Wood fiber mat for soil applications

• US 5,330,828 A
• Filed: 09/18/1992
• Issued: 07/19/1994
• Est. Priority Date: 01/07/1991
• Status: Expired due to Term

• Current Assignee: Terra-Mulch Products, LLC
• Original Assignee: Conwed Fibers
• Inventors: Jacobsen, William M. W. Jr., De Pass, Ernest, Belt, L. Carl
• Primary Examiner(s): Lesmes, George F.
• Assistant Examiner(s): MORRIS, TERREL H
• Application Number:
  US07/947,946
• Time in Patent Office: 669 Days
• Field of Search: 428/224, 428/280, 428/286, 428/296, 428/298, 405/15, 405/16, 405/19
• US Class Current: 442/416
• CPC Class Codes: B27N 3/00 Manufacture of substantially flat articles, e.g. boards, from particles or fibres
• CPC Class Codes: B27N 3/002 characterised by the type of binder compositions of macromolecular compounds C08L
• CPC Class Codes: C08L 23/12 Polypropene
• CPC Class Codes: C08L 2666/02 Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 2666/06 Homopolymers or copolymers of unsaturated hydrocarbons; Derivatives thereof
• CPC Class Codes: C08L 67/00 Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain of polyester-amides C08L77/12; of polyester-imides C08L79/08; Compositions of derivatives of such polymers
• CPC Class Codes: C08L 97/02 Lignocellulosic material, e.g. wood, straw or bagasse manufacture of articles made from lignocellulosic material by dry processes B27N
• CPC Class Codes: E02D 17/202 with flexible securing means
• CPC Class Codes: E02D 3/10 by watering, draining, de-aerating or blasting, e.g. by installing sand or wick drains E02D3/11 takes precedence; soil-penetrating vibrators with auxiliary watering E02D3/054; drainage of soil in general E02B11/00
• CPC Class Codes: Y10T 156/1023 Surface deformation only [e.g., embossing]
• CPC Class Codes: Y10T 428/24331 including nonapertured component
• CPC Class Codes: Y10T 428/24826 Spot bonds connect components
• CPC Class Codes: Y10T 442/698 Containing polymeric and natural strand or fiber materials

Abstract

Improved wood fiber mat comprised of a mixture of thermo-mechanically processed wood fibers and synthetic fibers.

Claims

1. A mat comprised of a thoroughly mixed blend of a predetermined percentage of wood fibers and a predetermined percentage of a thermoplastic material fiber, the wood fibers diameter being determined by a mesh screen, the wood fiber diameter ranging in size by using mesh screens between 8 mesh and 100 mesh, the melting temperature of said thermoplastic material fiber being below 400°

F., the thoroughly mixed blend of wood and thermoplastic fibers entangling to form a mat which has a porosity which permits vegetation to grow through the mat, and the wood and thermoplastic fibers being sized to allow the mat to become an integral part of the soil surface.

2. The mat of claim 1 wherein the thermoplastic material is polypropylene.

3. The mat of claim 2 including a predetermined percentage of a second thermoplastic material, the second thermoplastic material being characterized in that it has a melting temperature higher than that of polypropylene.

4. The mat of claim 2 wherein the thermoplastic fibers are between 1/4 inch and 3 inches in length and between 3 to 6 denier.

5. The mat of claim 4 wherein the wood fibers have been thermomechanically processed, and are comprised of 45-56% fibers from an ASTM size 8 screen;

14-18% fibers from an ASTM size 16 screen;

10-15% fibers from an ASTM size 50 screen, and 5-10% fibers from an ASTM size 100 screen.

6. The mat of claim 1 wherein the thermoplastic material is polyethylene.

7. The mat of claim 6 including a predetermined percentage of a second thermoplastic material, the second thermoplastic material being characterized in that it has a melting temperature higher than that of polyethylene.

8. The mat of claim 4 wherein select areas of the thermoplastic material have been bonded on one or both sides of the mat.

9. The mat of claim 8 including a layer of netting on one or both sides of the mat.

10. The mat of claim 9 wherein the netting is photodegradable.

11. The mat of claim 2 wherein the percentage of wood fibers is 85% and the percentage of polypropylene fibers is 15%.

12. The mat of claim 2 wherein the percentage of wood fibers is 94% and the percentage of polypropylene fibers is 6%.

13. The mat of claim 3 wherein the thermoplastic fibers are between 1/4 inch and 3 inches in length and between 3 to 6 denier.

14. The mat of claim 13 wherein the first thermoplastic material has been bonded in a predetermined pattern on one or both sides of the mat.

15. The mat of claim 14 including a layer of netting on one or both sides of the mat.

16. The mat of claim 14 wherein the netting is photodegradable.

17. The mat of claim 3 wherein the percentage of wood fibers is 80%, the percentage of polypropylene fibers is 10% and the percentage of polyester fibers is 10%.

18. The mat of claim 3 wherein the percentage of wood fibers is 60%, the percentage of polypropylene fibers is 20% and the percentage of polyester fibers is 20%.

19. The mat of claim 3 wherein the percentage of wood fibers is 90%, the percentage of polypropylene fibers is 5% and the percentage of polyester fibers is 5%.

20. The mat of claim 2 wherein the mat weighs 60 pounds per 1000 square feet.

21. The mat of claim 2 wherein the mat weighs 90 pounds per 1000 square feet.

22. The mat of claim 8 wherein the bonded area is comprised of a grid of squares formed of bonded material, with each square containing a "X" shaped pair of lines formed of bonded material, the ends of the lines bisecting the four corners of the square.

23. The mat of claim 8 wherein the bonded area is comprised of a grid of diamond like areas of bonded material.

24. The mat of claim 2 wherein the thermoplastic fibers are between 1/4 inch and 3 inches in length and between 10 to 15 denier.

25. The mat of claim 2 wherein the percentage of wood fibers is 90% and the percentage of polypropylene fibers is 10%.

26. A mat comprising a water absorption and retention material layer, the layer consisting essentially of a thoroughly mixed blend of a predetermined percentage of wood fibers and a predetermined percentage of a thermoplastic material fiber, the wood fiber diameter being determined by a mesh screen, the wood fiber diameter ranging in size by using mesh screens between 8 mesh and 100 mesh, the melting temperature of said thermoplastic material fiber being below 400°

F., the thoroughly mixed blend of wood and thermoplastic fibers entangling to form a mat which has a porosity which permits vegetation to grow through the mat and the wood and thermoplastic fibers being sized to allow the mat to become an integral part of the soil surface.