 11).

(28) As is evident from the results presented herein, CPET is a good candidate for the manufacture of extruded and uniaxially stretched integral grids because of a higher specific strength and better creep characteristics. At comparable stretch ratios, CPET exhibits almost double the specific strength of HDPE. That is, as is evident from FIG. 8, sample HDPE 2 (initial thickness of 2.9 mm) has a specific strength of 163 N/mm.sup.2, while sample CPET 4 (initial thickness of 3 mm) has a specific strength of 373 N/mm.sup.2.

(29) Since APET starting sheets crystallize during the heated stretching operation, APET starting sheets can achieve a specific strength similar to that of HDPE. But, the required crystallization associated with the heated stretching of APET starting sheets makes the process slow and more expensive. Hence, CPET starting sheets are clearly preferred for the present invention.

(30) The PETG starting sheets did not show any significant difference between unstretched and stretched samples even at a stretch ratio of 8.5:1.

(31) As is evident from FIGS. 2 and 3, the first 5600 hrs of creep data show that there is minimal strain associated with the CPET samples. That is, the strain is only 0.78% at 60% loading, and 1.34% at 70% loading.

(32) Another test demonstrated the ability to prepare a grid from a CPET sheet having an initial thickness of 1.4 mm. The sample was first punched, then stretched to a stretch ratio of 4.25:1, and finally placed under a loading of 60% of ultimate tensile strength. As is evident from FIG. 12, creep data for the 1.4 mm sample for the first 2000 hours shows a strain of only about 2.4%.

(33) The inventive polymer mesh structure has been described herein primarily in the context of being one that is uniaxially oriented, i.e., as being produced via uniaxial stretching of the punched starting material so as to form a uniaxial integral mesh structure.

(34) However, in yet another possible embodiment of the invention, the polymer mesh structure is one that is biaxially oriented. That is, in this embodiment of the invention, the substantially uniplanar starting material is biaxially stretched, i.e., first in the machine direction and then in the transverse direction, so as to form a biaxial integral mesh structure. As indicated above in the Background section, such a biaxial orientation method is disclosed in certain of the above-described patents, such as U.S. Pat. No. 4,374,798 to Mercer et al. (“Mercer '798”). See, for example, FIG. 16 of the instant application, which illustrates a substantially uniplanar biaxial integral geogrid as shown for a composite of FIGS. 3 and 5 of the Mercer '798 patent. Accordingly, the instant invention is also directed to a biaxially oriented mesh structure having the polyethylene terephthalate integral geogrid.

(35) While the integral PET grid according to the present invention exhibits the above-described advantageous characteristics, PET in general can be susceptible to hydrolysis during wet processing and in end use. PET is hydrolyzed by certain acids and by all strong bases, including some organic bases. The factors that can affect this hydrolysis include carboxyl end group (“CEG”), molecular weight, crystallinity, orientation, surface area, temperature, pH level, and the presence of cations. See FIG. 14, which summarizes the relative chemical resistance of various fiber-forming polymers used in geotextiles, and FIG. 15, which summarizes the effect of pH on the tensile strength of various geotextile polymers.

(36) For example, one literature source has proposed that PET hydrolysis is proportional to the square root of the CEG concentration. I. M. Ward, Mechanical Properties of Solid Polymers, Wiley Interscience, New York, 1971. Molecular weight inversely affects the CEG concentration. Hence, a higher molecular weight PET will be less susceptible to hydrolysis. Orientation can also lessen the hydrolytic effect in that it reduces the diffusion rate of the penetrant.

(37) Thus, while there are no specific additives that can retard hydrolysis in PET materials, one or more of the aforementioned variables of CEG, molecular weight, crystallinity, orientation, surface area, temperature, pH, and the presence of cations can be manipulated to improve resistance to hydrolysis.

(38) The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes may readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation described and shown.