CA2535801A1 - A blended mulch product, an erosion control medium and methods of making same - Google Patents

A blended mulch product, an erosion control medium and methods of making same Download PDF

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Publication number
CA2535801A1
CA2535801A1 CA 2535801 CA2535801A CA2535801A1 CA 2535801 A1 CA2535801 A1 CA 2535801A1 CA 2535801 CA2535801 CA 2535801 CA 2535801 A CA2535801 A CA 2535801A CA 2535801 A1 CA2535801 A1 CA 2535801A1
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Prior art keywords
fibers
control medium
substantially straight
erosion control
synthetic fibers
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Granted
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CA 2535801
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French (fr)
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CA2535801C (en
Inventor
Doris Ericka Lougheed
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TERRA-MULCH PRODUCTS LLC
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Canadian Forest Products Ltd
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Application filed by Canadian Forest Products Ltd filed Critical Canadian Forest Products Ltd
Priority to CA 2535801 priority Critical patent/CA2535801C/en
Priority to US11/352,384 priority patent/US7484330B2/en
Priority to US11/352,439 priority patent/US7681353B2/en
Publication of CA2535801A1 publication Critical patent/CA2535801A1/en
Priority to US12/343,567 priority patent/US7966765B2/en
Application granted granted Critical
Publication of CA2535801C publication Critical patent/CA2535801C/en
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Classifications

    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01G—HORTICULTURE; CULTIVATION OF VEGETABLES, FLOWERS, RICE, FRUIT, VINES, HOPS OR SEAWEED; FORESTRY; WATERING
    • A01G13/00—Protecting plants
    • A01G13/02—Protective coverings for plants; Coverings for the ground; Devices for laying-out or removing coverings
    • A01G13/0256—Ground coverings
    • A01G13/0262—Mulches, i.e. covering material not-pre-formed in mats or sheets
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K17/00—Soil-conditioning materials or soil-stabilising materials
    • C09K17/52—Mulches
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A40/00—Adaptation technologies in agriculture, forestry, livestock or agroalimentary production
    • Y02A40/10—Adaptation technologies in agriculture, forestry, livestock or agroalimentary production in agriculture
    • Y02A40/28—Adaptation technologies in agriculture, forestry, livestock or agroalimentary production in agriculture specially adapted for farming
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659—Including an additional nonwoven fabric
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/695—Including a wood containing layer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/697—Containing at least two chemically different strand or fiber materials
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/697—Containing at least two chemically different strand or fiber materials
    • Y10T442/698—Containing polymeric and natural strand or fiber materials

Abstract

In one aspect there is provided a blended mulch product which can be mixed with water and spray-applied to a ground surface to form an erosion control medium, the blended mulch product comprising: about 75% to about 92% by weight ligno-cellulosic fibers; about 1% to about 10% by weight substantially straight synthetic fibers; and a tackifier; wherein the substantially straight synthetic fibers maintain their substantially straight form in the blended mulch product and the erosion control medium.
Also provided are slurries in which the blended mulch product is mixed with water to produce the slurry, the slurry is spray-applied to a ground surface and the slurry dries on the ground surface to form an erosion control medium.

Claims (158)

1. A blended mulch product which can be mixed with water and spray-applied to a ground surface to form an erosion control medium, the blended mulch product comprising:

(a) about 75% to about 92% by weight ligno-cellulosic fibers;

(b) about 1% to about 10% by weight substantially straight synthetic fibers; and (c) a tackifier;

wherein the substantially straight synthetic fibers maintain their substantially straight form in the blended mulch product and the erosion control medium.
2. The blended mulch product of claim 1, wherein the presence of the substantially straight synthetic fibers in the blended mulch product does not increase a dry tensile strength of the erosion control medium formed from the blended mulch product as compared to an erosion control medium formed from a blended mulch product without the substantially straight synthetic fibers.
3. The blended mulch product of claim 1 or 2, wherein the presence of the substantially straight synthetic fibers in the blended mulch product increases a modulus of elasticity of the erosion control medium formed from the blended mulch product as compared to an erosion control medium formed from a blended mulch product without the substantially straight synthetic fibers.
4. The blended mulch product of any one of claims 1 to 3, wherein the presence of the substantially straight synthetic fibers in the blended mulch product increases a wet tensile strength of the erosion control medium formed from the blended mulch product as compared to an erosion control medium formed from a blended mulch product without the substantially straight synthetic fibers.
5. The blended mulch product of any one of claims 1 to 4, wherein the presence of the substantially straight synthetic fibers in the blended mulch product increases a tensile strength that is retained in the erosion control medium when rewetted, as compared to an erosion control medium formed from a blended mulch product without the substantially straight synthetic fibers.
6. The blended mulch product of any one of claims 1 to 5, wherein the substantially straight synthetic fibers, the ligno-cellulosic fibers and the tackifier form a substantially homogenous blend.
7. The blended mulch product of any one of claims 1 to 6, wherein the substantially straight synthetic fibers are monofilament fibers.
8. The blended mulch product of any one of claims 1 to 7, wherein the substantially straight synthetic fibers are each monofilament fibers that are sufficiently resistant to crimping so as to reduce entanglement of fibers in the erosion control medium, as compared to an erosion control medium formed from a blended mulch product having crimped synthetic fibers.
9. The blended mulch product of any one of claims 1 to 8, wherein the substantially straight synthetic fibers are each monofilament fibers that are sufficiently resistant to crimping so as to avoid interlocking between substantially straight synthetic fibers.
10. The blended mulch product of any one of claims 1 to 9, wherein the substantially straight synthetic fibers are each monofilament fibers that are sufficiently resistant to crimping so as to resist entanglement in the blended mulch product.
11. The blended mulch product of any one of claims 1 to 10, wherein the substantially straight synthetic fibers are each monofilament fibers that are sufficiently short in length so as to reduce entanglement of fibers in the erosion control medium, as compared to an erosion control medium formed from a blended mulch product having crimped synthetic fibers.
12. The blended mulch product of any one of claims 1 to 11, wherein the substantially straight synthetic fibers are each monofilament fibers that are sufficiently short in length so as to resist entanglement of fibers in the blended mulch product.
13. The blended mulch product of any one of claims 1 to 12, wherein the substantially straight synthetic fibers are a thermoplastic.
14. The blended mulch product of any one of claims 1 to 13, wherein the substantially straight synthetic fibers are selected from at least one of the group consisting of: a polyolefin, a polyester, a polyamide and a mixture thereof.
15. The blended mulch product of any one of claims 1 to 13, wherein the substantially straight synthetic fibers are polypropylene fibers.
16. The blended mulch product of any one of claims 1 to 13, wherein the substantially straight synthetic fibers are polyethylene fibers.
17. The blended mulch product of any one of claims 1 to 13, wherein the substantially straight synthetic fibers are polyester fibers.
18. The blended mulch product of any one of claims 1 to 13, wherein the substantially straight synthetic fibers are polyamide fibers.
19. The blended mulch product of any one of claims 1 to 13, wherein the substantially straight synthetic fibers are a mixture of fibers selected from at least two of the group consisting of: polypropylene fibers, polyethylene fibers, polyester fibers, and polyamide fibers.
20. The blended mulch product of any one of claims 1 to 19, wherein each of the substantially straight synthetic fibers have an elongated portion having a length of between about 0.25 inches to about 3 inches.
21. The blended mulch product of any one of claims 1 to 19, wherein each of the substantially straight synthetic fibers have an elongated portion having a length of between about 0.375 inches to about 0.625 inches.
22. The blended mulch product of any one of claims 1 to 21, wherein the substantially straight synthetic fibers consist of elongated synthetic fibers having a length along an elongated portion of about 0.25 inches to about 3 inches.
23. The blended mulch product of any one of claims 1 to 21, wherein tho substantially straight synthetic fibers consist of monofilament fibers having a length along an elongated portion of about 0.375 inches to about 0.625 inches.
24. The blended mulch product of any one of claims 1 to 23, wherein substantially all of the substantially straight synthetic fibers each have a denier measurement of about 4 denier to about 8 denier.
25. The blended mulch product of any one of claims 1 to 23, wherein substantially all of the substantially straight synthetic fibers each have a denier measurement of about 6 denier.
26. The blended mulch product of any one of claims 1 to 25, wherein the substantially straight synthetic fibers each have a straight ratio (D not:D
max) of at least about 3:5 to about 1:1; wherein D max represents a maximum potential distance of a particular synthetic fiber having a first end point and a second end point, with the first and second end points located at opposing ends of an elongated portion of the particular synthetic fiber, the maximum potential distance being measured along the elongated portion of the particular synthetic fiber when the particular synthetic fiber is completely straight; and wherein D not represents a notional shortest distance between said end points.
27. The blended mulch product of any one of claims 1 to 25, wherein the substantially straight synthetic fibers each have a straight ratio of (D not:D
max) of at least about 3:4 to about 1:1; wherein D max, represents a maximum potential distance of a particular synthetic fiber having a first end point and a second end point, with the first and second end points located at opposing ends of an elongated portion of the particular synthetic fiber, the maximum potential distance being measured along the elongated portion of the particular synthetic fiber when the particular synthetic fiber is completely straight; and wherein D not represents a notional shortest distance between said end points.
28. The blended mulch product of any one of claims 1 to 25, wherein the substantially straight synthetic fibers each have a straight ratio of (D not:D
max) of at least about 9:10 to about 1:1; wherein D max represents a maximum potential distance of a particular synthetic fiber having a first end point and a second end point, with the first and second end points located at opposing ends of an elongated portion of the particular synthetic fiber, the maximum potential distance being measured along the elongated portion of the particular synthetic fiber when the particular synthetic fiber is completely straight; and wherein D not represents a notional shortest distance between said end points.
29. The blended mulch product of any one of claims 1 to 28, wherein the erosion control medium formed from the blended mulch product has a dry tensile strength of about 17 SAS (N/g) to about 36 SAS (N/g).
30. The blended mulch product of any one of claims 1 to 28, wherein the erosion control medium formed from the blended mulch product has a dry tensile strength of about 22 SAS (N/g) to about 26 SAS (N/g).
31. The blended mulch product of any one of claims 1 to 30, wherein the erosion control medium formed from the blended mulch product has a wet tensile strength of about 4 SAS (N/g) to about 7 SAS (N/g).
32. The blended mulch product of any one of claims 1 to 31, wherein the substantially straight synthetic fibers do not have bends of between about 1 degree to about 90 degrees.
33. The blended mulch product of any one of claims 1 to 31, wherein the substantially straight synthetic fibers do not have bends of between about 1 degree to about 130 degrees.
34. The blended mulch product of any one of claims 1 to 31, wherein the substantially straight synthetic fibers do not have bends of between about 1 degree to about 175 degrees.
35. The blended mulch product of any one of claims 1 to 34, wherein the substantially straight synthetic fibers for use in the blended mulch product have a tensile modulus of at least about 131,000 psi.
36. The blended mulch product of any one of claims 1 to 35, wherein the substantially straight synthetic fibers for use in the blended mulch product have a flexural modulus of at least about 84,000 psi.
37. The blended mulch product of any one of claims 1 to 34, wherein the substantially straight synthetic fibers have a tensile modulus of at least about 84,000 psi, and a flexural modulus of at least about 131,000 psi.
38. The blended mulch product of any one of claims 1 to 34, wherein the substantially straight synthetic fibers have a tensile modulus of at least about 84,000 psi, a flexural modulus of at least about 131,000 psi, and a denier measurement of about 4 denier to about 8 denier.
39. The blended mulch product of any one of claims 1 to 34, wherein the substantially straight synthetic fibers have a tensile modulus of at least about 84,000 psi, a flexural modulus of at least about 200,000 psi, and a denier measurement of about 4 denier to about 8 denier.
40. The blended mulch product of any one of claims 1 to 34, wherein the substantially straight synthetic fibers have a tensile modulus of about 84,000 psi, a flexural modulus of about 200,000 psi, and a denier measurement of about 4.5 denier to about 7 denier.
41. The blended mulch product of any one of claims 1 to 40, wherein the blended mulch product comprises about 2% to about 4% by weight of the substantially straight synthetic fibers.
42. The blended mulch product of any one of claims 1 to 41, wherein the substantially straight synthetic fibers make up at least about 80% by weight of all synthetic fibers in the blended mulch product.
43. The blended mulch product of any one of claims 1 to 42, wherein the ligno-cellulosic fibers are thermomechanically refined wood fibers.
44. The blended mulch product of any one of claims 1 to 43, wherein the ligno-cellulosic fibers are softwood fibers.
45. The blended mulch product of any one of claims 1 to 44, wherein each of the ligno-cellulosic fibers have a length of between about 0.0625 inches and about 1.75 inches.
46. The blended mulch product of any one of claims 1 to 44, wherein each of the ligno-cellulosic fibers have a length of between about 0.125 inches and about 1 inch.
47. The blended mulch product of any one of claims 1 to 46, wherein each of the ligno-cellulosic fibers have a diameter of between about 0.01 mm to about 0.22mm.
48. The blended mulch product of any one of claims 1 to 47, wherein the ligno-cellulosic fibers have a moisture content of between about 9% to about 15%.
49. The blended mulch product of any one of claims 1 to 48, wherein the tackifier is a natural tackifier.
50. The blended mulch product of any one of claims 1 to 49, wherein the tackifier is a hydrocolloid based binder.
51. The blended mulch product of any one of claims 1 to 50, wherein the tackifier comprises a polysaccharide.
52. The blended mulch product of any one of claims 1 to 51, wherein the tackifier comprises guar gum.
53. The blended mulch product of any one of claims 1 to 52, wherein the blended mulch product comprises between about 8% by weight to about 12% by weight of the tackifier.
54. A blended mulch product which can be mixed with water and spray-applied to a ground surface to form an erosion control medium, the blended mulch product consisting of:

(a) about 80% to about 90% by weight ligno-cellulosic fibers;

(b) about 1% to about 10% by weight substantially straight synthetic fibers; and (c) a tackifier;

wherein at least about 80% by weight of the substantially straight synthetic fibers maintain their substantially straight form in the blended mulch product and the erosion control medium.
55. The blended mulch product of claim 54, wherein the presence of the substantially straight synthetic fibers in the blended mulch product does not increase a dry tensile strength of the erosion control medium formed from the blended mulch product as compared to an erosion control medium formed from a blended mulch product without the substantially straight synthetic fibers.
56. The blended mulch product of claim 54 or 55, wherein the presence of the substantially straight synthetic fibers in the blended mulch product increases a modulus of elasticity of the erosion control medium formed from the blended mulch product as compared to an erosion control medium formed from a blended mulch product without substantially straight synthetic fibers.
57. The blended mulch product of any one of claims 54 to 56, wherein the presence of the substantially straight synthetic fibers in the blended mulch product increases a wet tensile strength of the erosion control medium formed from the blended mulch product as compared to an erosion control medium formed from a blended mulch product without the substantially straight synthetic fibers.
58. The blended mulch product of any one of claims 54 to 57, wherein the presence of the substantially straight synthetic fibers in the blended mulch product increases a tensile strength that is retained in the erosion control medium when rewetted, as compared to an erosion control medium formed from a blended mulch product without the substantially straight synthetic fibers.
59. The blended mulch product of any one of claims 54 to 58, wherein the substantially straight synthetic fibers, the ligno-cellulosic fibers and the tackifier form a substantially homogenous blend.
60. The blended mulch product of any one of claims 54 to 59, wherein the substantially straight synthetic fibers are monofilament fibers.
61. The blended mulch product of any one of claims 54 to 60, wherein the substantially straight synthetic fibers are each monofilament fibers that are sufficiently resistant to crimping so as to reduce entanglement of fibers in the erosion control medium, as compared to an erosion control medium formed from a blended mulch product having crimped synthetic fibers.
62. The blended mulch product of any one of claims 54 to 61, wherein the substantially straight synthetic fibers are each monofilament fibers that are sufficiently resistant to crimping so as to avoid interlocking between substantially straight synthetic fibers.
63. The blended mulch product of any one of claims 54 to 62, wherein the substantially straight synthetic fibers are each monofilament fibers that are sufficiently resistant to crimping so as to resist entanglement in the blended mulch product.
64. The blended mulch product of any one of claims 54 to 63, wherein the substantially straight synthetic fibers are each monofilament fibers that are sufficiently short in length so as to reduce entanglement of fibers in the erosion control medium, as compared to an erosion control medium formed from a blended mulch product having crimped synthetic fibers.
65. The blended mulch product of any one of claims 54 to 64, wherein the substantially straight synthetic fibers are each monofilament fibers that are sufficiently short in length so as to resist entanglement of fibers in the blended mulch product.
66. The blended mulch product of any one of claims 54 to 65, wherein the substantially straight synthetic fibers are a thermoplastic.
67. The blended mulch product of any one of claims 54 to 66, wherein the substantially straight synthetic fibers are selected from at least one of the group consisting of: a polyolefin, a polyester, a polyamide and a mixture thereof.
68. The blended mulch product of any one of claims 54 to 66, wherein the substantially straight synthetic fibers are polypropylene fibers.
69. The blended mulch product of any one of claims 54 to 66, wherein the substantially straight synthetic fibers are polyethylene fibers.
70. The blended mulch product of any one of claims 54 to 66, wherein the substantially straight synthetic fibers are polyester fibers.
71. The blended mulch product of any one of claims 54 to 66, wherein the substantially straight synthetic fibers are polyamide fibers.
72. The blended mulch product of any one of claims 54 to 66, wherein the substantially straight synthetic fibers are a mixture of fibers selected from at least two of the group consisting of: polypropylene fibers, polyethylene fibers, polyester fibers, and polyamide fibers.
73. The blended mulch product of any one of claims 54 to 72, wherein each of the substantially straight synthetic fibers have an elongated portion having a length of between about 0.375 inches to about 0.625 inches.
74. The blended mulch product of any one of claims 54 to 73, wherein substantially all of the substantially straight synthetic fibers each have a denier measurement of about 4 denier to about 8 denier.
75. The blended mulch product of any one of claims 54 to 74, wherein each of the ligno-cellulosic fibers have a length of between about 0.125 inches and about 1 inch.
76. The blended mulch product of any one of claims 54 to 75, wherein each of the ligno-cellulosic fibers have a diameter of between about 0.01mm to about 0.22mm.
77. The blended mulch product of any one of claims 54 to 76, wherein the ligno-cellulosic fibers are softwood fibers.
78. The blended mulch product of any one of claims 54 to 77, wherein the tackifier comprises guar gum.
79. The blended mulch product of any one of claims 1 to 78, prepared by a process comprising:

a) fluffing the ligno-cellulosic fibers thereby forming fluffed ligno-cellulosic fibers;

b) mixing the substantially straight synthetic fibers with the fluffed ligno-cellulosic fibers, thereby forming mixed fibers; and c) mixing the tackifier with the mixed fibers, thereby forming the blended mulch product.
80. The blended mulch product prepared by the process of claim 79, wherein fluffing the ligno-cellulosic fibers is mechanical fluffing.
81. The blended mulch product prepared by the process of claim 79 or 80, wherein mixing the substantially straight synthetic fibers with the fluffed ligno-cellulosic fibers is mechanical mixing.
82. The blended mulch product prepared by the process of any one of claims 79 to 81, wherein mixing the tackifier with the mixed fibers is mechanical mixing.
83. The blended mulch product prepared by the process of any one of claims 79 to 82, wherein the process further comprises: (d) packaging the blended mulch product.
84. The blended mulch product prepared by the process of claim 83, wherein the blended mulch product is packaged in a plastic bag.
85. An erosion control medium for reducing erosion of a ground surface, formed from spray-application on the ground surface of a slurry comprising a blended mulch product and water, the erosion control medium comprising:

(a) ligno-cellulosic fibers;

(b) substantially straight synthetic fibers each having a straight ratio (D not:D max) of at least about 3:5 to about 1:1; wherein D max represents a maximum potential distance of a particular synthetic fiber having a first end point and a second end point, with the first and second end points located at opposing ends of an elongated portion of the particular synthetic fiber, the maximum potential distance being measured along the elongated portion of the particular synthetic fiber when the particular synthetic fiber is completely straight; and wherein D not represents a notional shortest distance between said end points; and (c) a tackifier;

wherein the erosion control medium forms a substantially homogenous open weave matrix on the ground surface.
86. The erosion control medium of claim 85, wherein the presence of the substantially straight synthetic fibers does not increase a dry tensile strength of the erosion control medium as compared to an erosion control medium without the substantially straight synthetic fibers.
87. The erosion control medium of claim 85 or 86, wherein the presence of the substantially straight synthetic fibers in the erosion control medium increases a modulus of elasticity of the erosion control medium as compared to an erosion control medium without the substantially straight synthetic fibers.
88. The erosion control medium of any one of claims 85 to 87, wherein the presence of the substantially straight synthetic fibers in the erosion control medium increases a wet tensile strength of the erosion control medium as compared to an erosion control medium without the substantially straight synthetic fibers.
89. The erosion control medium of any one of claims 85 to 88, wherein the presence of the substantially straight synthetic fibers in the erosion control medium increases a tensile strength that is retained in the erosion control medium when rewetted, as compared to an erosion control medium without the substantially straight synthetic fibers.
90. The erosion control medium of any one of claims 85 to 89, wherein the substantially straight synthetic fibers are each monofilament fibers that are sufficiently resistant to crimping so as to reduce entanglement of fibers in the erosion control medium, as compared to an erosion control medium having crimped synthetic fibers.
91. The erosion control medium of any one of claims 85 to 90, wherein the substantially straight synthetic fibers are each monofilament fibers that are sufficiently resistant to crimping so as to avoid interlocking between substantially straight synthetic fibers.
92. The erosion control medium of any one of claims 85 to 91, wherein the substantially straight synthetic fibers are each monofilament fibers that are sufficiently resistant to crimping so as to resist entanglement in the erosion control medium.
93. The erosion control medium of any one of claims 85 to 92, wherein the substantially straight synthetic fibers are each monofilament fibers that are sufficiently short in length so as to reduce entanglement of fibers in the erosion control medium, as compared to an erosion control medium having crimped synthetic fibers.
94. The erosion control medium of any one of claims 85 to 93, wherein the substantially straight synthetic fibers are each monofilament fibers that are sufficiently short in length so as to resist entanglement of fibers in the erosion control medium.
95. The erosion control medium of any one of claims 85 to 94, wherein the substantially straight synthetic fibers, the ligno-cellulosic fibers and the tackifier form a substantially homogenous erosion control medium.
96. The erosion control medium of any one of claims 85 to 95, wherein the substantially straight synthetic fibers are monofilament fibers.
97. The erosion control medium of any one of claims 85 to 96, wherein the substantially straight synthetic fibers are a thermoplastic.
98. The erosion control medium of any one of claims 85 to 97, wherein the substantially straight synthetic fibers are selected from at least one of the group consisting of: a polyolefin, a polyester, a polyamide and a mixture thereof.
99. The erosion control medium of any one of claims 85 to 97, wherein the substantially straight synthetic fibers are polypropylene fibers.
100. The erosion control medium of any one of claims 85 to 97, wherein the substantially straight synthetic fibers are polyethylene fibers.
101. The erosion control medium of any one of claims 85 to 97, wherein the substantially straight synthetic fibers are polyester fibers.
102. The erosion control medium of any one of claims 85 to 97, wherein the substantially straight synthetic fibers are polyamide fibers.
103. The erosion control medium of any one of claims 85 to 97, wherein the substantially straight synthetic fibers are a mixture of fibers selected from at least two of the group consisting of: polypropylene fibers, polyethylene fibers, polyester fibers, and polyamide fibers.
104. The erosion control medium of any one of claims 85 to 103, wherein each of the substantially straight synthetic fibers have an elongated portion having a length of between about 0.375 inches to about 0.625 inches.
105. The erosion control medium of any one of claims 85 to 104, wherein substantially all of the substantially straight synthetic fibers each have a denier measurement of about 4 denier to about 8 denier.
106. The erosion control medium of any one of claims 85 to 105, wherein the substantially straight synthetic fibers each have a straight ratio (D not:D
max) of at least about 3:4 to about 1:1; wherein D max represents a maximum potential distance of a particular synthetic fiber having a first end point and a second end point, with the first and second end points located at opposing ends of an elongated portion of the particular synthetic fiber, the maximum potential distance being measured along the elongated portion of the particular synthetic fiber when the particular synthetic fiber is completely straight; and wherein D not represents a notional shortest distance between said end points.
107. The erosion control medium of any one of claims 85 to 105, wherein the substantially straight synthetic fibers each have a straight ratio of (D not:D
max) of at least about 9:10 to about 1:1; wherein D max represents a maximum potential distance of a particular synthetic fiber having a first end point and a second end point, with the first and second end points located at opposing ends of an elongated portion of the particular synthetic fiber, the maximum potential distance being measured along the elongated portion of the particular synthetic fiber when the particular synthetic fiber is completely straight; and wherein D not represents a notional shortest distance between said end points.
108. The erosion control medium of any one of claims 85 to 107, wherein the substantially straight synthetic fibers do not have bends of between about 1 degree to about 90 degrees.
109. The erosion control medium of any one of claims 85 to 107, wherein the substantially straight synthetic fibers do not have bends of between about 1 degree to about 130 degrees.
110. The erosion control medium of any one of claims 85 to 107, wherein the substantially straight synthetic fibers do not have bends of between about 1 degree to about 175 degrees.
111. The erosion control medium of any one of claims 85 to 110, wherein the substantially straight synthetic fibers a tensile modulus of at least about 84,000 psi.
112. The erosion control medium of any one of claims 85 to 111, wherein the substantially straight synthetic fibers have a flexural modulus of at least about 131,000 psi.
113. The erosion control medium of any one of claims 85 to 110, wherein the substantially straight synthetic fibers have a tensile modulus of at least about 84,000 psi, and flexural modulus of at least about 131,000 psi.
114. The erosion control medium of any one of claims 85 to 110, wherein the substantially straight synthetic fibers have a tensile modulus of at least about 84,000 psi, a flexural modulus of at least about 131,000 psi, and a denier measurement of about 4 denier to about 8 denier.
115. The erosion control medium of any one of claims 85 to 110, wherein the substantially straight synthetic fibers have a tensile modulus of at least about 84,000 psi, a flexural modulus of at least about 200,000 psi, and a denier measurement of about 4 denier to about 8 denier.
116. The erosion control medium of any one of claims 85 to 110, wherein the substantially straight synthetic fibers have a tensile modulus of about 84,000 psi, a flexural modulus of about 200,000 psi, and a denier measurement of about 4.5 denier to about 7 denier.
117. The erosion control medium of any one of claims 85 to 116, wherein the erosion control medium comprises about 2% to about 4% by weight of the substantially straight synthetic fibers.
118. The erosion control medium of any one of claims 85 to 117, wherein each of the ligno-cellulosic fibers have a length of between about 0.125 inches and about 1 inch.
119. The erosion control medium of any one of claims 85 to 118, wherein each of the ligno-cellulosic fibers have a diameter of between about 0.01mm to about 0.22mm.
120. The erosion control medium of any one of claims 85 to 119, wherein the ligno-cellulosic fibers are softwood fibers.
121. The erosion control medium of any one of claims 85 to 120, wherein the tackifier is a hydrocolloid based binder.
122. The erosion control medium of any one of claims 85 to 121, wherein the tackifier comprises guar gum.
123. An erosion control medium for reducing erosion of a ground surface, formed from spray-application on the ground surface of a slurry mixture comprising a blended mulch product and water, the erosion control medium comprising:

(a) about 80% to about 90% by weight ligno-cellulosic fibers;

(b) about 1% to about 7% by weight substantially straight synthetic fibers; and (c) a tackifier;

wherein the erosion control medium forms a substantially homogenous open weave matrix on the ground surface.
124. The erosion control medium of claim 123, wherein the presence of the substantially straight synthetic fibers does not increase a dry tensile strength of the erosion control medium as compared to an erosion control medium without the substantially straight synthetic fibers.
125. The erosion control medium of claim 123 or 124, wherein the presence of the substantially straight synthetic fibers in the erosion control medium increases a modulus of elasticity of the erosion control medium as compared to an erosion control medium without the substantially straight synthetic fibers.
126. The erosion control medium of any one of claims 123 to 125, wherein the presence of the substantially straight synthetic fibers in the erosion control medium increases a wet tensile strength of the erosion control medium as compared to an erosion control medium without the substantially straight synthetic fibers.
127. The erosion control medium of any one of claims 123 to 126, wherein the presence of the substantially straight synthetic fibers in the erosion control medium increases a tensile strength that is retained in the erosion control medium when rewetted, as compared to an erosion control medium without the substantially straight synthetic fibers.
128. The erosion control medium of any one of claims 123 to 127, wherein the substantially straight synthetic fibers are each monofilament fibers that are sufficiently resistant to crimping so as to reduce entanglement of fibers in the erosion control medium, as compared to an erosion control medium having crimped synthetic fibers.
129. The erosion control medium of any one of claims 123 to 128, wherein the substantially straight synthetic fibers are each monofilament fibers that are sufficiently resistant to crimping so as to avoid interlocking between substantially straight synthetic fibers.
130. The erosion control medium of any one of claims 123 to 129, wherein the substantially straight synthetic fibers are each monofilament fibers that are sufficiently resistant to crimping so as to resist entanglement in the erosion control medium.
131. The erosion control medium of any one of claims 123 to 130, wherein the substantially straight synthetic fibers are each monofilament fibers that are sufficiently short in length so as to reduce entanglement of fibers in the erosion control medium, as compared to an erosion control medium having crimped synthetic fibers.
132. The erosion control medium of any one of claims 123 to 131, wherein the substantially straight synthetic fibers are each monofilament fibers that are sufficiently short in length so as to resist entanglement of fibers in the erosion control medium.
133. The erosion control medium of any one of claims 123 to 132, wherein the substantially straight synthetic fibers are polypropylene fibers.
134. The erosion control medium of any one of claims 123 to 132, wherein the substantially straight synthetic fibers are polyethylene fibers.
135. The erosion control medium of any one of claims 123 to 132, wherein the substantially straight synthetic fibers are polyester fibers.
136. The erosion control medium of any one of claims 123 to 132, wherein the substantially straight synthetic fibers are polyamide fibers.
137. The erosion control medium of any one of claims 123 to 132, wherein the substantially straight synthetic fibers are a mixture of fibers selected from at least two of the group consisting of: polypropylene fibers, polyethylene fibers, polyester fibers, and polyamide fibers.
138. The erosion control medium of any one of claims 123 to 137, wherein each of the substantially straight synthetic fibers have an elongated portion having a length of between about 0.375 inches to about 0.625 inches.
139. The erosion control medium of any one of claims 123 to 138, wherein substantially all of the substantially straight synthetic fibers each have a denier measurement of about 4 denier to about 8 denier.
140. The erosion control medium of any one of claims 123 to 139, wherein the substantially straight synthetic fibers each have a straight ratio (D not:D
max) of at least about 3:5 to about 1:1; wherein D max represents a maximum potential distance of a particular synthetic fiber having a first end point and a second end point, with the first and second end points located at opposing ends of an elongated portion of the particular synthetic fiber, the maximum potential distance being measured along the elongated portion of the particular synthetic fiber when the particular synthetic fiber is completely straight; and wherein D not represents a notional shortest distance between said end points.
141. The erosion control medium of any one of claims 123 to 139, wherein the substantially straight synthetic fibers each have a straight ratio (D not:D
max) of at least about 3:4 to about 1:1; wherein D max represents a maximum potential distance of a particular synthetic fiber having a first end point and a second end point, with the first and second end points located at opposing ends of an elongated portion of the particular synthetic fiber, the maximum potential distance being measured along the elongated portion of the particular synthetic fiber when the particular synthetic fiber is completely straight; and wherein D not represents a notional shortest distance between said end points.
142. The erosion control medium of any one of claims 123 to 139, wherein the substantially straight synthetic fibers each have a straight ratio of (D not:D
max) of at least about 9:10 to about 1:1; wherein D max represents a maximum potential distance of a particular synthetic fiber having a first end point and a second end point, with the first and second end points located at opposing ends of an elongated portion of the particular synthetic fiber, the maximum potential distance being measured along the elongated portion of the particular synthetic fiber when the particular synthetic fiber is completely straight; and wherein D not represents a notional shortest distance between said end points.
143. The erosion control medium of any one of claims 123 to 142, wherein the substantially straight synthetic fibers do not have bends of between about 1 degree to about 90 degrees.
144. The erosion control medium of any one of claims 123 to 142, wherein the substantially straight synthetic fibers do not have bends of between about 1 degree to about 130 degrees.
145. The erosion control medium of any one of claims 123 to 142, wherein the substantially straight synthetic fibers do not have bends of between about 1 degree to about 175 degrees.
146. The erosion control medium of any one of claims 123 to 145, wherein the substantially straight synthetic fibers have a flexural modulus of at least about 200000 psi.
147. The erosion control medium of any one of claims 123 to 145, wherein the substantially straight synthetic fibers have a flexural modulus of at least about 200000 psi and a denier measurement of about 4 denier to about 8 denier.
148. The erosion control medium of any one of claims 123 to 145, wherein the substantially straight synthetic fibers have a flexural modulus of about 200000 psi and a denier measurement of about 4.5 denier to about 7 denier.
149. The erosion control medium of any one of claims 123 to 148, wherein the erosion control medium comprises about 2% to about 4% by weight of the substantially straight synthetic fibers.
150. The erosion control medium of any one of claims 123 to 149, wherein each of the ligno-cellulosic fibers have a length of between about 0.125 inches and about 1 inch.
151. The erosion control medium of any one of claims 123 to 150, wherein each of the ligno-cellulosic fibers have a diameter of between about 0.01 mm to about 0.22mm.
152. The erosion control medium of any one of claims 123 to 151, wherein the ligno-cellulosic fibers are softwood fibers.
153. The erosion control medium of any one of claims 123 to 152, wherein the tackifier comprises guar gum.
154. The erosion control medium of any one of claims 85 to 153 prepared by a process comprising:

a) mixing a blended mulch product with water thereby forming a slurry, the blended mulch product comprising:

(i) about 75% to about 92% by weight ligno-cellulosic fibers;
(ii) about 1% to about 10% by weight substantially straight synthetic fibers; and (iii) a tackifier;

b) spray-applying the slurry to a ground surface thereby forming an applied slurry; and c) drying the applied slurry.
155. The erosion control medium prepared by the process of claim 154, wherein the process further comprises a second spray-application of the slurry.
156. The erosion control medium prepared by the process of claim 155, wherein the second spray-application is applied in a different direction as compared to a direction of a first spray application.
157. The erosion control medium prepared by the process of any one of claims to 156, wherein the slurry is spray applied to form an applied slurry having a thickness of about 0.1 inches to about 0.2 inches.
158. The erosion control medium prepared by the process of any one of claims to 156, wherein the slurry is spray applied to form an applied slurry having a thickness of about 0.125 inches.
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US11/352,439 US7681353B2 (en) 2006-02-09 2006-02-10 Erosion control medium
US12/343,567 US7966765B2 (en) 2006-02-09 2008-12-24 Blended mulch product and method of making same

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US20070184744A1 (en) 2007-08-09
US20090120148A1 (en) 2009-05-14
US7681353B2 (en) 2010-03-23
US7966765B2 (en) 2011-06-28
US20070180763A1 (en) 2007-08-09
CA2535801C (en) 2012-11-27
US7484330B2 (en) 2009-02-03

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