Method of manufacturing a composite nonwoven fabric suitable for geotextile use

Abstract

A composite fabric, suitable for geotextile use, is manufactured by obtaining a web of metal material consisting of a plurality individual strands of metal that are substantially parallel to each other, are substantially unidirectionally oriented, and have not undergone any carding, garneting, lapping, or needle punching processing, and wherein the individual strands of metal have not been cut to any particular length, and obtaining a scrim layer having a porous, open woven configuration. The web of metal material is attached to the scrim layer to form the composite fabric material. The attachment may be by needle punching the web of metal material to the scrim layer.

What is claimed is: 
     
         1 . A method of manufacturing a composite fabric material, comprising the steps of:
 obtaining a first web of metal material consisting of a plurality individual strands of metal that are substantially parallel to each other, are substantially unidirectionally oriented, and have not undergone any carding, garneting, lapping, or needle punching processing, and wherein the individual strands of metal have not been cut to any particular length;   obtaining a scrim layer having a first side, an opposing second side, and a porous, open woven configuration; and   attaching the first web of metal material to the first side of the scrim layer to form the composite fabric material.   
     
     
         2 . The method according to  claim 1 , wherein the scrim layer is water permeable. 
     
     
         3 . The method according to  claim 1 , wherein the first web of metal material comprises steel. 
     
     
         4 . The method according to  claim 1 , wherein the first web of metal material comprises stainless steel. 
     
     
         5 . The method according to  claim 1 , wherein the step of attaching the first web of metal material to the first side of the scrim layer comprises entangling at least a portion of the first web of metal material with the scrim layer. 
     
     
         6 . The method according to  claim 1 , wherein the step of attaching the first web of metal material to the first side of the scrim layer comprises needle punching at least a portion of the first web of metal material to the scrim layer. 
     
     
         7 . The method according to  claim 1 , further comprising the steps of:
 obtaining a second web of metal material consisting of a plurality individual strands of metal that are substantially parallel to each other, are substantially unidirectionally oriented, and have not undergone any carding, garneting, lapping, or needle punching processing, and wherein the individual strands of metal have not been cut to any particular length; and   attaching the second web of metal material to the second side of the scrim layer.   
     
     
         8 . The method according to  claim 7 , wherein the steps of attaching the first web of metal material to the first side of the scrim layer and attaching the second web of metal material to the second side of the scrim layer are performed substantially simultaneously. 
     
     
         9 . The method according to  claim 7 , wherein the scrim layer is interlocked between the first web of metal material and the second web of metal material. 
     
     
         10 . The method according to  claim 1 , wherein the composite fabric material is a geotextile material, and wherein the scrim layer includes a plurality of openings extending therethrough and created by the open woven configuration, the openings being sized to permit plant roots to grow therethrough.