Self Healing Salt Water Barrier

• US 20090130368A1
• Filed: 11/19/2007
• Published: 05/21/2009
• Est. Priority Date: 11/19/2007
• Status: Active Grant

• Current Assignee: Amcol International Corporation (Minerals Technologies Incorporated)
• Original Assignee: Amcol International Corporation (Minerals Technologies Incorporated)
• Inventors: Mosiewicz, Marek R., Beihoffer, Thomas W., Larionova, Nataliya V.
• Granted Patent: US 10,012,079 B2
• Time in Patent Office: Days
• US Class Current: 428/68
• CPC Class Codes: B32B 2255/02 on fibrous or filamentary layer
• CPC Class Codes: B32B 2262/0246 Acrylic resin fibres
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2262/0261 Polyamide fibres
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/0292 Polyurethane fibres
• CPC Class Codes: B32B 2262/04 Cellulosic plastic fibres, e.g. rayon
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/105 Ceramic fibres
• CPC Class Codes: B32B 2307/714 Inert, i.e. inert to chemical degradation, corrosion
• CPC Class Codes: B32B 2307/7145 Rot proof, resistant to bacteria, mildew, mould, fungi
• CPC Class Codes: B32B 2307/726 Permeability to liquids, absorption
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2307/728 Hydrophilic
• CPC Class Codes: B32B 2307/762 Self-repairing, self-healing
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 2581/00 Seals; Sealing equipment; Gaskets
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/14 next to a particulate layer
• CPC Class Codes: B32B 27/304 : comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 3/02 : characterised by features of form at particular places, e.g. in edge regions non-uniform thickness B32B3/263
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 7/05 : the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection using interposed adhesives or bonding materials applied in spaced arrangements B32B7/14
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: E02D 31/004 : Sealing liners
• CPC Class Codes: E21D 11/383 : by applying waterproof flexible sheets; Means for fixing the sheets to the tunnel or cavity wall
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/23 : Sheet including cover or casing
• CPC Class Codes: Y10T 428/24942 : including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 442/30 : Woven fabric [i.e., woven strand or strip material]
• CPC Class Codes: Y10T 442/60 : Nonwoven fabric [i.e., nonwoven strand or fiber material]

Abstract

Geocomposite articles that can provide a barrier against high conductivity water e.g., ocean water, are described and their method of manufacture, for waterproofing surfaces that contact high conductivity water. The geocomposite article mat includes a woven or non-woven geotextile sheet or mat containing a powdered or granular partially cross-linked acrylamide/acrylate/acrylic acid copolymer across its entire major surface(s). The powdered or granular copolymer has an unexpectedly high free-swell when hydrated with High Conductivity water, such as ocean water. A liquid-impermeable cover sheet is adhered to the upper major surfaces of the filled copolymer-carrying geotextile to provide a primary high conductivity water barrier layer that, if ruptured, is sealed by the swell of an underlying layer of water-insoluble, partially cross-linked acrylamide/acrylic acid copolymer.

Claims

1. A self-healing geocomposite article comprising:

a) at least one water-impermeable membrane layer; and

b) at least one active self-healing layer;

wherein the geocomposite article exhibits self-healing performance index less than 0.1 when tested by placing a 1 inch slit through all layers of the geocomposite article sealed at its edges under 4 meters of water with a conductivity of 1 mS/cm or greater.

2. The self-healing geocomposite article of claim 1, further including a woven or non-woven geotextile fabric containing at least a portion of the self-healing layer adhered to the membrane layer to sandwich the active self-healing layer between the membrane and the fabric.

3. The self-healing geocomposite article of claim 2, wherein the active self-healing layer is a powdered or granular high conductivity—

water absorbent material capable of absorbing water having a conductivity of at least 1 mS/cm.

4. The self-healing geocomposite article of claim 3, wherein the powdered or granular high conductivity water absorbent material is included in the article in an amount in the range of 0.1 ounce to 30 pounds per ft² of a major surface area of the article.

5. The self-healing geocomposite article of claim 3 wherein the water absorbent material has a free swell of greater than 35 mL/2 grams material in 4.5% sea salt in water solution.

6. The self-healing geocomposite article of claim 4, wherein the powdered or granular high conductivity water absorbent material is included in the article in an amount in the range of 0.1 ounce to 5 pounds per ft² of a major surface area of the article.

7. The self-healing geocomposite article of claim 3, wherein the active self-healing layer comprises a partially neutralized, partially cross-linked, water-insoluble acrylic acid copolymer.

8. The self-healing geocomposite article of claim 6, wherein the active-self-healing layer comprises a combination of said copolymer together with a second powdered or granular material selected from the group consisting of sodium smectite clay;

organophilic clay;

activated carbon;

coke breeze;

zero-valent iron;

apatite;

zeolite;

pete moss;

polymeric ion-exchange resin;

polymeric adsorbent; and

a mixture thereof.

9. The self-healing geocomposite article of claim 7, wherein the second powdered or granular material is included with the copolymer in an amount less than 50 wt.% based on the total weight of the copolymer and the second powdered or granular material.

10. The self-healing geocomposite article of claim 6, wherein the active self-healing layer is a partially cross-linked, water-insoluble acrylamide/acrylic acid/acrylate copolymer.

11. The self-healing geocomposite article of claim 6, wherein the active self-healing layer is a partially cross-linked, water-insoluble acrylamide/acrylic acid/acrylate copolymer identified by the CAS #31212-13-2.

12. The geocomposite article of claim 9, wherein the copolymer contains about 0-95 mole % acrylamide;

about 5-95 mole % sodium or potassium or lithium or ammonium acrylate; and

5-95 mole % acrylic acid.

13. The geocomposite article of claim 11, wherein the copolymer contains about 25-50 mole % acrylamide;

about 25-50 mole % sodium or potassium or lithium or ammonium acrylate; and

about 25-50 mole % acrylic acid.

14. The geocomposite article of claim 11, wherein the powdered or granular copolymer includes less than 5000 ppm acrylamide monomer.

15. The geocomposite article of claim 12, wherein the powdered or granular copolymer includes less than 1,000 ppm acrylamide monomer.

16. The geocomposite article of claim 13, wherein the powdered or granular copolymer includes less than 100 ppm acrylamide monomer.

17. The geocomposite article of claim 2, wherein the geotextile fabric, prior to receiving the powdered or granular copolymer, has an apparent opening size in the range of about 0.5 mm to about 6 mm.

18. The geocomposite article of claim 6, wherein the powdered or granular copolymer has a particle size such that at least 90% of the particles have a size in the range of about 6 mesh to about 325 mesh.

19. The geocomposite article of claim 2, wherein the powdered or granular copolymer comprises about 50% to about 99.9% by volume of the geotextile fabric.

20. The geocomposite article of claim 2, wherein the geotextile fabric is non-woven.

22. The geocomposite article of claim 19, wherein the water contains multivalent ions selected from the group consisting of Na⁺, Mg⁺⁺, Ca⁺⁺, A1⁺⁺ and combinations thereof.

23. The geocomposite article of claim 19, wherein the geocomposite article further includes a powdered or granular reactive material selected from the group consisting of activated carbon, coke breeze, zero-valent iron, apatite, organophilic clay, zeolite, polymeric ion exchange resins, polymeric adsorbing resins and mixtures thereof.

24. The geocomposite article of claim 19, wherein the geotextile fabric contains fibers selected from the group consisting of polyolefin, polyester, polyamide, and copolymers of any two or more of the foregoing.

25. The geocomposite article of claim 19, wherein the copolymer contains about 5-95 mole % acrylamide;

about 5-95 mole % sodium or potassium acrylate; and

5-95 mole % acrylic acid.

26. The geocomposite article of claim 25, wherein the copolymer contains about 25-50 mole % acrylamide;

about 25-50 mole % sodium or potassium acrylate; and

about 25-50 mole % acrylic acid.

27. The geocomposite article of claim 19, wherein the geotextile, prior to receiving the powdered or granular copolymer, has an apparent opening size in the range of about 0.5 mm to about 6 mm.

28. The geocomposite article of claim 19, wherein the powdered or granular copolymer has a particle size such that at least 90% of the particles have a size in the range of about 6 mesh to about 325 mesh.

30. The geocomposite article of claim 19, wherein the geotextile fabric is non-woven.

41. A method water proofing a surface from contact with a water source having a conductivity of at least 1 mS/cm comprising disposing the geocomposite article of claim 1, such that the water-impermeable cover sheet first contacts the water source.

42. A method water proofing a surface from contact with a water source having a conductivity of at least 1 mS/cm comprising disposing the geocomposite article of claim 12, such that the water-impermeable cover sheet first contacts the water source.

21. A geocomposite article capable of providing a water barrier SPI to water having a conductivity of at least 1 mS/cm comprising:

a geotextile fabric formed from woven or non-woven fibers;

a powdered or granular partially cross-linked, water-insoluble acrylamide/acrylate/acrylic acid copolymer carried in or on said geotextile fabric; and

a water-impermeable cover sheet adhered to a major surface of the article, adjacent to said copolymer to confine the copolymer within the geocomposite article, as a primary water-impermeable layer.

29. The geocomposite article of claim 21, wherein the powdered or granular reactive material comprises about 50% to about 99.9% by volume of the geotextile fabric.

31. A method of manufacturing a geocomposite article that provides a barrier to water having a conductivity of at least 1 mS/cm comprising:

providing a woven or non-woven geotextile sheet or mat;

contacting the geotextile sheet or mat with a powdered or granular partially cross-linked, water-insoluble acrylamide/acrylate/acrylic acid copolymer, and causing at least a portion of the powdered or granular copolymer to flow into the geotextile mat to fill at least a portion of the geotextile sheet or mat within openings thereof; and

adhering a liquid-impermeable cover sheet onto a major surface of the geotextile mat adjacent to the copolymer after the mat has received the powdered or granular copolymer.

32. The method of claim 31 including the step of securing a liquid-impermeable cover sheet to a lower major surface of the geotextile sheet or mat before contacting the geotextile sheet or mat with the powdered or granular copolymer.

33. The method of claim 31, further including the step of covering edges of the pre-formed geotextile mat with a water-impermeable sheet material layer.

34. The method of claim 31, wherein the edges of the geotextile sheet or mat are covered with excess material from the water-impermeable cover sheet.

35. The method of claim 31 wherein the excess material of the cover sheet is secured to cover the edges of the geotextile fabric by adhesively securing the cover sheet over the edges of the geotextile fabric, or heat-sealing the cover sheet surrounding the edges of the geotextile fabric.

36. The method of claim 31, wherein the powdered or granular copolymer is caused to flow into the geotextile fabric by vibrating the geotextile fabric while in contact with the powdered or granular copolymer.

37. The method of claim 31, wherein the powdered or granular copolymer is caused to flow into the geotextile fabric by applying a vacuum to an undersurface of the geotextile fabric to draw the powdered or granular copolymer into the sheet or mat from an upper surface.

38. The method of claim 31, including the step of providing the water-impermeable cover sheet having a dimension larger than the major surface of the geotextile fabric to provide excess cover material so that the excess cover material extends over an edge surface of the geocomposite article, and securing the excess cover material to the geotextile article to cover the edge surface, thereby reducing or eliminating escape of powdered or granular copolymer through the covered edge surface of the geotextile article.

39. The method of claim 36, including the step of covering all edge surfaces with excess cover material, and securing the excess cover material to the geocomposite article thereby reducing or eliminating escape of powdered or granular copolymer through all edge surfaces of the geotextile article.

40. The method of claim 36, wherein the cover sheet is secured over the edge surface by an expedient selected from the group consisting of adhesively securing, thermal welding techniques,—

vibrational welding and ultrasonic welding.