Method of manufacturing an improved wood fiber mat for soil applications

• US 5,484,501 A
• Filed: 06/24/1994
• Issued: 01/16/1996
• 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): Ryan, Patrick J.
• Assistant Examiner(s): Weisberger, Richard C.
• Application Number:
  US08/265,458
• Time in Patent Office: 571 Days
• Field of Search: 156/62.2, 156/62.6, 156/209, 156/296, 156/209, 156/296, 264/121, 264/122, 264/128, 162/117
• US Class Current: 156/209
• 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 process for manufacturing a mat comprising the steps of:

weighing and mixing together predetermined quantities of wood fibers and a thermoplastic fiber material having a melting temperature below 400°

F., 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, and the wood and thermoplastic fibers being sized to allow the mat to become an integral part of the soil surface;

blending the fibers together, the mixed blend of wood and thermoplastic fibers entangling to form a mat which has a porosity which permits vegetation to grow through the mat;

laying the mixture of fibers onto a moving conveyor;

bonding selected areas of the mat using a pair of embossing rolls, the embossing rolls being heated such that the compression caused by the embossing rolls causes the thermoplastic material to melt and bond in the selected areas, wherein the unselected areas maintain their porosity to permit vegetation to germinate therethrough.

2. The process of claim 1 wherein the one embossing roll is heated up to approximately 450°

F. and the other embossing roll is heated up to approximately 400°

F.

3. The process of claim 2 wherein the pressure applied to the mat is between 500 and 100 pounds per linear inch.

4. The process of claim 1 further including the steps of:

cutting the mat into predetermined lengths, and

rolling and packaging the mat for shipment.

5. The process of claim 1 further including the steps of:

adding a layer of netting to one or both sides of the mat prior to the step of embossing;

cutting the mat at predetermined lengths, and

rolling and packaging the mat for shipment.

6. The process of claim 1 wherein the conveyor moves at between 40 and 70 feet per minute.

7. The process of claim 1 wherein the selected areas are comprised of a grid of squares formed of bonded material, with each square containing an "X" shaped pair of lines formed of bonded material, the ends of the lines bisecting the four corners of the square.

8. The process of claim 1 wherein the selected areas are comprised of a grid of diamond like areas of bonded material.

9. The process of claim 1 further including the step of running the mat product through a calendaring station to glaze seal the surface of both sides of the mat product.