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WO1996003211A1 - Tapis composite absorbant ameliore - Google Patents

Tapis composite absorbant ameliore Download PDF

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Publication number
WO1996003211A1
WO1996003211A1 PCT/US1995/008959 US9508959W WO9603211A1 WO 1996003211 A1 WO1996003211 A1 WO 1996003211A1 US 9508959 W US9508959 W US 9508959W WO 9603211 A1 WO9603211 A1 WO 9603211A1
Authority
WO
WIPO (PCT)
Prior art keywords
web
composite mat
mat
cotton
synthetic
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US1995/008959
Other languages
English (en)
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
HOLINEE Corp
Original Assignee
HOLINEE Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by HOLINEE Corp filed Critical HOLINEE Corp
Priority to AU31307/95A priority Critical patent/AU3130795A/en
Publication of WO1996003211A1 publication Critical patent/WO1996003211A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/28—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer impregnated with or embedded in a plastic substance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/02—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising animal or vegetable substances, e.g. cork, bamboo, starch
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B9/047—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material made of fibres or filaments
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00—Treatment of water, waste water, or sewage
    • C02F1/68—Treatment of water, waste water, or sewage by addition of specified substances, e.g. trace elements, for ameliorating potable water
    • C02F1/681—Treatment of water, waste water, or sewage by addition of specified substances, e.g. trace elements, for ameliorating potable water by addition of solid materials for removing an oily layer on water
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/425—Cellulose series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/488—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with bonding agents
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/498—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/593—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives to layered webs
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02B—HYDRAULIC ENGINEERING
    • E02B15/00—Cleaning or keeping clear the surface of open water; Apparatus therefor
    • E02B15/04—Devices for cleaning or keeping clear the surface of open water from oil or like floating materials by separating or removing these materials
    • E02B15/10—Devices for removing the material from the surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/20—Fibres of continuous length in the form of a non-woven mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/10—Natural fibres, e.g. wool, cotton
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • B32B2471/04—Mats

Definitions

  • nonorganic absorbent materials are used in the cleanup of oil or other contaminants spilled in the oceans and waterways. These materials are employed in several ways.
  • One method consists of placing pieces of nonorganic material in a porous bag. Such bags are then thrown onto the surface of the water, to be retrieved later after absorbing a quantity of the contaminant.
  • Another method consists of deploying a sheet or mat composed of nonorganic, synthetic materials on the surface of the contaminated water, and retrieving the mat after it has absorbed a portion of the contaminant.
  • synthetic mats absorb only 7 to 15 times their weight. Deployment and retrieval of such mats is typically done by a winch mounted on a boat, which might tow the mat once it has been deployed; therefore, such mats must be strong and dimensionally stable so as to avoid tearing either during deployment or retrieval.
  • Another use for such mats is to clean beaches contaminated by oil by pulling a mat across the beach After use, these materials are typically cleansed with a detergen or other solvent to remove as much of the oil or other contaminan as possible, and then disposed in a landfill.
  • a mat in accordance with the invention comprising a nonwoven laminar web composed of a natural fiber having absorbent properties and a nonwoven laminar web composed of a synthetic fibrous material having buoyant properties secured together to collectively form a composite mat.
  • a predetermined quantity of a polymeric emulsion is applied to at least one side of the composite mat to contribute to buoyancy and flame resistance.
  • the two webs are secured together by needling.
  • a preferred embodiment of the present invention is comprised of a cotton fibrous laminar web, a planer surface of which is in proximal interface with a planer surface of a synthetic web.
  • Th synthetic web when constructed of materials such as low density polyprophelene, has a specific gravity less than 1.0, hence contributing to the buoyancy of the mat.
  • the cotton web and synthetic web are secured together by needling, thereby forming a composite mat.
  • Each side of the composite mat is impregnated with a polymeric emulsion containing polyvinyl chloride, which has a specific gravity less than 1.0, thereby contributing to the buoyancy of the mat, and is inherently flame retardant.
  • the polymeric emulsion should penetrate each side of the mat to a depth of at least 25% of the thickness of the mat.
  • the natural-fiber in the natural-fiber web is cotton, fibers of which contain naturally occurring oils. It is desirable to retain these oils, as they have a specific gravity less than 1.0, thereby contributing to the buoyancy of the mat when retained.
  • polymeric emulsion be of a flame retardant composition such as polyvinyl chloride. This characteristic greatly enhances the safety of storing the mat in large quantities until ultimately disposed of.
  • While one objective of the present invention is to provide an absorbent composite mat that is buoyant, it is anticipated that other non-water related applications for the mat will become apparent. For those applications not requiring buoyancy, the present invention meets the .need for an absorbent and more environmentally safe product that can be economically disposed of.
  • One such embodiment does not include the components required for buoyancy but includes one natural-fiber laminar web that is needle punched for dimensional stability.
  • Another embodiment includes multiple natural-fiber webs, all secured together by needling thereby forming a mat capable of absorbing large quantities of oil. Either of the embodiments could be impregnated on at least one side with a polymeric emulsion, and preferably an emulsion that is flame retardant.
  • FIG. 1 isometrically illustrates a preferred embodiment of th present invention
  • Fig. 2 illustrates an enlarged fragmentary view of a corne elevation of the preferred embodiment of Fig. 1;
  • Fig. 3 illustrates application of the polymeric emulsion t the mat hereof.
  • Figs. 4A and 4B are flow diagrams depicting a process fo constructing the preferred embodiment of the present inventio shown in Figs. 1 - 3.
  • web refers to a film or layer of fiber loosely interacting so as to enable friction between the fibers t hold the fibers together in a loose, air-pocketed, non-woven fil or layer.
  • Such a “web” is typically delivered from a card o garnett, but can also be formed by air deposition.
  • Garnetted web where used herein refers to a web delivere from a garnett, which is similar to a card.
  • Cross-lapped web where used herein refers to a we consisting of layers of garnetted webs and being formed by a cross lapping machine.
  • Figure 1 shows a preferre embodiment of the mat hereof generally designated 18.
  • the length (L2) and width (LI) are not critical to the present invention, and it is anticipated that the present invention can be manufactured in many different widths and lengths depending on the ultimate application for the product.
  • the mat comprises a single cotton fibrous laminar web (10) comprised of two cross-lapped webs (10a and 10b), each comprised of three garnetted webs (lOal- 10a3, lObl- 10b3) , and a nonwoven synthetic fibrous laminar web (12) .
  • the synthetic web is secured to the cotton web (10) by a needling process, the needles (30) of this process displacing and intertwining the synthetic and cotton fibers leaving elongated holes (16) .
  • the above is impregnated on both sides with a polymeric emulsion (14) , the depth of penetration (L6) of the polymeric emulsion shown by the shading in Figure 3.
  • Each garnetted web (such as lOal) for these purposes is comprised of open cotton fibers intertwined and layered. Three such garnetted webs are laid together to form each cross-lapped web (10a and 10b) . Each cross-lapped web traversely overlies upon the other, each with a planer surface in close proximal contact, so as to together form the single cotton fibrous laminar web (10) .
  • the thickness (L5, Fig. 3) of the cotton web (10) in the completed product is usually between 0.25 inches and 0.50 inches while a thickness of about 0.38 inches is preferred for the application of forming a hollow cylindrical sleeve to wrap around a cylindrical boom.
  • the thickness of each cross-lapped web (10a and 10b) is approximate-ly the same, as is the thickness of each garnetted web thereof. The thickness of these components varies with compression during the preferred fabrication process to be described below.
  • the preferred material for the cotton web of this embodimen is ginned or reginned cotton.
  • Cotton fibers contain naturall occurring oils which typically have a specific gravity of less tha 1.0 (although cotton fibers with the oils are nonbuoyant) therefore, it is desirable to retain these oils as they contribut to the overall buoyancy of the completed mat.
  • the cotton of th mat retains its natural oils as the temperature used in the dryin process (described below) is kept below the vaporizatio temperature of the oils.
  • Other varieties of cotton, includin machine grade and textile grade could also be used.
  • the nonwoven synthetic fibrous laminar web (12) in thi preferred embodiment is comprised of synthetic fibers that ar currently marketed under a variety of trademarks such as Vante nonwoven or Cerex nonwoven.
  • the synthetic compositio polyprophelene is the preferred composition for these purpose because it has a specific gravity of approximately .88, thereb contributing to the overall buoyancy of the completed mat.
  • Th preferred synthetic web of polyprophelene fibers for these purposes weighs .3 ounces per square yard.
  • the synthetic web (12) has a planer surface in close proximal interface with a planer surface of the cotton web, and is secured to the cotton web (10) by needling, which also serves to interconnect the six garnetted webs (10al-3, 10bl-2 ⁇ and which is further discussed below.
  • each side of the mat (18) is impregnated with a continuous uninterrupted layer of polymeric emulsion (14) .
  • the polymeric emulsion used in this embodiment is a polymeric emulsion containing polyvinyl chloride.
  • the particular variety used can be generically described as a polyvinyl chloride emulsion, and is commercially available under the trademark Air Flex 4530.
  • the preferred variety of this material for manufacturing this embodiment is an emulsion with a concentration equivalent to 50% solids plus or minus 5%. This variety of emulsion results in optimum penetration, is inherently flame resistant, and has a specific gravity of less than 1.0, thereby contributing to the desired level of buoyancy.
  • the optimum predetermined quantity of polymeric emulsion for the desired degree of buoyancy in the preferred embodiment is that quantity that would constitute 10 - 20% of the total weight of the composite mat.
  • Such a quantity of polyvinyl chloride emulsion of the above described type when applied to each side of the mat results in the desired depth of penetration and contributes to the desired degree of buoyancy of the mat.
  • polymeric emulsions and specifically, polymer resins
  • resins containing acrylic or polyvinyl acetate can be utilized such as resins containing acrylic or polyvinyl acetate.
  • these other materials also have specific gravities less than 1.0, they are not inherently flame resistant, so other flame retardant ingredients must be added to these resins to attain this desirable characteristic.
  • the mat as described above has sufficient buoyancy to remai afloat, when saturated with oil, for at least 72 hours. Furthermore, due to the absorbent properties of the natural fiber, cotton, this mat is able to absorb a quantity of oil at least 2 times its own weight. Synthetic fibrous materials typically onl absorb 7 to 15 times their weight.
  • the mat is preferably fabricated using the process shown i the flow diagram of Figures 4A and 4B.
  • two identical lines can be used (Line 1 and Line 2) from the point of entry of the raw cotton (Point A) until combining the cross-lapped webs (10a and 10b) in a merged flow beginning at Line 3, Point K. Since the second line is identical to the first, it will not be discussed (as the components of Line 2 are identified in Fig. 4A by the letter "A" following the numeric designation, but are otherwise identical to their numeric counterparts in Line 1) .
  • Compressed masses of staple cotton are fed into (Point A) a machine (50) commonly known as a picker, which also serves as an fiber opener as it opens the masses of staple cotton to form loose, open fibers that are delivered (Point C) from the picker (50) into a hopper (60) . These fibers are then delivered from the hopper to a garnetting machine (70) , which converts the loose, open cotton fibers into a garnetted web (such as lOal, Fig. 2) , which emerges from the garnetting machine at Point E. At this point, the garnetted web is approximately 5-6 inches thick.
  • the garnetted web is then transported to a cross-lapper machine (90) which forms a cross-lapped web (such as 10a, Fig. 2) consisting of three garnetted webs (10al-3, Fig. 2).
  • the thickness of the mat is controlled by the number of garnetted webs used to form the cross-lapped web. In this preferred embodiment, three garnetted webs were selected, but other embodiments of various thicknesses could be produced by cross-lapping a greater or fewer number of garnetted webs.
  • the means for transporting (80,100, 110,170,190) garnetted webs, cross-lapped webs, and the mat are well known and commercially available, and will not be discussed herein except where specially designed components have been added.
  • the cross-lapped webs of the two lines are combined via transporting means (100) at Point K to form a single cotton fibrous laminar web composed of six garnetted webs (10al-3, 10bl-3) .
  • the combining is accomplished by arranging the transporting means (100) with respect to the second cross-lapper (90A) so that the output from the second cross lapper is fed directly onto the top of the cross-lapped web from the first cross- lapper (90) .
  • the entire cotton fibrous laminar web (10) comprising the two cross-lapped webs is then conveyed away from the cross- lapper machines towards a compression roll (120) by well known transporting means (110) .
  • the cotton web (10) After emerging from the compression roll, the cotton web (10) is approximately 3 inches -thick.
  • the purpose of compressing the cotton web is to increase the density in preparation for the needling process.
  • the cotton web After compression (Point M) the cotton web is transported to a needle loom (140), while the synthetic web (12) is concomitantly dispensed from a roll and placed in proximal interface with the bottom planer surface of the cotton web, said roll constituting part of the means for adding the synthetic web (130) .
  • the two webs are transported into the needle loom (140) in close, proximal contact by a transporting means (135) , the close contact maintained by compression from the rollers employed in the transporting means and the friction between the two webs.
  • Needle looms are well known and commercially available to secure nonwoven webs by mechanically orienting, entangling, and intertwining the fibers through the webs. This process is termed in the trade as “needling” or “needle punching”.
  • needle loom barbed needles are set into a needle board that punches into the webs and withdraws, leaving the fibers entangled as well as holes (16) .
  • the size and density of the needles, and the design of the barb vary depending on the type of web.
  • a needle board having an array of needles of 73 - 114 needles per linear inch is used, the needles being of 36 gauge and 3 1/2 inches long, with barbs of type 3 barbs per apex, regular barb arrangement.
  • Such needles are commercially available under the trademark and model Foster Needles, 36 gauge, 3 barbs/apex, 3 1/2 inches long.
  • a two step needling process is preferred where the needles are first partially inserted 95% of the total thickness of the two webs, and then, without advancing the webs, inserted again through the entire thickness enabling the barbs to pierce the synthetic web before being withdrawn. After every two step punch, the webs are advanced, and the two steps are repeated.
  • the rate of needle punching and the rate of advancing the webs are coordinated to provide 50-150 punches per square inch.
  • compression of the webs takes place, so that the composite mat thus formed has a thickness (L3) of approximately 0.38 inches, plus or minus 0.10 inches.
  • the mat is transported by means (150) to a spray station (160) where a polymeric emulsion (14) containing polyvinyl chloride is sprayed on the top cotton side of the mat.
  • a polymeric emulsion (14) containing polyvinyl chloride is sprayed on the top cotton side of the mat.
  • the rate of dispensing the emulsion and the rate of transporting the composite mat are coordinated to provide the preferred predetermined quantity of polymeric emulsion of 10-20% of the total weight of the completed composite mat, thereby impregnating the mat. This quantity was found to provide the desired depth of penetration without undue buildup of emulsion on the surface of the mat.
  • the mat is conveyed through an oven (180) by well known transporting means (170) for drying.
  • the drying time depends on the temperature, air flow, and orientation of the mat with respect to the air flow in a particular oven. Regardless of the type of oven used, the temperature of the mat should not exceed about 300 degrees F. so as to prevent the natural oils of the cotton fibers from being vaporized. Typically, a drying time of about 2-3 minutes is required at 300 degrees F.
  • the mat After drying, the mat is inverted by the transporting means (190) so that the synthetic web is on top before entering a spray station (200) where the synthetic side of the composite mat is sprayed with the same emulsion similarly as before and then dried similarly as before. Having been dried, the finished product, a preferred embodiment of the mat, emerges from the oven (Point Z) .
  • the finished mat is highly absorbent, buoyant, dimensionally stable, strong, and flame resistant.
  • One intended application thereof is in the cleanup of oil spills on bodies of water and can be operatively achieved in several ways.
  • the mat can be cut into strips that are placed into a porous bag that is then thrown into the spill to be retrieved some time later after cleansing the contaminated water by absorbing a quantity of oil therefrom.
  • Another method is to fashion the mat into a hollow cylindrical sleeve to wrap around a cylindrical boom, the sleeve complementing the buoyancy of the boom. The boom is then deployed around the oil spill or deployed as a barrier to the spreading of the spill.
  • An additional method is to deploy a large sheet of the composite mat from a vessel that then tows the sheet through oil contaminated water from which the sheet absorbs oil. Similarly, a large sheet of the composite mat can be dragged across a beach by an appropriate vehicle to clean up oil that washes ashore. It can also be utilized as a drop cloth by engine mechanics to absorb oil spilled during engine maintenance or as a plant wipe down material. Although these two uses would not exploit the buoyant characteristics of the composite mat, the mat would have waste disposal advantages over other products currently used due to the use of organic materials in its construction.
  • One advantage of the mat described above is that by virtue of the use of cotton it can absorb at least twenty (20) times its own weight of a high viscosity oil.
  • synthetic materials such as polyesters and polyprophelene, commonly used for oil spill control only absorb seven to fifteen times their weight. Its ability to absorb a greater amount of oil is attributed to the cotton fibers that can take oil into the body of the fiber, thereby using its full structure. This contrasts with synthetic fibers used for that purpose that simply hold the oil to the outside of the fiber in much the manner of a styrofoam cup if placed in oil.
  • Another advantage of this embodiment is that its raw material costs are low due to the use of—unprocessed staple cotton which may be unsuitable for manufacturing textiles for clothing. Such cotton is less expensive than synthetic materials currently used in other products.
  • Still another advantage is that it is highly buoyant. Cotto alone has a specific gravity of 1.25, so it would sink if throw into water. Combining the cotton web with a synthetic web to for a mat and impregnating both sides of the mat with a polymeri emulsion, where the synthetic web and emulsion both have a specifi gravity of less than 1, results in a mat that is buoyant (having specific gravity of less than 1) .
  • this preferred embodimen exploits the superior oil absorbent properties of cotton whil overcoming its inherent lack of buoyancy.
  • This preferre embodiment can float in sea water, the mat saturated with oil, fo approximately 72 hours or more.
  • Yet another advantage is that it is dimensionally stable an strong due to the use of the synthetic web and the needlin process.
  • This preferred embodiment has a ball burst strength of 75 lbs. as measured by ASTM test no. D3787-80, ball burst method.
  • ASTM test no. D3787-80 ball burst method.
  • the mat is rendered flame resistant.
  • FMVSS Federal Motor Vehicle Safety Standard
  • No. 302 also known in the industry as a horizontal burn test.
  • the preferred embodiment can be cleansed of the oil, whereas cleansing of other organic materials such as peat moss or wood chips is uneconomical if not impossible.
  • this mat has the advantage over wholly synthetic mats as it can be disposed in most landfills due to its almost entirely organic construction, whereas many landfills will not accept products composed mostly of synthetic materials. Even where incineration is the desired method of disposal, the composite mat described above, being organic, produces less toxic and fewer hydrocarbon emissions than the synthetic materials currently used for oil cleanup.
  • Variations of the present invention could be fabricated using one or multiple laminar webs composed of a natural fiber having oil absorbent properties.
  • the embodiment using a single natural-fiber web would be needle punched for dimensional stability.
  • the multiple webs would be secured together in a superposed selection by needling.
  • These embodiments could be fabricated in the manner described above, except that the means for adding the synthetic fibrous laminar web (130) would be eliminated, as would the spray stations (160 and 200) , and the oven (180) .
  • Such product variations would be suitable for use as drop cloths or plant wipe down materials, and would share the preferred embodiments's advantages of low raw material cost, economical waste disposal, and high absorbency, but would lack the strength and buoyancy of the preferred embodiment described above.
  • Still another variation of the present invention could b constructed of wool or hemp instead of cotton. These embodiments could be manufactured just as the embodiments described above, except that these fibers would be substituted for the cotton. These embodiments being organic, hence biodegradable, would be improvements over synthetic materials currently used; however, cotton is more absorbent and, currently, less costly.
  • Additional embodiments could be constructed by eliminating the needling process, and utilizing other means for securing the nonwoven synthetic fibrous laminar web to the nonwoven natural- fiber laminar web.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Environmental & Geological Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Hydrology & Water Resources (AREA)
  • Medicinal Chemistry (AREA)
  • Water Supply & Treatment (AREA)
  • Organic Chemistry (AREA)
  • Ceramic Engineering (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

On décrit un tapis composite absorbant amélioré (18) comprenant au moins une couche en une étoffe (10) non tissée en fibres naturelles stratifiées, fixée à une étoffe (12) non tissée en fibres synthétiques stratifiées. Au moins une surface du tapis composite est imprégnée avec une émulsion polymère (14). Une forme d'exécution préférée fait appel à des fibres de coton brut, pour les fibres naturelles. On traite ces fibres sur une garnetteuse et on forme une étoffe (10) qui est alors fixée à une étoffe synthétique plus mince (12), par un procédé d'aiguilletage (30). Finalement, on pulvérise sur l'ensemble une émulsion (14) d'un polymère contenant du chlorure de polyvinyle, afin d'améliorer la flottabilité du tapis.
PCT/US1995/008959 1994-07-27 1995-07-17 Tapis composite absorbant ameliore Ceased WO1996003211A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU31307/95A AU3130795A (en) 1994-07-27 1995-07-17 Improved absorbent composite mat

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US28144394A 1994-07-27 1994-07-27
US08/281,443 1994-07-27

Publications (1)

Publication Number Publication Date
WO1996003211A1 true WO1996003211A1 (fr) 1996-02-08

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WO (1) WO1996003211A1 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0807463A3 (fr) * 1996-05-17 1998-02-04 Rohm And Haas Company Tapis réutilisable pour enlever des contaminants liquides
US5965030A (en) * 1997-04-15 1999-10-12 Rohm And Haas Company Reusable mat for removing liquid contaminants
WO2000044850A1 (fr) * 1999-01-28 2000-08-03 Forschungszentrum Karlsruhe Gmbh Procede permettant d'eliminer la contamination par les huiles minerales et utilisation du chanvre
WO2011138583A1 (fr) 2010-05-06 2011-11-10 George Lyall Walker Procédé de récupération de déversements de pétrole
JP2018008259A (ja) * 2016-07-04 2018-01-18 日本ソリッド株式会社 油吸着材

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3888766A (en) * 1973-03-09 1975-06-10 Uniroyal Inc Oil sorption material
US4832852A (en) * 1987-04-06 1989-05-23 John D. Hollingsworth On Wheels, Inc. Nonwoven oil absorbing material and method
US5146996A (en) * 1991-01-16 1992-09-15 Gainer Jr William C Apparatus and method for thrusting a cover over a target area
US5225812A (en) * 1991-05-30 1993-07-06 Wright State University Protective composite liner

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3888766A (en) * 1973-03-09 1975-06-10 Uniroyal Inc Oil sorption material
US4832852A (en) * 1987-04-06 1989-05-23 John D. Hollingsworth On Wheels, Inc. Nonwoven oil absorbing material and method
US5146996A (en) * 1991-01-16 1992-09-15 Gainer Jr William C Apparatus and method for thrusting a cover over a target area
US5225812A (en) * 1991-05-30 1993-07-06 Wright State University Protective composite liner

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0807463A3 (fr) * 1996-05-17 1998-02-04 Rohm And Haas Company Tapis réutilisable pour enlever des contaminants liquides
US5965030A (en) * 1997-04-15 1999-10-12 Rohm And Haas Company Reusable mat for removing liquid contaminants
WO2000044850A1 (fr) * 1999-01-28 2000-08-03 Forschungszentrum Karlsruhe Gmbh Procede permettant d'eliminer la contamination par les huiles minerales et utilisation du chanvre
WO2011138583A1 (fr) 2010-05-06 2011-11-10 George Lyall Walker Procédé de récupération de déversements de pétrole
JP2018008259A (ja) * 2016-07-04 2018-01-18 日本ソリッド株式会社 油吸着材

Also Published As

Publication number Publication date
AU3130795A (en) 1996-02-22

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