US 12,139,870 B2
Multilayer integral geogrids having a cellular layer structure, and methods of making and using same
Joseph Cavanaugh, Cumming, GA (US); Manoj Kumar Tyagi, Fayetteville, GA (US); Daniel Mark Baker, Broomfield, GA (US); Andrew Curson, Burnley (GB); Tom-Ross Jenkins, Balldon (GB); Andrew Edward Waller, Newton Le Willows (GB); and Daniel John Gallagher, Adlington (GB)
Assigned to TENSAR INTERNATIONAL CORPORATION, Alpharetta, GA (US)
Filed by Tensar International Corporation, Alpharetta, GA (US)
Filed on Jul. 26, 2023, as Appl. No. 18/359,120.
Application 18/359,120 is a division of application No. 17/557,504, filed on Dec. 21, 2021, granted, now 11,753,788.
Claims priority of provisional application 63/154,209, filed on Feb. 26, 2021.
Claims priority of provisional application 63/154,588, filed on Feb. 26, 2021.
Prior Publication US 2024/0026628 A1, Jan. 25, 2024
This patent is subject to a terminal disclaimer.
Int. Cl. B29C 48/21 (2019.01); B29C 48/30 (2019.01); B32B 3/26 (2006.01); B32B 5/18 (2006.01); B32B 27/08 (2006.01); B32B 27/32 (2006.01); B32B 37/16 (2006.01); E02D 3/00 (2006.01); E02D 17/02 (2006.01); E02D 17/20 (2006.01); E02D 29/02 (2006.01)
CPC E02D 17/202 (2013.01) [B29C 48/21 (2019.02); B29C 48/30 (2019.02); B29C 48/304 (2019.02); B32B 3/266 (2013.01); B32B 5/18 (2013.01); B32B 27/08 (2013.01); B32B 27/32 (2013.01); B32B 37/16 (2013.01); E02D 3/005 (2013.01); E02D 17/02 (2013.01); E02D 29/02 (2013.01); B32B 2250/24 (2013.01); B32B 2250/40 (2013.01); B32B 2264/104 (2013.01); B32B 2307/518 (2013.01); B32B 2307/732 (2013.01); E02D 2300/0006 (2013.01); E02D 2300/0084 (2013.01)] 8 Claims
OG exemplary drawing
 
1. A method of making a multilayer integral geogrid for interlocking with, stabilizing, and strengthening a soil or aggregate, said method comprising:
providing a multilayer polymer sheet having a plurality of layers each of a polymeric material, with at least a first outer layer and a second outer layer of the plurality of layers having an expansion structure capable of forming a cellular structure in the first and second outer layers of the multilayer integral geogrid;
providing a patterned plurality of holes or depressions in the multilayer polymer sheet; and
biaxially orienting the multilayer polymer sheet having the patterned plurality of holes or depressions therein to provide a plurality of interconnected oriented strands and partially oriented junctions forming a repeating pattern of outer hexagons having an array of openings therein,
supporting ribs extending inwardly from each of the outer hexagons to support inside each of the outer hexagons a smaller inner hexagon having an open center and oriented strands and tri-nodes, each of the tri-nodes interconnecting only one of the supporting ribs and two of the oriented strands of the inner hexagon,
the outer hexagons, the supporting ribs and the inner hexagons defining three different geometric configurations which are repeating throughout an entirety of the integral geogrid, and
the oriented strands and the partially oriented junctions of the outer hexagons defining a plurality of linear strands that extend continuously throughout the entirety of the integral geogrid,
so as to provide the biaxially oriented integral geogrid with at least a first cellular outer layer and a second cellular outer layer configured to improve an initial interaction between, and compatibility of the soil or aggregate with, the integral geogrid, so as to maximize soil or aggregate density and properties after compaction.