Geotextiles Configured for Moisture Management

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. Provisional Ser. No. 63/728,065 filed Dec. 4, 2024, U.S. Provisional Ser. No. 63/730,841 filed Dec. 11, 2024, and U.S. Provisional Ser. No. 63/733,816 filed Dec. 13, 2025. The entire disclosures of the above applications are incorporated herein by reference.

FIELD

The present disclosure relates to geotextiles configured for moisture management.

BACKGROUND

This section provides background information related to the present disclosure which is not necessarily prior art.

Moisture accumulation in pavement systems leads to loss of subgrade modulus, pumping, localized softening, and accelerated pavement failure. Extended saturation increases time-to-drain and weakens base and subgrade layers. Frost heave further exacerbates damage when water within frost-susceptible soils freezes, expands, lifts pavement, and then softens again during thaw cycles. Traditional woven geotextiles lack the ability to actively transport moisture laterally under load and therefore cannot mitigate moisture-driven deterioration mechanisms.

DRAWINGS

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations and are not intended to limit the scope of the present disclosure.

FIG. 1 illustrates dual-mode moisture transport mechanisms implemented in and/or achievable in exemplary embodiments of the present disclose. As shown, the dual-mode moisture transport mechanisms include micro-scale capillary wicking and macro-scale hydraulic flow. The smaller arrow indicates water movement along the yarn surfaces, thus representing micro-scale capillary wicking. The larger arrow indicates conduit-like water transport, thus representing macro-scale hydraulic flow.

FIG. 2 illustrates example hollow yarns (e.g., cylindrical tubes with internal lumen, etc.), a cord-based geotextile (e.g., braided cord structure, monofilament yarn, DREF or friction spun yarn, etc.), and geogrid (e.g., geogrid including high-denier PET-filaments, etc.) that may be used in exemplary embodiments disclosed herein to achieve the dual-mode moisture transport mechanisms shown in FIG. 1.

FIG. 3 illustrates the example hollow yarns, cord-based geotextile, and geogrid shown in FIG. 2 along with arrows representing moisture movement. The larger arrows indicate hydraulic “conduit” flow. And the smaller arrows represent wicking ..

FIG. 4 illustrates an exemplary “hollow-yarn” geotextile (e.g., including hollow yarns/fibers/tubing, etc.) installed between a subbase and subgrade of a roadway system according to exemplary embodiments of the present disclosure. The “hollow-yarn” geotextile permits moisture ingress through moisture-permeable exteriors of the hollow yarns and into the hollow interiors of the hollow yarns, whereby the moisture is transportable internally along the hollow yarns toward a drainage zone. The “hollow-yarn” geotextile may also function as a lateral drainage layer, reduce time-to-drain of the subbase layer, mitigate frost heave by redistributing pore water prior to freeze conditions, and provide dual-mode moisture transport including capillary wicking and hydraulic conductivity.

FIG. 5 illustrates an exemplary “cord-based” geotextile (e.g., including monofilament yarn, DREF or friction spun yarn, and/or braided cord, etc.) installed between a subbase and subgrade of a roadway system according to exemplary embodiments of the present disclosure. The geotextile includes monofilament yarn, DREF or friction spun yarn, and/or braided cord that define moisture movement channels configured to transfer, convey, or transport moisture along the length of the monofilament yarn, DREF or friction spun yarn, and/or braided cord. The geotextile may also function as a lateral drainage layer, reduce time-to-drain of the subbase layer, mitigate frost heave by redistributing pore water prior to freeze conditions, and provide dual-mode moisture transport including capillary wicking and hydraulic conductivity.

FIG. 6 illustrates an exemplary geogrid (e.g., geogrid including high-denier PET-filaments, etc.) installed between a subbase and subgrade of a roadway system according to exemplary embodiments of the present disclosure. The geogrid may also function as a lateral drainage layer, reduce time-to-drain of the subbase layer, mitigate frost heave by redistributing pore water prior to freeze conditions, and provide dual-mode moisture transport including capillary wicking and hydraulic conductivity.

FIG. 7 includes a line graph of Horizontal Flow Rate in liters per day (L/m/day) versus Overburden Pressure in kilopascals (kPa) from 2% gradient flow rate comparative testing of exemplary “hollow-yarn” geotextile fabrics (labeled H0.5, H1, H2, and D1) including hollow tubing inserted therein according to exemplary embodiments and a control woven geotextile fabric having a plain weave without any hollow tubing.

FIG. 8 includes a line graph of Horizontal Flow Rate in liters per day (L/m/day) versus Overburden Pressure in kilopascals (kPa) from 0% gradient flow rate comparative testing of exemplary “hollow-yarn” woven geotextile fabrics (labeled H0.5, H1, H2, D2, and D1) including hollow tubing (e.g., yarns/fibers/tubing, etc.) inserted therein according to exemplary embodiments and a control woven geotextile fabric having a plain weave without any hollow tubing.

FIG. 9 includes a line graph of Wet Front Movement in inches versus Time in minutes (min) from horizontal wicking—ASTM C1559 (modified) comparative testing of exemplary “cord-based” geotextile fabrics (labeled WD22 AAL and DREF2) including engineered fill yarns (e.g., monofilament yarn, DREF or friction spun yarn, braided cord, etc.) according to exemplary embodiments and a control geotextile (labeled WD 22) without any engineered fill yarn.

FIG. 10 includes a line graph of Height in inches versus Time in minutes (min) Overburden Pressure in kilopascals (kPa) from vertical wicking-ASTM C1559 (modified) comparative testing of exemplary “cord-based” geotextile fabrics (labeled DREF1 and FB) including engineered fill yarns (e.g., monofilament yarn, DREF or friction spun yarn, braided cord, etc.) according to exemplary embodiments and a control geotextile (labeled WD 22) without any engineered fill yarn.

FIG. 11 includes a line graph of Horizontal Flow Rate in liters per day (L/m/day) versus Overburden Pressure in kilopascals (kPa) from 2% gradient flow rate comparative testing (ASTM D4716) of an exemplary geogrid (e.g., geogrid including high-denier PET-filaments, etc.) including ribs defining moisture movement channels according to exemplary embodiments and a control geotextile that did not include moisture movement channels defined by ribs.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference to the accompanying drawings.

“Hydraulic stabilization” may be used to describe pavement performance improvements achieved through moisture control rather than traditional mechanical reinforcement. Disclosed herein are exemplary embodiments of geotextile systems and geogrid systems that have demonstrated hydraulic stabilization effects and that actively produce the advantageous effects of hydraulic stabilization. The disclosed exemplary geotextile systems and geogrid systems provide engineered structural pathways that enhance moisture movement, accelerate drainage, and preserve subgrade integrity, which are useful for directly supporting hydraulic stabilization within roadway systems.

1. Governing Mechanism: Moisture Management

Testing has demonstrated that enhanced roadway performance is not attributable solely to geosynthetic tensile reinforcement, confinement, or strength at low strain levels. Rather another contributor is moisture management, which includes the control of water, redistribution of water, and removal of water from within pavement layers and subgrade soils. Moisture-driven deterioration—such as softening, modulus loss, pumping, and freeze-thaw damage—is substantially reduced or mitigated when water is rapidly evacuated or removed from critical zones.

In exemplary embodiments disclosed herein (e.g., “hollow-yarn” geotextiles, “cord-based” geotextiles, geogrids, etc.), moisture transport occurs through two distinct mechanisms: capillary wicking and hydraulic conductivity.

A. Capillary Wicking

Capillary wicking is the primary moisture transport mechanism in the disclosed exemplary embodiments of “cord-based” geotextiles, which may include DREF/friction-spun yarns, braided cords, engineered monofilaments, etc. Capillary wicking may also be the primary moisture transport mechanism in the disclosed exemplary embodiments of geogrids, which may be constructed from very high-denier polyethylene terephthalate (PET) continuous filament yarns, etc.

Capillary wicking is driven by capillary attraction between filaments or along engineered yarn surfaces. Capillary wicking occurs in both the machine direction (MD) and cross-machine direction (CD) in the disclosed geogrids (e.g., PET-filament geogrids, etc.). Preliminary evidence highly suggests similar behavior in cord-based geotextiles (e.g., geotextiles including DREF/friction-spun yarns, braided cords, engineered monofilaments, etc.) and in the geogrid formation. Wicking pathways are preserved and remain functional under compaction due to structurally stable cords or hollow-yarn (tubes) architectures.

B. Hydraulic Conductivity

Hydraulic conductivity is the primary moisture transport mechanism in the disclosed exemplary embodiments of “hollow-yarn” geotextiles, which include hollow yarns/fibers/tubing (broadly, hollow members or tubular elements). Hydraulic conductivity is still present with the “cord-based” geotextiles and geogrids disclosed herein. But hydraulic conductivity is a secondary moisture transport mechanism as capillary wicking is the primary moisture transport mechanism for “cord-based” geotextiles and geogrids disclosed herein.

Hydraulic conductivity occurs and is enabled by internal geometries of the yarns, cords, or filament bundles that preserve interstitial voids internal to the fabric. The interstitial voids are capable of carrying water and permit water transport through the fabric plane analogous to geocomposite behavior. In exemplary embodiments, the geotextile fabric includes hollow yarns/fibers/tubing that function as miniature conduits, supporting longitudinal hydraulic flow.

The combined action of capillary wicking and hydraulic conductivity provides multi-scale/broad-spectrum moisture movement: micro-scale capillary uptake and macro-scale hydraulic flow. This combined dual mechanism represents a significant advancement in the scientific technical foundation of the present disclosure.

2. Resulting Performance Outcome: Hydraulic Stabilization

Hydraulic stabilization refers to the improvement in pavement and soil performance achieved through engineered acceleration of moisture removal and redistribution. Exemplary embodiments disclosed herein directly support, enable, and enhance hydraulic stabilization by:

• • Reducing pore-water pressure in saturated zones.
  • Increasing the rate at which moisture leaves the base or subgrade.
  • Promoting more uniform moisture distribution across the pavement profile.
  • Improving or enhancing modulus recovery following precipitation (rainfall or snowmelt) or thaw events.
  • Reducing frost-heave potential by removing water prior to freezing cycles.
  • Minimizing pumping and localized softening under traffic loads.

This performance mode is distinct from conventional geotextile reinforcement and constitutes a core differentiating feature of the disclosed exemplary geotextile and geogrid systems.

3. Structural Contributions

In exemplary embodiments disclosed herein (e.g., “hollow-yarn” geotextiles, “cord-based” geotextiles, geogrids, etc.), structural features are introduced that that collectively support the hydraulic stabilization framework.

For example, exemplary embodiments are disclosed of “hollow-yarn” geotextiles that include hollow yarns, fibers, and/or tubing with permeable exteriors configured for allowing moisture to permeate therethrough and enter the hollow interiors of the yarns/fibers/tubing. After moisture has permeated through the permeable exteriors and entered the hollow interiors of the yarns/fibers/tubing, the moisture is transferrable internally along the yarns/fibers/tubing through moisture movement channels defined by the hollow interiors of the yarns/fibers/tubing. Key features of the “hollow-yarn” geotextile configurations include:

• • Rigid “tube like” hollow interior yarns/fibers/tubing support conduit flow both internally and externally (within the fabric itself) (confirmed via ASTM D4716 testing data).
  • Permeable exteriors facilitate or allow water entry for capillary-assisted internal transport.
  • Hydraulic conductivity is the dominant moisture movement mechanism with the “hollow-yarn” geotextile configurations.

Exemplary embodiments are disclosed of “cord-based” geotextile that include DREF/friction-spun yarns, braided cords, engineered monofilaments, etc. Key features of the “cord-based” geotextile configurations include:

• • Cord architecture significantly increases wicking capabilities of the core and also protects the core long term.
  • Conduit-like behavior emerges and is observed when the cores (e.g., PET monofilament yarns, multifilament yarns, hollow yarns, etc.) include protected void regions.

Exemplary embodiments are disclosed of geogrids constructed from high-denier PET continuous-filament yarns. Key features of the geogrid construction include:

• • PET filament ribs exhibit capillary uptake between filaments.
  • High-denier bundles preserve inter-filament voids, enabling multidirectional wicking (MD and CD).
  • Wicking occurred in both the MD and CD, enabling moisture equalization across the plane of the geotextile.
  • Demonstrated ability to overcome gravitational effects in vertical testing better than a conventional fabric without CD wicking yarns.

4. Unified Performance Principles

Across the exemplary embodiments disclosed herein (e.g., e.g., “hollow-yarn” geotextiles, “cord-based” geotextiles, geogrids, etc.), the following principles apply:

• • Moisture management improves pavement durability.
  • Capillary and hydraulic mechanisms act or operate synergistically.
  • Structural elements must preserve voids and channel pathways within the fabric itself under compaction.
  • Increased drainage rate leads or correlates directly with extended roadway life.

Accordingly, inventive aspects of the present disclosure include or relate to:

• • Geotextile fabrics including cord cores comprising protected void regions (e.g., “cord-based” geotextiles including DREF/friction-spun yarns, braided cords, engineered monofilaments, etc.).
  • Geotextile fabrics including hollow yarns/fibers/tubing configured to maintain interstitial voids under compaction.
  • Dual-mode moisture transport (capillary wicking and hydraulic conductivity).
  • Multidirectional wicking capability and hydraulic conductivity (e.g., PET-filament geogrids, other geogrid, etc.).
  • Conduit-supported hydraulic flow (e.g., “hollow-yard” geotextile fabrics including hollow yarns/fibers/tubing configured to maintain interstitial voids under compaction.
  • Accelerated drainage and redistribution.
  • Methods for stabilizing pavements via engineered moisture management.
  • Integration of geosynthetics to achieve hydraulic stabilization in base, subbase, and frost-susceptible soils.

Accordingly, the exemplary embodiments disclosed herein (e.g., e.g., “hollow-yarn” geotextiles, “cord-based” geotextiles, geogrids, etc.) introduce and represent novel, engineered implementations of hydraulic stabilization. For example, the dual moisture mechanisms, load-responsive behavior, and multidirectional wicking disclosed herein are novel, innovative, and differentiating features that strongly support patentability of the claimed inventions.

In addition, the following a non-exhaustive summary of key innovations and technical advantages associated with the exemplary embodiments disclosed herein. Conventional wicking-based geotextiles designed for moisture transport typically rely on very small interfilament capillary channels created by multifilament yarn structures. These wicking pathways are intended to transport moisture along the exterior surfaces of fine filaments within tightly compacted bundles. These channels enable wicking but exhibit significant shortcomings in roadway applications including Fragile Capillary Structure, High Risk of Clogging, and Uncertain Long-Term Reliability as explained in more detail below.

Fragile Capillary Structure: The microchannel size is extremely small and easily damaged. The micro-channels are extremely small and formed by soft, deformable filaments. During installation-particularly under aggregate placement and compaction-these channels are easily crushed, disrupting capillary continuity and reducing wicking efficiency. The capillary grooves and micro-channels used for wicking in these prior-art systems:

• • are typically micron-scale;
  • are formed by soft or easily deformable filaments; and
  • can be compressed or crushed during installation, particularly during aggregate placement and compaction.
    Once deformed, the capillary continuity is disrupted and long-term wicking effectiveness diminishes substantially.

High Risk of Clogging and Susceptibility to Clogging Over Time: Fine soil particles, biofilm growth, and mineral deposits can obstruct these conventional narrow pathways. Long-term creep deformation further compromises channel integrity, leading to progressive loss of functionality. Because the capillary openings in prior-art wicking yarns are extremely small, they:

• • can become blocked by fine soil particles;
  • may accumulate biofilm or mineral deposition over time; and
  • can lose functional continuity due to long-term creep deformation of the yarn structure.
    This leads to degradation of wicking performance throughout the service life of the roadway—an issue not addressed or mitigated by conventional technology. Also, nylon when in a prolonged saturated state may undergo hydrolysis that will break down the nylon.

Uncertain Long-Term Reliability in Roadway Applications: Roadway environments impose severe conditions: heavy/significant overburden pressures, cyclic traffic loads, compaction forces, fine-grained sediments, and repeated wet-dry cycles. These conditions challenge the durability of traditional micro-channel wicking systems. As these channels collapse or clog, their capillary performance cannot be assumed to reliably maintain moisture transport functionality throughout the pavement's design life.

Exemplary embodiments disclosed herein (e.g., e.g., “hollow-yarn” geotextiles, “cord-based” geotextiles, geogrids, etc.) include distinctive features that are distinguishable over conventional geotextiles. For example, disclosed herein are exemplary embodiments that include cord yarns featuring a sheath structure, hollow yarns/fibers/tubing, or geogrids including ribs that define moisture movement channels, which are distinguished from prior-art wicking systems by demonstrating that:

• • prior-art wicking channels are fragile, easily damaged, and prone to clogging, making long-term performance uncertain;
  • the disclosed hollow yarns maintain moisture-movement capability even after installation stresses and even in instances of overburden pressure which is present in roadway applications due to traffic loading; and
  • dual-mode moisture movement (wicking+hydraulic conduction) is preserved over time, yielding reliable moisture management, hydraulic stabilization, and improved subgrade modulus.
    The disclosed exemplary embodiments maintain structural integrity under load. For example, exemplary embodiments of the “hollow-yarn” geotextiles disclosed herein include hollow yarns that retain their internal conduits even after installation and under sustained overburden pressure, ensuring uninterrupted hydraulic performance. Exemplary embodiments disclosed herein are configured for dual-mode moisture movement that combines capillary wicking with hydraulic conduction, enabling efficient water transport even when fine sediments or biofilm are present. Exemplary embodiments disclosed herein have enhanced durability and reliability and are able to maintain moisture management and subgrade stabilization over the full service life of roadway applications, improving pavement performance and reducing maintenance costs.

Disclosed herein are exemplary embodiments of woven geotextile fabrics incorporating engineered hollow yarns/fibers/tubing (broadly, hollow members or tubular elements) configured for hydraulic conductivity-driven moisture management. The hollow yarns/fibers/tubing act as internal flow conduits while simultaneously providing structural rigidity to the woven matrix, enabling enhanced lateral moisture transport and hydraulic stabilization of roadway layers.

In exemplary woven geotextile fabrics disclosed herein, hollow yarns/fibers/tubing preserve inter-fiber void spaces, preventing collapse under load. When certain materials are used, the hollow yarns/fibers/tubing can also prevent the woven fabric's inter-fabric void spaces from closing under load. Test results using D4716-derived procedures show approximately 2× increase in lateral water transport (L/m/day). But this can be up to 500× depending on the geometry, interval spacing of the hollow yarns/fibers/tubing. Excessive hollow-yarn frequency can reduce conductivity by occupying void volume, such that a preferred or optimal spacing range (e.g. tube inserted every 0.8 inches to 2.2 inches, etc.) is used in exemplary embodiments. The disclosed woven geotextile fabrics can also behave similarly to a thin geocomposite drainage layer as described in roadway drainage theory.

Hydraulic stabilization can be identified as having two dominant performance mechanisms: wicking and hydraulic conductivity. Both hydraulic conductivity and wicking can be leveraged but in the case of the disclosed woven geotextile fabrics including hollow yarns/fibers/tubing therein, the predominant moisture management mechanism is hydraulic conductivity. And the hollow yarns/fibers/tubing are preferably configured to contribute to the primary moisture management mechanism of hydraulic conductivity:

• • pressure-driven in-plane flow enhanced by rigid hollow yarns;
  • maintain drainage functionality under confinement; and
  • redistribute localized saturated zones and reduces pore pressure.

The hollow yarns/fibers/tubing are also preferably configured to contribute to a secondary moisture management mechanism by providing for an internal conduit flow when water is “wicked” into the hollow yarns/fibers/tubing. More specifically, the hollow yarns/fibers/tubing include permeable exteriors that allow moisture to permeate therethrough and enter the hollow interiors of the yarns/fibers/tubing. After moisture has permeated through the permeable exteriors and entered the hollow interiors of the yarns/fibers/tubing, the moisture is transferrable internally along the yarns/fibers/tubing through moisture movement channels defined by the hollow interiors of the yarns/fibers/tubing. The hollow yarns/fibers/tubing thus support moisture equalization across a profile, e.g., a roadway profile, etc.

Experimental data demonstrates the following for the disclosed woven geotextile fabrics including hollow yarns/fibers/tubing:

• • Nearly double the moisture-movement capacity versus traditional woven stabilization geotextiles;
  • Performance depends on hollow-yarn geometry, spacing, and weave pattern;
  • Hollow yarns with permeable walls support dual-mode moisture movement; and
  • Too high a yarn count reduces inter-void space and decreases conductivity.
    In some exemplary embodiments, the disclosed woven geotextile fabrics include hollow yarns/fibers/tubing that do not have permeable exteriors.

The disclosed woven geotextile fabrics including hollow yarns/fibers/tubing may be used for roadway drainage (e.g., placed beneath base/subbase, edge-drain integration, frost-prone regions, etc.) to thereby:

• • Function as a lateral drainage layer analogous to geocomposite drains;
  • Reduce time-to-drain and supports long-term pavement performance;
  • Act as a capillary break; and
  • Reduce risk of frost heave by removing and redistributing pore water before freeze conditions occur.

In exemplary embodiments, a woven geotextile fabric includes hollow yarns/fibers/tubing configured for hydraulic conductivity enhancement, interstitial void protection and preservation, and bidirectional moisture transport. The hollow yarns/fibers/tubing may have an inner diameter/outer diameter ratio between 0.001 and 1000. The hollow yarns/fibers/tubing may be inserted within the woven geotextile fabric at a frequency from 1 to 1000 per inch. The hollow yarns/fibers/tubing (or other means/materials for channelizing water flow) may have cross-sectional shape(s) that are the same as or different from each other. The cross-sectional shape(s) may include one or more of round, circular, flat, multi-lobal, oval, trilobal, triangular, rectangular, non-circular, non-rectangular, other closed cross-sectional shape, etc. Additionally, the hollow yarns/fibers/tubing may be concentric or eccentric in nature, and may be singular, or present in multiples. The weave pattern for the woven geotextile fabric may include a plain (1×1) weave, various types of twill weaves (e.g., 2×1, 2×2, 3×1, 3×3, 4×4, etc.), herringbone weave, satin weave, basket wave, leno weave, etc. In some exemplary embodiments, the geotextile fabric may have a knitted construction.

With reference to the figures, FIG. 7 includes a line graph of Horizontal Flow Rate in liters per day (L/m/day) versus Overburden Pressure in kilopascals (kPa) from 2% gradient flow rate comparative testing of exemplary woven geotextile fabrics (labeled H0.5, H1, H2, and D1) including hollow tubing inserted therein according to exemplary embodiments and a control woven geotextile fabric having a plain weave without any hollow tubing.

FIG. 8 includes a line graph of Horizontal Flow Rate in liters per day (L/m/day) versus Overburden Pressure in kilopascals (kPa) from 0% gradient flow rate comparative testing of exemplary woven geotextile fabrics (labeled H0.5, H1, H2, D2, and D1) including hollow tubing inserted therein according to exemplary embodiments and a control woven geotextile fabric having a plain weave without any hollow tubing.

The woven geotextile fabric D1 had a plain weave and 1.8 to 2.2 mm diameter tubing inserted every 0.8 to 1.2 inches. The woven geotextile fabric D2 had a plain weave and 1.8 to 2.2 mm diameter tubing inserted every 1.8 to 2.2 inches. The woven geotextile fabric H1 had a 2×2 twill weave and 0.8 to 1.2 mm diameter tubing inserted every 0.8 to 1.2 inches. The woven geotextile fabric H2 had a 2×2 twill weave and 0.8 to 1.2 mm diameter tubing inserted every 1.8 to 2.2 inches. The woven geotextile fabric H0.5 had a 2×2 twill weave and 0.8 to 1.2 mm diameter tubing inserted every 0.25 to 0.75 inches.

Experimental data (e.g., FIGS. 7 and 8, etc.) demonstrates that exemplary embodiments of the woven geotextile fabrics including hollow tubing inserted therein may be configured to have nearly double the moisture-movement capacity versus traditional woven stabilization geotextiles. The resulting performance will depend on hollow yarn/fiber/tubing geometry, insertion frequency or spacing, and weave pattern type. In addition, hollow yarns/fibers/tubing with permeable outer walls support dual-mode moisture movement as disclosed herein. As shown by a comparison of the experimental data for the woven geotextile fabric 4 in FIG. 8, water conductivity may be reduced if the woven geotextile fabric is configured with too high of a hollow yarn/fiber/tubing that reduces inter-void space and decreases water conductivity.

The plain weave, 2×2 twill weaves, tubular diameters, and spacing disclosed for this comparative testing are provided for purpose of illustration. Other exemplary embodiments include woven geotextiles with different weaves (e.g., plain (1×1) weave, other twill weaves (e.g., 2×1, 3×1, 3×3, 4×4, etc.), herringbone weave, satin weave, basket wave, leno weave, etc.), different diameters, and/or different spacings.

In exemplary embodiments, a woven geotextile fabric includes integrated tubular elements for enhanced flow. For example, the fabric may incorporate continuous tubes (e.g., polymeric tubes, etc.) within the fill yarn system. The tubes create preferential flow channels, significantly increasing in-plane transmissivity compared to conventional woven geotextiles without any tubing.

In exemplary embodiments, the woven geotextile fabric may have a weave pattern (e.g., 2×2 twill weave, 3×3 twill weave, plain weave, etc.) that provides improved structural stability of the woven geotextile fabric and minimizes distortion under compressive loads. The weave pattern preferably allows better integration of the tubular elements without compromising warp and fill yarn alignment, ensuring uniform load distribution.

The woven geotextile fabric may have a variable tube diameter and placement in exemplary embodiments of the present disclosure. For example, the woven geotextile fabric may comprise tubes having a diameter within a range from 0.8 mm to 2.2 mm and that are strategically inserted at intervals ranging from 0.5 inches to 2.2 inches. This configuration may enable customization of hydraulic performance for specific site conditions, offering versatility beyond standard drainage fabrics.

The disclosed woven geotextile fabrics including hollow yarns/fibers/tubing have superior hydraulic performance under stress. For example, ASTM D4716 testing confirms that the woven geotextile fabrics including hollow yarns/fibers/tubing maintain high flow rates even at 20 kPa normal stress, where conventional fabrics exhibit near-zero transmissivity.

The disclosed woven geotextile fabrics including hollow yarns/fibers/tubing have a dual-function design. More specifically, the disclosed woven geotextile fabrics serve both as soil separators and drainage conduits, reducing the need for separate drainage layers and simplifying installation. This integrated dual-function approach can lower material costs and accelerate construction timelines.

The disclosed woven geotextile fabrics including hollow yarns/fibers/tubing may provide one or more of the following advantages over conventional woven geotextile fabrics without any hollow tubing.

• • Higher transmissivity under load: The disclosed woven geotextile fabrics including hollow yarns/fibers/tubing outperform conventional woven geotextile fabrics by providing sustained flow at elevated stresses.
  • Customizable hydraulic capacity: Tube spacing and diameter can be tailored for site-specific requirements.
  • Improved durability: Weave pattern (e.g., twill weave, etc.) combined with tubular reinforcement enhances resistance to crushing and deformation.

Accordingly, disclosed herein are exemplary embodiments of geotextile fabrics (whether the fabrics are woven, nonwoven, knitted, or a composite geotextile thereof, etc.) made with unique hollow core yarns, fibers, and/or tubing (broadly, hollow members or means/materials usable for channelizing water flow) with certain enhanced characteristics to allow moisture to efficiently enter the hollow interiors (e.g., hollow cores, etc.) of the yarns/fibers/tubing. The incorporation of hollow core yarns/fibers/tubing results in conduit flow internally within the yarn/fiber/tubing defined by its structure, significantly enhancing the moisture management of the geotextile/road system. Additional moisture management performance can be achieved by engineering the arrangement of warp and weft yarns to achieve inter-fiber interactions of the yarn/fabric structure, along with chemical treatments applied during production or thereafter to contribute to the overall effectiveness of moisture management.

After the moisture has effectively entered the hollow interiors of the yarns/fibers/tubing, the moisture can then be transferred, conveyed, or transported internally along or through the hollow interior paths or conduits within the yarns/fibers/tubing, e.g., from subbase soil(s) within a project to an adjoining area(s) (e.g., road way ditches, etc.).

In exemplary embodiments, a geotextile fabric includes yarns, fibers, and/or tubing configured for internally transporting moisture. The yarns/fibers/tubing have hollow interiors (e.g., longitudinally extending hollow core having a closed cross-sectional shape, etc.) and permeable exteriors (e.g., outer layers having voids, holes, perforations, fluid inlets, etc.). The permeable exteriors are configured for allowing moisture to efficiently enter the hollow interiors of the yarns/fibers/tubing. After the moisture has effectively entered the hollow interiors of the yarns/fibers/tubing, the moisture can then be transferred, conveyed, or siphoned (e.g., channelized downwardly in the direction of gravity, by means of conduit flow within the hollow interiors of the yarns/fibers/tubing, etc.) internally along the moisture movement channels or conduits defined by the hollow interiors of the yarns/fibers/tubing, e.g., from subbase soil(s) within a project to an adjoining area(s) (e.g., road way ditches, etc.). Accordingly, the exemplary geotextile fabrics disclosed herein are able to transport moisture internally along and within the hollow interiors of the yarns/fibers/tubing themselves after that moisture has permeated through the moisture-permeable exteriors into the hollow interiors of the yarns/fibers/tubing.

In exemplary embodiments, hollow core yarns (or other means/materials for channelizing water flow) for a moisture management geotextile fabric may be made via an extrusion process or via a finishing process after extrusion to either the yarn and/or fabric. During the extrusion process to manufacture the hollow core yarns, the outer layer must be opened, fractured, perforated, etc. in some manner to provide the hollow core yarns with moisture-permeable exteriors that allow for egress or entrance of moisture into the hollow cores or interior areas of the hollow core yarns. This can be accomplished by introducing a foaming agent or other additives (e.g., nanomaterials, etc.) during the extrusion of the yarn. By closely controlling the level of foaming agent as well as the processing parameters, the outer shell will have “voids” due to the escape of gases during the extrusion process. The result will be fractures or holes within the outer shell, which will improve transportation of moisture down the hollow core of the yarn.

In other exemplary embodiments, hollow core yarns (or other means/materials for channelizing water flow) for a moisture management geotextile fabric may be loaded with very high levels of calcium carbonate. Calcium carbonate is a natural substance that can be introduced to polymers during extrusion. At higher load levels of the calcium carbonate, the outer shell of the hollow core yarn can be fractured. This is a conventional process that may be used in baby diapers or adult incontinence wear wherein the fracturing is controlled to hold back moisture molecules while allowing air to pass through. In exemplary embodiments disclosed herein, the hollow core yarns for a moisture management geotextile fabric may be dosed with an amount of calcium carbonate along with manipulation of the yarn to allow for water molecules to enter the hollow core area while holding back dirt and other debris in the subbase soils.

In further exemplary embodiments, the yarns/fibers/tubing (or other means/materials for channelizing water flow) may have exteriors that are initially impermeably but configured to be permeable for allowing moisture to efficiently enter the hollow interiors of the yarns/fibers/tubing. For example, the yarns/fibers/tubing for a moisture management geotextile fabric can be produced with common polymers. The outer walls of the yarns/fibers/tubing can then be perforated with a chemical process, mechanical process, heat penetration process, laser process, such as micro fibrillation or other suitable process, which will create small holes, perforations, openings, etc. in the outer walls of the yarns/fibers/tubing. For example, the yarns/fibers/tubing may be provided with permeable exteriors via micro fibrillation, laser perforation, hot perforation, cold perforation, utilizing soluble polymers or a finishing process, etc. As a result, water can enter the hollow interiors of the yarns/fibers/tubing, via the perforated outer walls, and be transported internally along and within the hollow interiors of the yarn/fiber/tubing to an adjoining area(s).

In further exemplary embodiments, the yarns/fibers/tubing (or other means/materials for channelizing water flow) may have exteriors that are initially impermeably but configured to be permeable for allowing moisture to efficiently enter the hollow interiors of the yarns/fibers/tubing. For example, the yarns/fibers/tubing for a moisture management geotextile fabric can be produced with one or more common polymers. The outer walls of the yarns/fibers/tubing can be made from polymer A, whereas the interior of the yarns/fibers/tubing can be made from a soluble polymer B which when dissolved, will create the hollow interior and small holes, perforations, openings, etc. in the outer walls of the yarns/fibers/tubing. As a result, water can enter the hollow interiors of the yarns/fibers/tubing, via the outer walls, and be transported internally along and within the hollow interiors of the yarn/fiber to an adjoining area(s).

In exemplary embodiments, the geotextile fabric includes hollow core yarns/fibers/tubing (or other means/materials for channelizing water flow) having cross-sectional shape(s) that are the same as or different from each other. The cross-sectional shape(s) may include one or more of round, flat, multi-lobal, oval, trilobal, triangular, rectangular, non-circular, non-rectangular, other closed cross-sectional shape, etc. Additionally, they may be concentric or eccentric in nature, and may be singular, or present in multiples. In exemplary embodiments, the yarns/fibers/tubing include moisture-permeable exteriors and longitudinally extending hollow interiors having varying cross-sectional shapes. The permeable exteriors are configured for allowing moisture to efficiently enter the hollow interiors of the yarns/fibers/tubing. After the moisture has effectively entered the hollow interiors of the yarns/fibers/tubing, the moisture can then be transferred, conveyed, or transported (e.g., channelized downwardly in the direction of gravity, by means of conduit flow within the hollow interiors of the yarns and/or fibers, etc.) internally along the moisture movement channels defined by the hollow interiors of the yarns/fibers/tubing.

In exemplary embodiments, the geotextile fabric includes warp and weft systems comprising hollow core yarns/fibers/tubing as disclosed herein. The hollow core yarns/fibers/tubing may comprise monofilament (e.g., polypropylene monofilament, polyester monofilament, polyethylene monofilament, nylon monofilament, combinations thereof, etc.), tape yarns, fibrillated tapes, spun yarn (e.g., core-sheath spun yarn, ring-spun yarn, rotor-spun yarn, open-end spun yarn, etc.), multifilament yarns (e.g., polypropylene multifilament yarn, polyethylene terephthalate (PET) multifilament yarn, etc.), etc. Materials used for the hollow core yarns/fibers/tubing may include polypropylene, polyester, polyethylene terephthalate (PET), nylon, rayon, polyethylene, fiberglass, terpolymer, acrylic, aramid fibers, natural fibers, biodegradable fibers, etc.

In exemplary embodiments, the weave pattern for the geotextile fabric may include a plain (1×1) weave, various types of twill weaves (e.g., 2×1, 2×2, 3×1, 3×3, 4×4, etc.), herringbone weave, satin weave, basket wave, leno weave, and others. The warp and weft yarn systems may incorporate one or more types of different hollow core yarns, such as multifilament yarns, spun yarns with different cross-sectional shapes, monofilaments, tape yarns, fibrillated yarns, combinations thereof, etc. Additionally, the warp and weft yarn system may be of a single layer or of more than one layer. The layers may be formed during the initial fabric manufacturing process, or may be formed by a two-step process as in the case of a composite geotextile fabric system.

A geotextile fabric disclosed herein may be installed at a location that allows moisture from subbase soil(s) to permeate through the permeable exteriors and enter the hollow interiors of the yarns/fibers/tubing and then be transferred internally along the yarns/fibers/tubing through the moisture movement channels defined by the hollow interiors of the yarns/fibers/tubing to an adjoining area(s).

Also disclosed are exemplary methods of using a geotextile fabric disclosed herein. In exemplary embodiments, the method includes installing the geotextile fabric at a location at which moisture from subbase soil(s) is allowed to permeate through the permeable exteriors and enter the hollow interiors of the yarns/fibers/tubing and then be transferred internally along the yarns/fibers/tubing through the moisture movement channels defined by the hollow interiors of the yarns/fibers/tubing to an adjoining area(s).

Disclosed exemplary methods of making a geotextile fabric. In exemplary embodiments, the method includes: extruding yarns/fibers/tubing having hollow interiors and outer layers that are opened, fractured, and/or perforated during the extruding; and using the extruded yarns/fibers/tubing having the hollow interiors and the outer layers to make the geotextile fabric. The outer layers of the extruded yarns/fibers/tubing are configured for allowing moisture to permeate therethrough and enter the hollow interiors of the extruded yarns/fibers/tubing. After moisture has permeated through the outer layers of the extruded yarns/fibers/tubing and entered the hollow interiors of the extruded yarns/fibers/tubing, the moisture is transferrable internally along the extruded yarns/fibers/tubing through moisture movement channels defined by the hollow interiors of the extruded yarns/fibers/tubing.

In exemplary embodiments, the method includes introducing a foaming agent during the extruding, which foaming agent causes gases to escape during the extruding to thereby create openings, fractures, perforations, and/or holes within the outer layers of the extruded yarns/fibers/tubing. Or the method includes dosing a sufficiently high level calcium carbonate, nanomaterials, and/or other suitable additive during the extruding to thereby create openings, fractures, perforations, and/or holes within the outer layers of the extruded yarns/fibers/tubing that will allow for water molecules to enter the hollow interiors of the extruded yarns/fibers/tubing while holding back dirt and other debris.

In exemplary embodiments, a method of making a geotextile fabric includes perforating yarns/fibers/tubing, via a chemical process, mechanical process, heat penetration process, laser process, or finishing process, outer walls of the yarns/fibers/tubing to thereby provide the yarns/fibers/tubing with permeable exteriors; and using the yarns/fibers/tubing with the perforated outer walls to make the geotextile fabric. The perforated outer walls of the yarns/fibers/tubing are configured for allowing moisture to permeate therethrough and enter the hollow interiors of the yarns/fibers/tubing. After moisture has permeated through the perforated outer walls of the yarns/fibers/tubing and entered the hollow interiors of the yarns/fibers/tubing, the moisture is transferrable internally along the yarns/fibers/tubing through the moisture movement channels defined by the hollow interiors of the yarns/fibers/tubing.

In exemplary embodiments, the method includes perforating the outer walls of the yarns/fibers/tubing via micro fibrillation, laser perforation, hot perforation, cold perforation, or utilizing soluble polymers.

Disclosed herein are exemplary embodiments of geotextile fabrics (whether the fabrics are woven, nonwoven, knitted, or a composite geotextile thereof, etc.) made with unique yarns (e.g., monofilament yarns, DREF or friction spun yarns, braided cords, etc.) with certain enhanced characteristics that allow moisture to be transferred, conveyed, or transported along the yarns, e.g., from subbase soil(s) within a project to an adjoining area(s) (e.g., road way ditches, etc.).

In exemplary embodiments, a geotextile fabric includes one or more of monofilament yarn, DREF or friction spun yarn, and/or braided cord woven, knitted, or inserted within the geotextile fabric in either the machine direction and/or cross machine direction. The monofilament yarn, DREF or friction spun yarn, and/or braided cord defines one more moisture movement channels such that moisture is transferrable, conveyable, or transportable along the length(s) of the one or more moisture movement channels defined by the monofilament yarn, DREF or friction spun yarn, and/or braided cord.

In exemplary embodiments, a geotextile fabric includes monofilament yarns having cross-sectional shapes (e.g., trilobal, multilobed, U-shaped, S-shaped, C-shaped, W-shaped, non-round shapes, non-oval shapes, etc.) such that the monofilament yarns integrally define moisture movement channels (e.g., longitudinally extending water transport channels along the lengths of the monofilament yarns, etc.). The monofilament yarns may have cross-sectional shapes that are the same as or different from each other.

The monofilament yarns are woven, knitted, or inserted into the fabric structure in either the machine direction and/or cross machine direction. The cross-sectional shapes of the monofilament yarns are selectively configured such that moisture is transferrable, conveyable, or transportable along the lengths of the moisture movement channels defined by the monofilament yarns, e.g., from subbase soil(s) within a project to an adjoining area(s) (e.g., road way ditches, etc.).

By way of example only, the monofilament yarn may comprise a 2000 denier single filament yarn having an S-shaped cross-section. The monofilament yarn may comprise polypropylene monofilament, polyester monofilament, polyethylene monofilament, nylon monofilament, combinations thereof, etc. Alternatively, other embodiments may include other monofilament yarns, e.g., with a higher or lower denier than 2000, other cross-sectional shape, etc.

Accordingly, an exemplary method of manufacturing a geotextile fabric configured for moisture management includes weaving, knitting, or inserting monofilament yarns into the fabric structure in either the machine direction and/or cross machine direction. The cross-sectional shapes of the monofilament yarns are selectively configured (e.g., trilobal, multilobed, U-shaped, S-shaped, C-shaped, W-shaped, non-round shapes, non-oval shapes, etc.) to integrally define moisture movement channels such that moisture is transferrable, conveyable, or transportable along the moisture movement channels defined by the monofilament yarns, e.g., from subbase soil(s) within a project to an adjoining area(s) (e.g., road way ditches, etc.). The monofilament yarns may have cross-sectional shapes that are the same as or different from each other.

In exemplary embodiments, a geotextile fabric includes DREF or friction spun yarns woven, knitted, or inserted periodically or intermittently within the fabric in the machine direction and/or cross machine direction. The DREF or friction spun yarn may comprise filaments that define inter-fiber capillary moisture movement channels between the filaments within the DREF or friction yarn such that moisture is transferrable, conveyable, or transportable along the lengths of the inter-fiber capillary moisture movement channels defined between the filaments of the DREF or friction spun yarn.

The DREF or friction spun yarns can be made with filaments extruded or otherwise formed with any cross-sectional shape, such as round, oval, trilobal, multilobed, U-shaped, S-shaped, C-shaped, W-shaped, non-round shape, non-oval shape, etc. The filaments are not bulked or texturized but left straight within the core of the yarn. For increased moisture movement capability, the DREF or friction spun yarns may include microdenier filaments (e.g., having less than 1.0 denier per filament, etc.) in the core that will significantly increase the number of inter-fiber capillary moisture movement channels. To help protect the inter-fiber capillary moisture movement channels and to aid in transfer of moisture, other fibers having the same formulations as or different formulations than the filaments may be used to wrap the core bundle of straight filaments/fibers for more efficient moisture movement.

In exemplary embodiments, the geotextile fabric includes DREF or friction spun yarns as disclosed in U.S. Pat. No. 7,866,138, which is incorporated herein by reference. For example, the geotextile fabric may include spun yarn formed with a core of microdenier synthetic filaments (e.g., having less than 1.0 denier per filament, etc.) wrapped with a sheath, which generally includes carded staple fibers that are spun around the core. The microdenier synthetic filaments may comprise polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), nylon, polypropylene, polyethylene, aramids, bi-components, blends thereof, etc. The staple fibers of the sheath may comprise natural fibers, man-made fibers, blends thereof, etc. The sheath may comprise a series of staple spun microfibers mixed with staple fibers. The yarn may be spun on a friction spinning machine.

Accordingly, an exemplary method of manufacturing a geotextile fabric configured for moisture management includes weaving, knitting, or inserting DREF or friction spun yarns periodically or intermittently within the fabric in the machine direction and/or cross machine direction. The DREF or friction spun yarn may comprise filaments that define inter-fiber capillary moisture movement channels between the filaments within the DREF or friction yarn such that moisture is transferrable, conveyable, or transportable along the lengths of the inter-fiber capillary moisture movement channels defined between the filaments of the DREF or friction spun yarn. In this exemplary method, the DREF or friction spun yarns can be made with filaments extruded or otherwise formed with any cross-sectional shape, such as round, oval, trilobal, multilobed, U-shaped, S-shaped, C-shaped, W-shaped, non-round shape, non-oval shape, etc. Also in this exemplary method, the filaments are not bulked or texturized but left straight within the core of the yarn. For increased moisture movement capability, the method may include using DREF or friction spun yarns having microdenier filaments in the core that will significantly increase the number of inter-fiber capillary moisture movement channels. To help protect the inter-fiber capillary moisture movement channels and to aid in transfer of moisture, the method may include using other fibers to wrap the core bundle of straight filaments/fibers for more efficient moisture movement.

In exemplary embodiments, a geotextile fabric includes braided cords woven, knitted, or inserted periodically or intermittently within the fabric in the machine direction and/or cross machine direction. The braided cord may comprise filaments that define inter-fiber capillary moisture movement channels between the filaments within the braided cord, such that moisture is transferrable, conveyable, or transportable along the lengths of the inter-fiber capillary moisture movement channels defined between the filaments of the braided cord.

The braided cords can be made with filaments extruded or otherwise formed with any cross-sectional shape, such as round, oval, trilobal, multilobed, U-shaped, S-shaped, C-shaped, W-shaped, non-round shape, non-oval shape, etc. A braided cord may be defined as a system of three or more threads intertwined in such a way that two threads are never twisted around each other. Further, a braided cord can include a braided outside/cover with or without a core structure. Some exemplary embodiments may include yarns that are braided, intertwined, or otherwise joined together to form a structure (e.g., circular cylindrical structure, etc.) around a core instead of the braided cords disclosed in this paragraph.

Accordingly, an exemplary method of manufacturing a geotextile fabric configured for moisture management includes weaving, knitting, or inserting braided cords periodically or intermittently within the fabric in the machine direction and/or cross machine direction. The braided cord may comprise filaments that define inter-fiber capillary moisture movement channels between the filaments within the braided cord, such that moisture is transferrable, conveyable, or transportable along the lengths of the inter-fiber capillary moisture movement channels defined between the filaments of the braided cord.

In this exemplary method, the braided cords can be made with filaments extruded or otherwise formed with any cross-sectional shape, such as round, oval, trilobal, multilobed, U-shaped, S-shaped, C-shaped, W-shaped, non-round shape, non-oval shape, etc. Also in this exemplary method, a braided cord is defined as a system of three or more threads intertwined in such a way that two threads are never twisted around each other. Further, a braided cord can include a braided outside/cover with or without a core structure.

In some cases, the braided cord can be braided or twisted around a group of filaments within the core of the yarn. These core filaments or yarns can have the same formulation as different formulation than the filaments or yarns on the outside. In these cases, the core filaments are not bulked or texturized but left straight within the core and the outside sheath yarn. For increased moisture movement capability, the filaments in the core can be microdenier filaments (e.g., having less than 1.0 denier per filament, etc.) that will significantly increase the number of inter-fiber capillary moisture movement channels.

As noted above, monofilament yarns, DREF or friction spun yarns, and/or braided cords may be woven, knitted, or inserted into a geotextile fabric structure in either the machine direction and/or cross machine direction. In such exemplary embodiments, the weave pattern for the geotextile fabric may include a plain (1×1) weave, various types of twill weaves (e.g., 2×1, 2×2, 3×1, 3×3, 4×4, etc.), herringbone weave, satin weave, basket wave, leno weave, and others. The warp and weft yarn systems of the geotextile fabric may comprise tape yarns, fibrillated tapes, spun yarn (e.g., core-sheath spun yarn, ring-spun yarn, rotor-spun yarn, open-end spun yarn, DREF or friction spun yarn, etc.), multifilament yarns (e.g., polypropylene multifilament yarn, polyethylene terephthalate (PET) multifilament yarn, etc.), monofilament (e.g., polypropylene monofilament, polyester monofilament, polyethylene monofilament, nylon monofilament, combinations thereof, etc.), etc.

Materials used for the warp and/or weft yarns of the geotextile fabrics may include polypropylene, polyester, polyethylene terephthalate (PET), nylon, rayon, polyethylene, fiberglass, terpolymer, acrylic, aramid fibers, natural fibers, biodegradable fibers, other polymers, other raw materials, etc. Additionally, the warp and weft yarn system may be of a single layer or of more than one layer. The layers may be formed during the initial fabric manufacturing process, or may be formed by a two-step process as in the case of a composite geotextile fabric system. In addition, the geotextile fabrics disclosed herein may be woven or knitted as the process of knitting can be used to accomplish fabric formation instead of weaving. Further, the yarns and fibers disclosed herein can also be incorporated into a fabric with a nonwoven structure.

In exemplary embodiments, a geotextile fabric configured for moisture management disclosed herein may be used in combination with a geogrid as disclosed herein.

Disclosed herein are exemplary embodiments of geogrids configured to have certain characteristics to allow moisture to be transferred, conveyed, or transported from subbase soil(s) within a project to an adjoining area(s) (e.g., road way ditches, etc.).

In exemplary embodiments, a geogrid includes ribs that are modified during the production process to integrally form moisture movement channels (e.g., longitudinally extending water transport channels along the lengths of extruded ribs, etc.) such that moisture is transferrable, conveyable, or transportable along the lengths of such channels. The ribs may be configured to have cross-sectional shapes or profiles (e.g., trilobal, multilobed, U-shaped, S-shaped, non-round shape, non-oval shape, etc.) that integrally define moisture movement channels.

Alternatively, or additionally the ribs may have hollow interiors defining moisture movement channels such that after moisture has entered the hollow interiors of the ribs, the moisture is transferrable internally along the ribs through the moisture movement channels defined by the hollow interiors of the ribs. The hollow interiors of the ribs may comprise longitudinally extending hollow cores having closed cross-sectional shapes such that after moisture has entered the longitudinally extending hollow cores of ribs, the moisture is longitudinally transferrable internally along the longitudinally extending hollow cores of the ribs. The closed cross-sectional shapes of the longitudinally extending hollow cores of the ribs may include one or more of round, flat, trilobal, multilobed, oval, triangular, rectangular, non-circular, and non-rectangular. Also, the ribs may include permeable exteriors configured for allowing moisture to permeate therethrough and enter the hollow interiors of the one or more ribs such that after moisture has permeated through the permeable exteriors and entered the hollow interiors of the ribs, the moisture is transferrable internally along the ribs through the moisture movement channels defined by the hollow interiors of the ribs.

In exemplary embodiments, permeable exteriors of the one or more ribs comprise impermeable outer layers of the one or more ribs that are perforated with perforations configured for allowing moisture to enter the hollow interiors of the one or more ribs. The permeable exteriors of the one or more ribs may comprise impermeable outer layers including openings, fractures, perforations, and/or holes therethrough that are configured for allowing moisture to enter the hollow interiors of the one or more ribs. The one or more ribs may comprise extruded hollow ribs having outer layers that are opened, fractured, and/or perforated during the extrusion process to thereby provide the extruded hollow ribs with permeable outer layers that allow moisture to permeate therethrough and enter the hollow interiors of the extruded hollow ribs. For example, the outer layers of the extruded hollow ribs may be opened, fractured, and/or perforated by introducing a foaming agent during the extrusion process, which foaming agent causes gases to escape during the extrusion process thereby creating openings, fractures, perforations, and/or holes within the outer layers of the extruded hollow ribs. Or the outer layers of the extruded hollow ribs may opened, fractured, and/or perforated by dosing a sufficiently high level calcium carbonate, nanomaterials, and/or other suitable additive during the extrusion process, which thereby creates openings, fractures, perforations, and/or holes within the outer layers of the extruded hollow ribs that will allow water molecules to enter the hollow interiors of the extruded hollow ribs while holding back dirt and other debris. As yet another example, the outer walls of the one or more ribs may be perforated via a chemical process, mechanical process, heat penetration process, laser process, finishing process, micro fibrillation, laser perforation, hot or cold perforation, or utilizing soluble polymers to thereby provide the one or more ribs with the permeable exteriors.

An exemplary method of manufacturing a geogrid configured for moisture management includes extruding a sheet for the geogrid; puncturing the sheet to thereby form openings between ribs of the geogrid; and drawing the punctured extruded sheet in the machine direction and/or cross machine direction to thereby form the geogrid. The three processes of extruding, puncturing, and drawings may be performed in-line, in a continuous single process, and/or separately. The geogrid includes one or more ribs defining one more moisture movement channels such that moisture is transferrable along the lengths of the one or more moisture movement channels defined by the one or more ribs. For example, the one or more ribs may have cross-sectional shapes or profiles (e.g., trilobal, multilobed, U-shaped, S-shaped, other non-round shapes, other non-oval shapes, etc.) and/or have hollow interiors integrally defining moisture movement channels (e.g., longitudinally extending water transport channels along the lengths of the extruded ribs, etc.). Alternatively, the geogrid may be formed by using an oscillating die process.

Another exemplary method of manufacturing a geogrid configured for moisture management includes extruding ribs for the geogrid and bonding the extruded ribs together to thereby form the geogrid. For example, the geogrid may be bonded using technology to bond the extruded ribs together at certain intervals to achieve the desired results. The method further incudes forming moisture movement channels along the ribs (e.g., longitudinally extending water transport channels along the lengths of the extruded ribs, etc.) either during the extrusion or after the extrusion formation. In the latter case, the method may include using an embossing process for formation of the moisture movement channels along the extruded ribs. The extruded ribs may have cross-sectional shapes or profiles (e.g., trilobal, multilobed, U-shaped, S-shaped, other non-round shapes, other non-oval shapes, etc.) and/or have hollow interiors integrally defining moisture movement channels (e.g., longitudinally extending water transport channels along the lengths of the extruded ribs, etc.). By way of example, the bonded geogrid including the bonded extruded ribs may comprise a laminated nonwoven geogrid.

Geogrids formed from woven or knitted grids can also be configured for moisture management. In these exemplary embodiments, there are a number of methods that may be used to make the woven or knitted geogrids configured for moisture management.

An exemplary embodiment includes monofilament rib yarns woven, knitted, or inserted into the grid structure with other high tenacity rib yarns. The monofilament rib yarns have cross-sectional shapes (e.g., trilobal, multilobed, U-shaped, S-shaped, other non-round shapes, other non-oval shapes, etc.) and/or have hollow interiors integrally defining moisture movement channels (e.g., longitudinally extending water transport channels along the lengths of the extruded ribs, etc.) such that moisture is transferrable, conveyable, or transportable along the lengths of such channels.

The monofilament rib yarns may comprise polypropylene monofilament, polyester monofilament, polyethylene monofilament, nylon monofilament, combinations thereof, etc. The other high tenacity rib yarns may comprise high tenacity PET (polyethylene terephthalate) filament yarns or yarns made from other substances and materials that provide high tenacity yarns, such as nylon, polypropylene, polyethylene, aramids, high molecular weight polyethylene (UHMWPE), fiberglass, basalt, etc. Examples of high tenacity yarns may include yarns having a tenacity within a range from 6.5 grams per denier up to 40 grams per denier, yarns with a tenacity less than 6.5 grams per denier (e.g., 6 grams per denier, at least 4.5 grams per denier, etc.), yarns with a tenacity more than 40 grams per denier.

An exemplary method of manufacturing a geogrid configured for moisture management includes weaving or knitting rib yarns to form the geogrid. At least some rib yarns (e.g., monofilament rib yarns, etc.) include or integrally define moisture movement channels (e.g., longitudinally extending water transport channels along the lengths of the monofilament rib yarns, etc.) such that moisture is transferrable, conveyable, or transportable along the lengths of such channels. For example, the method may include weaving or knitting high tenacity rib yarns and monofilament rib yarns having cross-sectional shapes (e.g., trilobal, multilobed, U-shaped, S-shaped, other non-round shapes, other non-oval shapes, etc.) and/or having hollow interiors that integrally define moisture movement channels.

In exemplary embodiments, a geogrid includes multifilament rib yarns woven, knitted, or inserted into the grid structure with other high tenacity rib yarns. The multifilament rib yarns include filaments having cross-sectional shapes or profiles (e.g., trilobal, multilobed, U-shaped, S-shaped, other non-round shapes, other non-oval shapes, etc.) that integrally define or form moisture movement channels along the lengths of the filaments (e.g., longitudinally extending water transport channels along the lengths of the filaments, etc.). Moisture is transferrable, conveyable, or transportable along the lengths of such intra fiber channels within the multiple filaments of the multifilament rib yarn. The multifilament rib yarn may comprise polypropylene multifilament yarn, polyethylene terephthalate (PET) multifilament yarn, etc.

An exemplary method of manufacturing a geogrid configured for moisture management includes inserting multifilament rib yarns within the geogrid ribs with other high tenacity rib yarns. The multifilament rib yarns include filaments extruded (broadly, formed) with cross-sectional shapes or profiles (e.g., trilobal, multilobed, U-shaped, S-shaped, other non-round shapes, other non-oval shapes, etc.) and/or with hollow interiors that integrally define or form moisture movement channels along the lengths of the filaments (e.g., longitudinally extending water transport channels along the lengths of the filaments, etc.). Moisture is transferrable, conveyable, or transportable along the lengths of such intra fiber channels within the multiple filaments of the multifilament rib yarn.

In other exemplary embodiments, a geogrid includes multifilament rib yarns having any cross-sectional shape or profile (e.g., round, oval, trilobal, multilobed, U-shaped, S-shaped, triangular, rectangular, non-circular, non-rectangular, non-round shape, non-oval shapes, other cross-sectional shapes, geometries, profiles, etc.) and/or any other filament formation. In these exemplary embodiments, the multifilament rib yarns are configured such that intercapillary channels are defined between the filaments or fibers within the multifilament rib yarn. Moisture is transferrable, conveyable, or transportable along the lengths of the intercapillary channels defined between the filaments or fibers within the multifilament rib yarn. Also, in these exemplary embodiments, the geogrid can be woven or knitted.

In exemplary embodiments, the geogrids configured for moisture management disclosed herein may be used as a standalone product. But in other exemplary embodiments, a geogrid configured for moisture management disclosed herein may be used in combination (e.g., woven, inserted incorporated, integrated, etc.) with a geotextile fabric.

In exemplary embodiments, a geogrid configured for moisture management disclosed herein may be used in combination with a geotextile fabric disclosed herein that is also configured for moisture management.

In exemplary embodiments, a geogrid configured for moisture management disclosed herein may be incorporated or integrated with a geotextile fabric are disclosed in U.S. Pat. No. 11,873,588, which is herein by reference. Accordingly, an exemplary method includes weaving a geogrid configured for moisture management in a continuous step with a geotextile fabric. In this exemplary method, the yarns predetermined (e.g., produced, prepared, etc.) for the woven geotextile fabric and integrated geogrid configured for moisture management may be integrally woven together in a single step or operation on a weaving machine to thereby provide the woven geotextile fabric and integrated geogrid. The yarns for the woven geotextile fabric and the geogrid are integrally woven together (e.g., in a single weaving step or operation on a weaving machine, etc.), such that neither the geotextile fabric nor the integrated geogrid grid are manufactured separately from each other at different times and/or via different process as distinct products that must thereafter be subsequently joined together. The woven geotextile fabric and integrated geogrid are configured such that the yarn type and yarn density changes in both the machine direction and the cross machine direction in exemplary embodiments. This exemplary method thus does not require the additional steps or operations of manufacturing the woven geotextile fabric separately from the geogrid and thereafter physically attaching (e.g., laminating, gluing, heating to bond the layers together, mechanical fastening, etc.) a separately manufactured geotextile fabric to a separately manufactured geogrid.

Alternative exemplary embodiments include separately manufacturing a geogrid configured for moisture management as disclosed herein and a geotextile fabric as distinct products in separate manufacturing steps or processes. Then, the distinct geotextile fabric and the geogrid configured for moisture management may be attached (e.g., laminated, glued, heat bonded, mechanical fastened, etc.) to each other in an additional manufacturing step or process to thereby provide combination of the geotextile fabric and the geogrid configured for moisture management.

In exemplary embodiments, the machine direction rib yarns and the cross machine direction rib yarns may be made from high tenacity PET (polyethylene terephthalate) filament yarns, nylon, polypropylene, polyester, polyethylene terephthalate (PET), rayon, polyethylene, fiberglass, high molecular weight polyethylene (UHMWPE), fiberglass, basalt, terpolymer, acrylic, aramid fibers, natural fibers, biodegradable fibers, etc. Examples of high tenacity yarns include yarns having a tenacity within a range from 6.5 grams per denier up to 40 grams per denier, yarns with a tenacity less than 6.5 grams per denier (e.g., 6 grams per denier, at least 4.5 grams per denier, etc.), yarns with a tenacity more than 40 grams per denier.

In addition, the machine direction rib yarns and the cross machine direction rib yarns do not have to be made from the same materials. For example, the machine direction rib yarns may be made from a first material different than a second material from which the cross machine direction rib yarns are made. Also, by way of example, each machine direction rib yarn does not necessarily have to be made of the same material as each other machine direction rib yarn in all embodiments. Likewise, each cross machine direction rib yarn does not necessarily have to be made of the same material as each other cross machine direction rib yarn in all embodiments.

In exemplary embodiments in which a geogrid configured for moisture management disclosed herein is used in combination with a geotextile fabric, the weave pattern for the geotextile fabric may include a plain (1×1) weave, various types of twill weaves (e.g., 2×1, 2×2, 3×1, 3×3, 4×4, etc.), herringbone weave, satin weave, basket wave, leno weave, and others. The warp and weft yarn systems of the geotextile fabric may comprise multifilament yarns, spun yarns with different cross-sectional shapes, monofilaments, tape yarns, fibrillated yarns, combinations thereof, etc. Additionally, the warp and weft yarn system may be of a single layer or of more than one layer. The layers may be formed during the initial fabric manufacturing process, or may be formed by a two-step process as in the case of a composite geotextile fabric system.

In exemplary embodiments, a geotextile comprises a plurality of structural elements including one or more yarns, cords, or filament bundles arranged to form a fabric, a grid, and/or an integrated fabric and grid. At least a portion of the structural elements may include capillary-active surfaces and/or may be configured to promote capillary wicking of moisture along at least one direction of the geotextile. Additionally, or alternatively, at least a portion of the structural elements may include internal void regions configured to maintain hydraulic conductivity under compaction. The geotextile may be operable for providing dual-mode moisture transport through both capillary wicking and hydraulic flow thereby allowing for removal and redistribution of water from pavement layers and subgrade soils.

The structural elements may comprise cords or yarns having a core region surrounded by a protective sheath. The core region may include interstitial voids or channels configured to enable longitudinal water transport. And the sheath may maintain structural integrity of the geotextile under compaction to preserve the interstitial voids or channels. In some exemplary embodiments, the interstitial voids or channels may be defined by one or more hollow yarns, hollow fibers, or hollow tubing within the core region.

The structural elements may comprise hollow yarns, hollow fibers, or hollow tubing having an internal lumen extending along a longitudinal axis. The internal lumen may be configured to provide conduit-like hydraulic flow. And the hollow yarns, hollow fibers, or hollow tubing may include exterior surfaces that are not permeable or that are permeable to permit water ingress into the internal lumen.

The geotextile may comprise a geogrid that may include ribs formed from bundles of continuous PET filaments and/or non-texturized yarns. The bundles may preserve inter-filament voids under compaction. And the ribs may define moisture movement channels such that moisture is transferrable along the length of the moisture movement channels defined by the ribs.

The geotextile may be configured for dual-mode moisture transport including capillary wicking along filament surfaces and hydraulic conductivity through internal void regions.

The geotextile may be configured such that capillary wicking occurs in at least two orthogonal directions within a plane of the geotextile. The structural elements may be configured to maintain void geometry under compaction loads during pavement installation.

The geotextile may comprise a woven structure including warp and weft yarn systems. The structural elements may comprise a plurality of hollow members integrated within the woven structure. Each hollow member may include a longitudinally extending hollow interior defining a moisture movement channel; and a moisture-permeable exterior configured to allow moisture to enter the hollow interior, such that moisture entering the hollow interior is transportable internally along the moisture movement channel to an adjoining area. The hollow members may comprise hollow yarns, hollow fibers, or hollow tubing integrated within the woven structure. The woven structure may have a weave pattern configured to enhance structural stability of the geotextile under compressive loads, the weave pattern selected from a plain weave, a twill weave, a herringbone weave, a satin weave, a basket weave, or a leno weave; and/or the hollow members are formed from a material resistant to crushing and deformation; and/or the hollow members may comprise polypropylene, polyester, polyethylene terephthalate (PET), nylon, or combinations thereof.

In some exemplary embodiments, at least a portion of the structural elements include the capillary-active surfaces /d/ may be configured to promote capillary wicking of moisture along at least one direction of the geotextile. At least a portion of the structural elements include internal void regions configured to maintain hydraulic conductivity under compaction. And the geotextile is operable for providing dual-mode moisture transport through both capillary wicking and hydraulic flow thereby allowing for removal and redistribution of water from pavement layers and subgrade soils.

The structural elements may comprise one or more yarns including monofilament yarn, DREF or friction spun yarn, and/or braided cord. The one or more yarns may be woven, knitted, or inserted within the geotextile fabric in a machine direction and/or a cross-machine direction. And the one or more yarns may define one or more moisture movement channels configured to transfer, convey, or transport moisture along the length of the one or more yarns. The one or more yarns may comprise monofilament yarns woven, knitted, or inserted within the geotextile fabric in either the machine direction and/or cross machine direction. The monofilament yarns may have a cross-sectional shape(s) that integrally defines the moisture movement channels. The one or more yarns may comprise DREF or friction spun yarns woven, knitted, or inserted periodically or intermittently within the geotextile fabric in the machine direction and/or the cross machine direction. The DREF or friction spun yarns may comprise filaments defining inter-fiber capillary moisture movement channels between the filaments within the DREF or friction yarns such that moisture is transferrable, conveyable, or transportable along the lengths of the inter-fiber capillary moisture movement channels defined between the filaments of the DREF or friction spun yarns. The filaments of each DREF or friction spun yarn may be not bulked or not be texturized but remain straight within the core of the corresponding DREF or friction spun yarn. Additional fibers may be wrapped around the core bundles of straight filaments of the DREF or friction spun yarns. The filaments may comprise microdenier filaments. Each DREF or friction spun yarn may comprise a core of microdenier synthetic filaments wrapped with a sheath of carded staple fibers.

The one or more yarns may comprise braided cords woven, knitted, or inserted periodically or intermittently within the geotextile fabric the machine direction and/or the cross machine direction. The braided cords may comprise filaments defining inter-fiber capillary moisture movement channels between the filaments within the braided cords, such that moisture is transferrable, conveyable, or transportable along the lengths of the inter-fiber capillary moisture movement channels defined between the filaments of the braided cords. The braided cords may be braided or twisted around a group of core filaments. The core filaments of each braided core may not be bulked or texturized but remain straight within the core of the corresponding braided core. The core filaments may comprise microdenier filaments. The braided cords may comprise a system of three or more threads intertwined such that two threads are never twisted around each other.

The geotextile may comprise a geogrid including one or more ribs defining one more moisture movement channels such that moisture is transferrable along the length of the one or more moisture movement channels defined by the one or more ribs. The one or more ribs may have cross-sectional shapes or profiles integrally defining the one or more moisture movement channels. The geogrid may comprise multifilament rib yarns configured such that intercapillary channels are defined between the filaments or fibers within the multifilament rib yarns, whereby moisture is transferrable, conveyable, or transportable along the lengths of the intercapillary channels defined between the filaments or fibers within the multifilament rib yarns.

A roadway system may comprise a geotextile as disclosed herein and a pavement structure including a base layer and a subbase layer. The geotextile may be positioned beneath the base layer or within the subbase layer such that the geotextile is operable to:

• • function as a lateral drainage layer; reduce time-to-drain of the subbase layer; mitigate frost heave by redistributing pore water prior to freeze conditions; and provide dual-mode moisture transport including capillary wicking and hydraulic conductivity.

In exemplary embodiments, a geotextile drainage fabric comprises a woven structure formed from warp and fill yarns. A plurality of tubular elements is integrated within the woven structure. The tubular elements are spaced at predetermined intervals and extend substantially along the fabric length to define preferential fluid flow channels.

The tubular elements may comprise hollow yarns, hollow fibers, or hollow tubing integrated within the woven base structure.

Each tubular element may include a longitudinally extending hollow interior defining a moisture movement channel, and a moisture impermeable exterior.

The woven structure may have a weave pattern configured to enhance structural stability of the geotextile drainage fabric under compressive loads. The weave pattern may be selected from a plain weave, a twill weave, a herringbone weave, a satin weave, a basket weave, or a leno weave.

The tubular elements may be formed from a material resistant to crushing and deformation. The tubular elements may comprise polypropylene, polyester, polyethylene terephthalate (PET), nylon, or combinations thereof.

The tubular elements may be inserted at a frequency of 1 to 1000 per inch. The tubular elements have an inner diameter to outer diameter ratio between 0.001 and 1000.

The geotextile drainage fabric may be configured for dual-mode moisture transport including capillary wicking and hydraulic conductivity. And the geotextile drainage fabric may be configured to serve as both a soil separator and drainage conduit thereby reducing the need for separate drainage layers.

Each tubular element may include: a longitudinally extending hollow interior defining a moisture movement channel; and a moisture-permeable exterior configured to allow moisture to enter the hollow interior, such that moisture entering the hollow interior is transportable internally along the moisture movement channel to an adjoining area. The tubular elements may be configured to contribute to hydraulic conductivity of the geotextile drainage fabric via rigidity of the tubular elements enhancing pressure-driven in-plane flow, maintaining drainage functionality under confinement, and redistributing localized saturated zones and reduces pore pressure. And the tubular elements may be configured to contribute to a secondary moisture management mechanism of the geotextile drainage fabric by providing the moisture movement channels defined by the hollow interiors of the tubular elements. A roadway system may comprise the geotextile drainage fabric and a pavement structure including a base layer and a subbase layer. The geotextile drainage fabric may be positioned beneath the base layer or within the subbase layer to permit moisture ingress through moisture-permeable exteriors of the tubular elements and into the hollow interiors of the tubular elements. Moisture may be transportable internally along the tubular elements toward a drainage zone. The geotextile drainage fabric may be configured to: function as a lateral drainage layer; reduce time-to-drain of the subbase layer; mitigate frost heave by redistributing pore water prior to freeze conditions; and provide dual-mode moisture transport including capillary wicking and hydraulic conductivity.

In exemplary embodiments, a geotextile fabric comprises a woven structure including warp and weft yarn systems. A plurality of hollow members are integrated within the woven structure, wherein each hollow member may include a longitudinally extending hollow interior defining a moisture movement channel.

The hollow members may comprise hollow yarns, hollow fibers, or hollow tubing integrated within the woven structure.

Each hollow member may include a moisture-permeable exterior configured to allow moisture to enter the hollow interior, such that moisture entering the hollow interior is transportable internally along the moisture movement channel to an adjoining area.

The woven structure may have a weave pattern configured to enhance structural stability of the geotextile fabric under compressive loads. The weave pattern may be selected from a plain weave, a twill weave, a herringbone weave, a satin weave, a basket weave, or a leno weave.

The hollow members may be formed from a material resistant to crushing and deformation. And the hollow members may comprise polypropylene, polyester, polyethylene terephthalate (PET), nylon, or combinations thereof.

The hollow members may be inserted at a frequency of 1 to 1000 per inch. The hollow members may have an inner diameter to outer diameter ratio between 0.001 and 1000.

The geotextile fabric may be configured for dual-mode moisture transport including capillary wicking and hydraulic conductivity. The geotextile fabric may be configured to serve as both a soil separator and drainage conduit thereby reducing the need for separate drainage layers.

The hollow members may be configured to contribute to hydraulic conductivity of the geotextile fabric via rigidity of the hollow members enhancing pressure-driven in-plane flow, maintaining drainage functionality under confinement, and redistributing localized saturated zones and reduces pore pressure. The hollow members may be configured to contribute to a secondary moisture management mechanism of the geotextile fabric by providing the moisture movement channels defined by the hollow interiors of the hollow members.

A roadway system may comprise the geotextile fabric and a pavement structure including a base layer and a subbase layer. The geotextile fabric may be positioned beneath the base layer or within the subbase layer to permit moisture ingress through moisture-permeable exteriors of the hollow members and into the hollow interiors of the hollow members, whereby the moisture is transportable internally along the hollow members toward a drainage zone. The geotextile fabric may be configured to: function as a lateral drainage layer; reduce time-to-drain of the subbase layer; mitigate frost heave by redistributing pore water prior to freeze conditions; and provide dual-mode moisture transport including capillary wicking and hydraulic conductivity.

In exemplary embodiments, a geotextile fabric configured for moisture management comprises one or more yarns including monofilament yarn, DREF or friction spun yarn, and/or braided cord. The one or more yarns are woven, knitted, or inserted within the geotextile fabric in a machine direction and/or a cross-machine direction. And the one or more yarns define one or more moisture movement channels configured to transfer, convey, or transport moisture along the length of the one or more yarns.

The one or more yarns may comprise monofilament yarns woven, knitted, or inserted within the geotextile fabric in either the machine direction and/or cross machine direction. The monofilament yarns may have a cross-sectional shape(s) that integrally defines the moisture movement channels. The monofilament yarns may have cross-sectional shapes that are the same as or different from each other. The cross-sectional shapes of the monofilament yarns may include one or more of trilobal, multilobed, U-shaped, S-shaped, C-shaped, and W-shaped.

The one or more yarns may comprise DREF or friction spun yarns woven, knitted, or inserted periodically or intermittently within the geotextile fabric in the machine direction and/or the cross machine direction. The DREF or friction spun yarns may comprise filaments defining inter-fiber capillary moisture movement channels between the filaments within the DREF or friction yarns such that moisture is transferrable, conveyable, or transportable along the lengths of the inter-fiber capillary moisture movement channels defined between the filaments of the DREF or friction spun yarns. The filaments may be extruded or otherwise formed with a cross-sectional shape(s) including one or more of round, oval, trilobal, multilobed, U-shaped, S-shaped, C-shaped, and W-shaped. The filaments of each DREF or friction spun yarn may be non-bulked or non-texturized but remain straight within the core of the corresponding DREF or friction spun yarn. Additional fibers may be wrapped around the core bundles of straight filaments of the DREF or friction spun yarns. The filaments may comprise microdenier filaments. Each DREF or friction spun yarn may comprise a core of microdenier synthetic filaments wrapped with a sheath of carded staple fibers.

The one or more yarns may comprise braided cords woven, knitted, or inserted periodically or intermittently within the geotextile fabric the machine direction and/or the cross machine direction. The braided cords may comprise filaments defining inter-fiber capillary moisture movement channels between the filaments within the braided cords, such that moisture is transferrable, conveyable, or transportable along the lengths of the inter-fiber capillary moisture movement channels defined between the filaments of the braided cords. The filaments may be extruded or otherwise formed with a cross-sectional shape(s) including one or more of round, oval, trilobal, multilobed, U-shaped, S-shaped, C-shaped, and W-shaped. The braided cords may be braided or twisted around a group of core filaments. The core filaments of each braided core may be non-bulked or non-texturized but remain straight within the core of the corresponding braided core. The core filaments may comprise microdenier filaments. The braided cords may comprise a system of three or more threads intertwined such that two threads are never twisted around each other.

The geotextile fabric may be configured for dual-mode moisture transport including capillary wicking and hydraulic conductivity. And the geotextile fabric may be configured to serve as both a soil separator and drainage conduit thereby reducing the need for separate drainage layers.

A roadway system may comprise the geotextile fabric and a pavement structure including a base layer and a subbase layer. The geotextile fabric may be positioned beneath the base layer or within the subbase layer to permit moisture into the moisture movement channels, whereby the moisture is transportable within the moisture movement channels along the length of the one or more yarns. The geotextile fabric may be configured to: function as a lateral drainage layer; reduce time-to-drain of the subbase layer; mitigate frost heave by redistributing pore water prior to freeze conditions; and provide dual-mode moisture transport including capillary wicking and hydraulic conductivity.

In exemplary embodiments, a geogrid configured for moisture management comprises one or more ribs defining one more moisture movement channels such that moisture is transferrable along the length of the one or more moisture movement channels defined by the one or more ribs.

The one or more ribs may have cross-sectional shapes or profiles integrally defining the one or more moisture movement channels. The cross-sectional shapes or profiles of the one or more ribs may include one or more of trilobal, multilobed, U-shaped, S-shaped, non-round shape, and non-oval shape.

The geogrid may comprise an extruded sheet that is punctured to thereby form openings in the extruded sheet between the one or more ribs and that is drawn in the machine and cross machine directions.

The one or more ribs may comprise one or more extruded ribs that are bonded together to thereby form the geogrid. The one or more extruded ribs may be provided with the one or more moisture movement channels: during the extrusion of the one or more extruded ribs; or after the extrusion via an embossing process.

The geogrid may comprise a woven or knitted geogrid.

The geogrid may comprise monofilament rib yarns woven, knitted, or inserted into the grid structure with high tenacity rib yarns. And the monofilament rib yarns may define moisture movement channels such that moisture is transferrable along the lengths of the moisture movement channels defined by the monofilament rib yarns.

The geogrid may comprise multifilament rib yarns woven, knitted, or inserted into the grid structure with high tenacity rib yarns. At least one multifilament rib yarn may comprise filaments defining moisture movement channels along the lengths of the filaments of the at least one multifilament rib yarn such that moisture is transferrable, conveyable, or transportable along the lengths of the moisture movement channels defined by the multiple filaments of the at least one multifilament rib yarn. The filaments of the at least one multifilament rib yarn may be configured to integrally define intra fiber moisture movement channels along the lengths of the filaments of the at least one multifilament rib yarn such that moisture is transferrable, conveyable, or transportable along the lengths of the intra fiber moisture movement channels with the multiple filaments of the at least one multifilament rib yarn. The filaments of the at least one multifilament rib yarn may have cross-sectional shapes or profiles integrally defining the moisture movement channels along the lengths of the filaments of the at least one multifilament rib yarn.

The geogrid may comprise multifilament rib yarns configured such that intercapillary channels are defined between the filaments or fibers within the multifilament rib yarns, whereby moisture is transferrable, conveyable, or transportable along the lengths of the intercapillary channels defined between the filaments or fibers within the multifilament rib yarns.

The geogrid may comprise machine direction ribs and cross machine direction ribs such that a plurality of open areas or apertures are cooperatively defined between the machine direction ribs and the cross machine direction ribs. One or more machine direction ribs may define one or more moisture movement channels such that moisture is transferrable along the lengths of the one or more moisture movement channels defined by the one or more machine direction ribs. Additionally, or alternatively, one or more cross machine direction ribs may define one or more moisture movement channels such that moisture is transferrable along the lengths of the one or more moisture movement channels defined by the one or more cross machine direction ribs. For example, all of the machine direction ribs define moisture movement channels such that moisture is transferrable along the lengths of the moisture movement channels defined by the machine direction ribs; and/or all of the cross machine direction ribs define moisture movement channels such that moisture is transferrable along the lengths of the moisture movement channels defined by the cross machine direction ribs.

The one or more ribs may include hollow interiors defining the one or more moisture movement channels such that after moisture has entered the hollow interiors of the one or more ribs, the moisture is transferrable internally along the one or more ribs through the one more moisture movement channels defined by the hollow interiors of the one or more ribs. The hollow interiors of the one or more ribs may comprise longitudinally extending hollow cores having closed cross-sectional shapes such that after moisture has entered the longitudinally extending hollow cores of the one or more ribs, the moisture is longitudinally transferrable internally along the longitudinally extending hollow cores of the one or more ribs. The closed cross-sectional shapes of the longitudinally extending hollow cores of the one or more ribs may include one or more of round, flat, trilobal, multilobed, oval, triangular, rectangular, non-circular, and non-rectangular. The one or more ribs may include permeable exteriors configured for allowing moisture to permeate therethrough and enter the hollow interiors of the one or more ribs such that after moisture has permeated through the permeable exteriors and entered the hollow interiors of the one or more ribs, the moisture is transferrable internally along the one or more ribs through the one or more moisture movement channels defined by the hollow interiors of the one or more ribs.

The geogrid may be integrated with a woven geotextile fabric such that: machine direction ribs and cross machine direction ribs cooperatively define the geogrid integrally woven within the woven geotextile fabric; and woven geotextile fabric areas in a field of the geogrid are generally between the machine direction ribs and the cross machine direction ribs.

The machine direction ribs and cross machine direction ribs may cooperatively define the geogrid integrally woven within the woven geotextile fabric without a separate physical non-woven attachment between the geogrid and the woven geotextile fabric.

The machine direction ribs and cross machine direction ribs may cooperatively define the geogrid integrally woven within the woven geotextile fabric without a lamination, glue, or heat bond between the geogrid and the woven geotextile fabric.

The machine direction ribs and cross machine direction ribs may cooperatively define the geogrid integrally woven within the woven geotextile fabric without laminating, gluing, heat bonding, or mechanical fastening the geogrid and the woven geotextile fabric.

The woven geotextile fabric may comprise a plurality of yarns integrally woven together including: machine direction rib yarns defining the machine direction ribs; cross machine direction rib yarns defining the cross machine direction ribs; machine direction field yarns and cross machine direction field yarns cooperatively defining the woven geotextile fabric areas generally between the machine direction ribs and the cross machine direction ribs. The machine direction ribs and the cross machine direction ribs may cooperatively define the geogrid as an integral part of the woven geotextile fabric. And the machine direction ribs and the cross machine direction ribs may be thicker and have higher tensile strength than the machine direction field yarns and the cross machine direction field yarns.

A roadway system may comprise the geogrid and a pavement structure including a base layer and a subbase layer. The geogrid may be positioned beneath the base layer or within the subbase layer to permit moisture into the one or more moisture movement channels defined by the one or more ribs of the geogrid, whereby the moisture is transportable within the one or more moisture movement channels. The geogrid may be configured to: function as a lateral drainage layer; reduce time-to-drain of the subbase layer; mitigate frost heave by redistributing pore water prior to freeze conditions; and provide dual-mode moisture transport including capillary wicking and hydraulic conductivity.

Example embodiments are provided so that this disclosure will be thorough and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. In addition, advantages and improvements that may be achieved with one or more exemplary embodiments of the present disclosure are provided for purpose of illustration only and do not limit the scope of the present disclosure, as exemplary embodiments disclosed herein may provide all or none of the above mentioned advantages and improvements and still fall within the scope of the present disclosure.

Specific dimensions, specific materials, and/or specific shapes disclosed herein are example in nature and do not limit the scope of the present disclosure. The disclosure herein of particular values and particular ranges of values for given parameters are not exclusive of other values and ranges of values that may be useful in one or more of the examples disclosed herein. Moreover, it is envisioned that any two particular values for a specific parameter stated herein may define the endpoints of a range of values that may be suitable for the given parameter (i.e., the disclosure of a first value and a second value for a given parameter can be interpreted as disclosing that any value between the first and second values could also be employed for the given parameter). For example, if Parameter X is exemplified herein to have value A and also exemplified to have value Z, it is envisioned that parameter X may have a range of values from about A to about Z. Similarly, it is envisioned that disclosure of two or more ranges of values for a parameter (whether such ranges are nested, overlapping, or distinct) subsume all possible combination of ranges for the value that might be claimed using endpoints of the disclosed ranges. For example, if parameter X is exemplified herein to have values in the range of 1-10, or 2-9, or 3-8, it is also envisioned that Parameter X may have other ranges of values including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3, 3-10, and 3-9.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. For example, when permissive phrases, such as “may comprise”, “may include”, and the like, are used herein, at least one embodiment comprises or includes the feature(s). As used herein, the singular forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being “on”, “engaged to”, “connected to” or “coupled to” another element or layer, it may be directly on, engaged, connected, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to”, “directly connected to” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

The term “about” when applied to values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If, for some reason, the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring or using such parameters. For example, the terms “generally”, “about”, and “substantially” may be used herein to mean within manufacturing tolerances.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer, or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath”, “below”, “lower”, “above”, “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements, intended or stated uses, or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.