O
`Umted States Patent
`
`119]
`
`Spittle
`
`US005741832A
`
`1111 Patent Number:
`
`5,741,832
`
`[45] Date of Patent:
`
`Apr. 21, 1998
`
`7/1934 Espy .......................................... 524/13
`1/1995 Harada et al.
`.
`524/35
`1/1996 Jacobsen, J1'.etal.
`264/121
`6/1996 Robertson ....................... 47/56
`7/1996 Monroe etal.
`......................... 523/123
`
`
`
`4,453,042
`5,382,610
`5,484,501
`5526.255
`5,532,293
`
`[54] MECHANICALLY BONDED FIBER Muncn
`AND PROCESS FOR PRODUCING SAME
`
`[76]
`
`Inventor: Kevin Scott Spittle. 7934 Ravenwood
`La__gmn1ey_N_c_2g164
`
`[21] APP1, No; 740,919
`
`[22]
`
`F1154;
`
`Nov, 5, 1995
`
`Rented us, Application Data
`
`[62] Division of Ser. No. 663,033, Jun. 7, 1996.
`
`Int. Cl.‘ ............................. C09K 17/52; COSL 1/02;
`[51]
`[52] U S Cl
`523/132 43/gslgg/3;/2P6
`W '47/95; 47/56;-"264/121; 523/125; 524/93
`524/13; 524/15; 524/16; 524/35; 524/56
`[58] Field of Search .............................. 47/9. 91>. 95. 56;
`264/121;523/128_132524/9.13. 15.16.
`35
`
`[56]
`
`References Cited
`U.S. PATENT DOCUMENTS
`
`FOREIGN PATENT DOCUMENTS
`
`6613
`202223
`2245555
`07985
`
`2/1934
`Japan ......................................... 47/56
`3/1939
`Japan ......................... 47/95
`
`1/1992 United Kingdom ......
`.. ... 47/95
`5/1992 WIPO .................................... 264/121
`
`p,,,-,,,,,,y Ewm,-,,e,_pete, A_ Slew,
`Attome); Agent, or F1'me—Br1'an M. Dingrnan
`[57]
`ABSTRACT
`
`_
`A "“’°“*‘“‘°a“Y'b°"“°d- W“‘°"“"5°“’e“‘ fib“ ‘““1°h
`1nc1ud1'ng nat11ral and crimped synthgtic fibers that are
`mumately m1xed to form a mechamcally-bonded fiber
`mulch. A water-absorbent polymer-based material is dis-
`persed throughout the fiber mulch to increase its water
`b
`t’
`'
`.
`3 mm Ion capaclty
`
`1,962,806
`
`3/1934 Clapp ........................................ 47/9 P
`
`4 Claims, 1 Drawing Sheet
`
`SCOTTS EX. 1007
`
`SCOTTS EX. 1007
`
`

`
`U.S. Patent
`
`Apr. 21, 1998
`
`5,741,832
`
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`
`1
`MECHANICALLY BONDED FIBER MULCH
`AND PROCESS FOR PRODUCING SAME
`
`This is a division of application Ser. No. 08/663.033.
`filed Jun. 7. 1996 pending.
`
`5
`
`FIELD OF INVENTION
`
`This invention relates to a fiber mulch for application to
`seed beds. and the process for producing such mulch.
`
`BACKGROUND OF INVENTION
`
`Various types of mulches are commonly applied over
`grass seed beds. The purpose of these mulches is to increase
`grass seed germination and decrease soil erosion to allow the
`seedlings to become firmly established in the seeded area.
`These mulches typically consist of natural materials such as
`straw. wood shavings. or paper. The mulches are mixed with
`water and agitated in a holding tank. and then sprayed onto
`the seed bed. Some such mulches are woven into blankets
`that are designed to be laid down over seed beds.
`
`Such mulches are somewhat effective. They do absorb
`and retain some water. thus keeping the seed bed more
`hydrated then when mulch is not used. They additionally
`deflect some of the rain. thereby decreasing to some extent
`soil erosion. However. most such mulches are loose con-
`figurations of unbonded fibers that easily wash away. The
`paper-based mulches tend to bond into a papier mache-like
`mat that inhibits oxygen and sunlight transfer. and the ability
`of seedlings to emerge through the mulch. thus affecting the
`vegetation establishment.
`There have also been introduced into the market chemi-
`cally bonded natural fiber spray-applied mulches. These
`mulches use a vegetable gum binder such as guar gum to
`bind together natural fibers. Although this mulch is
`extremely well bonded. it has not been successful for a
`number of reasons. The chernically-bonded mulch forms an
`almost impenetrable layer over the seed bed that is poor at
`passing the needed oxygen and water through to the seed
`bed. and is also very difficult for the germinated seedlings to
`penetrate. Accordingly. the results for this product have been
`poor.
`
`SUMMARY OF THE INVENTION
`
`It is therefore an object of this invention to provide a seed
`bed mulch that increases seed germination rates.
`It is a further object of this invention to provide such a
`mulch that establishes more seedlings.
`It is a further object of this invention to provide such a
`mulch that increases the amount of vegetation per acre in
`newly seeded beds.
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`It is a further object of this invention to provide such a
`mulch that reduces soil erosion. even on steeply-sloped
`surfaces.
`
`55
`
`It is a further object of this invention to provide such a
`mulch which increases water absorption into the seed bed.
`It is a further object of this invention to provide such a
`mulch that reduces water run oil‘ from the mulched seed bed.
`
`It is a ftnther object of this invention to provide such a
`mulch that reduces the amount of expensive seed that is
`washed off of the seed bed.
`
`5,741,832
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`2
`
`It is a further object of this invention to provide such a
`mulch which results in faster seed germination.
`It is a further object of this invention to provide such a
`mulch that provides erosion control for an extended period
`of time.
`
`This invention results from the realization that an effec-
`tive fiber mulch that may be spray-applied to seed beds may
`be accomplished with an intimate mixture of primarily
`natural fibers such as wood fibers with a small percentage of
`crimped synthetic fibers that act to bind the wood fibers
`together in an open but strong matrix. with a small percent-
`age of a polymer—based water absorbent material dispersed
`throughout the mechanically-bonded fiber mulch to increase
`the water absorption capability of the mulch and maintain
`the seeds and seedlings hydrated.
`This invention features a mechanically-bonded. water-
`absorbent fiber mulch. and a process for making such a fiber
`mulch. The mulch includes natural fibers and synthetic fibers
`that are intimately mixed to form a mechanically-bonded
`fiber mulch in which the synthetic fibers hold together the
`natural fibers. A polymer-based water absorbent is dispersed
`throughout the fiber mulch to increase the mulch water
`absorption capacity.
`The natural fibers may comprise about 65% to 95% (by
`weight) of the mulch. and preferably comprise about 90% of
`the mulch. Wood fibers are the preferred natural fibers.
`although other natural fibers such as jute and many other
`types of available natural fibers may be used.
`The synthetic fibers preferably comprise about 5% to 15%
`(by weight) of a mulch. and more preferably approximately
`5%. The preferred fibers are relatively short (about 1/2" long)
`crirnped polyester fibers that interlock to one another and to
`the wood fibers to create an open. yet mechanically bonded.
`fiber matrix that remains in place even on steep slopes. yet
`is open enough to allow water and oxygen to pass through
`into the seed bed and allow the seedlings to grow up through
`the matrix.
`
`The polymer-based water absorbent is preferably present
`at about 5% to 15% of the mulch weight. The water
`absorbent is preferably a powder such as a polyacrylamide—
`based copolymer powder that absorbs many times its own
`weight in water.
`The fiber mulch thus prevents erosion both because of the
`mechanical properties of the mulch as well as its water-
`absorbent properties. The water absorbency provides a
`longer lasting. more even hydration of the seed and seed-
`lings to maximize germination and plant growth. The matrix
`is sufliciently open to allow air to easily pass through to
`further foster plant growth. The synthetic fibers degrade
`more slowly than the natural fibers. thereby providing a
`longer-term erosion control medium. lasting perhaps up to
`one year.
`
`This mulch is preferably produced by entraining the
`natural fibers in an air stream. and introducing into this air
`stream the synthetic fibers in a ratio of about 0.05-0.25 parts
`synthetic to natural fibers. to create an intimately mixed.
`mechanically-bonded fiber mulch. The polymer-based water
`absorbent is then dispersed into the fiber mulch to increase
`its water absorption capacity. The water absorbent is pref-
`erably mechanically dispersed into the mixed natural fiber-
`synthetic fiber mulch.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`It is a further object of this invention to provide such a
`mulch which increases the stress tolerance of the seedlings.
`It is a further object of this invention to provide such a
`mulch that increases the oxygen transfer to the seed bed.
`
`65
`
`Other objects. features and advantages will occur to those
`skilled in the art from the following description of the
`preferred embodiments. and the accompanying drawings. in
`which:
`
`

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`3
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`5.741.832
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`4
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`20
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`35
`
`FIG. 1 is a simplified. enlarged. schematic diagram of a
`mechanically-bonded water-absorbent fiber mulch accord-
`ing to this invention; and
`FIG. 2 is a schematic diagram of a preferred process for
`producing the mulch of this invention.
`This invention may be accomplished with a mechanically-
`bonded. water-absorbent fiber mulch. preferably including
`approximately 90% by weight wood fibers. approximately
`5% by weight crimped synthetic fibers. and approximately
`5% by weight polymer~based water absorbent powder. This
`invention is not limited to the particular materials chosen.
`nor the particular preferred materials ratios. The fiber mulch
`is a mechanically-bonded open weave accomplished by
`reason of the synthetic fibers’ entanglement with one
`another and with the wood fibers to hold the wood fiber
`together in a matrix which is sufliciently open to allow air to
`pass through. and seedlings to grow up through. Apolymer-
`based water absorbent such as a polyacrylamide-based pow-
`der is dispersed throughout
`the matrix to increase the
`water-holding capacity of the mulch so that more water is
`provided to the seed bed. and water run-off is inhibited.
`The mulch of this invention is depicted very schemati-
`cally in FIG. 1. in which natural fibers 12 are intimately
`mixed with synthetic fibers 14 to form a mechanically-
`bonded fiber mulch. Water absorbent 16 is dispersed
`throughout
`the fiber mulch to increase the mulch water
`absorption capacity.
`Natural fibers 12 are preferably wood fibers of about
`one-eighth to three-quarters inch in length. Wood fibers
`provide a quality natural mulch. However. such natural
`fibers do not bond together well. Thus. when they are used
`alone in a mulch.
`the mulch is easily disturbed on the
`surface. allowing heavy rains to wash the mulch. seed. and
`soil from sloped surfaces. thus greatly decreasing the etfec-
`tiveness of the mulch. To overcome such problems. the
`wood fibers in this invention are intimately mixed with a
`relatively small amount of synthetic fibers 14. which are
`preferably crimped polyester fibers about 1/2" in length and
`4.75 Denier. Such fibers are available commercially as
`33628A Type N91 4.75><0.5 SDOW from the Hoechst-
`Celanese Corporation. Spartanburg. S.C. The crimped syn-
`thetic fibers hold onto one another and to the wood fibers
`fairly tenaciously. It has been found that the ratio of such
`synthetic fibers to the natural fibers should be in the range of
`0.05-0.25 parts by weight synthetic to natural fibers to
`create a mechanically-bonded fiber mulch that can be spray
`applied to seed beds. Too much of the crimped fiber causes
`too much entanglement. which makes the product difiicult to
`keep uniformly mixed in the spray applicator. and thus
`diflicult to uniformly apply. Too little synthetic fiber does not
`sufliciently bond together the natural fibers to create the
`results obtained by the mulch of the present invention.
`The polymer-based water absorbent 16 is preferably a
`powder that is mixed with the bonded fiber matrix. prefer-
`ably by mechanical mixing. A preferred water absorbent
`polymer material
`is “Tacking Agent 111" available from
`Spittle Enterprises. Inc.. of Huntersville. N.C. Tacking
`Agent III is a copolymer of polyacrylamide that absorbs five
`to ten times its own weight in water. The absorbent thus
`increases the water-absorption capability of the mulched
`seed bed. thus providing better hydration to the seed and
`seedlings. which leads to quicker germination. more com-
`plete germination. and more plant mass per acre. A surfac-
`tant may be added as well to increase the water absorption
`of the wood fiber.
`A preferred process for producing the fiber mulch of this
`invention is depicted schematically in FIG. 2 as process 30.
`
`Wood fibers are entrained in an air flow within conduit 32.
`The proper amount of synthetic fiber is added to this
`entrained flow within conduit 32 upstream of fan 34. The
`materials mix together in conduit 32. and pass through fan
`34 and into surge storage container 36. The turbulence
`created in the air flow and by the fan intimately mixes the
`wood and polyester fibers to create a mechanically-bonded
`fiber mulch. The Tacking Agent 111 powder is metered into
`this mixed mulch in screw feeder 38 which moves the mulch
`from storage 36 to bagger hopper 40. It has been found that
`this mechanical dispersion of the absorbent polymer powder
`is preferable to dispersion in the air stream. as the powder
`can be easily blown out of the matrix and lost. or unevenly
`dispersed in the matrix. as a result.
`The mulch of this invention is preferably applied to areas
`being vegetated as follows. The mulch product. which is
`packed and shipped in bails. is added to the mixing tank of
`a standard hydro-seeding machine that uses mechanical or
`jet agitation. The fertilizer. seed and soil amendments can
`also be added if desired. Preferably. however. the seed bed
`is first prepared by mixing the seed. fertilizer. soil
`amendments. and a relatively small amount of the mulch of
`this invention and applying that to the seed bed. Then. one
`or two layers of the mulch in water are sprayed on top of the
`seed bed to form the protective. water-absorbent mulch
`matrix layer over the seed bed.
`It has been found that the mulch of this invention is
`preferably applied at a rate of about 3000 pounds per acre for
`new turf beds. The mulch can also be used with other
`vegetative beds. such as crops.
`Most preferably. the seed. fertilizer. soil amendments and
`600 pounds of the mulch of this invention are mixed and
`spray applied to an acre of soil. When possible. a cultipacker
`or lawn roller is then run over the soil to improve the
`seed-to-soil contact.
`Alayer of the mulch of this invention is then spray applied
`over the prepared seed bed. preferably covering at least 95%
`of the seed bed. This can be accomplished by mixing 1200
`pounds of the mulch of this invention in 3000 gallons of
`water and spray applying that to the one acre seed bed. A
`second application of the mulch at the same rate. when
`possible from the opposite direction of the first application.
`is then sprayed on in order to increase the soil coverage. and
`thus the mulch effectiveness.
`The mulch of this invention. when applied in this manner.
`has been found to decrease soil erosion from sloped surfaces
`by up to 30 times. and to reduce water runoff by up to 5
`times. as compared to straw blanket and excelsior blanket
`mulch products. The mass of plants per acre grown under
`such conditions as compared to the other two mulches has
`been shown to be more than 50% greater. with much greater
`seedling germination rates as well.
`Although specific features of this invention are shown in
`some drawings and not others. this is for convenience only
`as each feature may be combined with any or all of the other
`features in accordance with the invention.
`Other embodiments will occur to those skilled in the art
`and are within the following claims:
`What is claimed is:
`1. A process for producing a mechanically-bonded. water-
`absorbent fiber mulch. comprising:
`entraining natural fibers in an airstream;
`introducing into said air stream synthetic fibers in a ratio
`of about 0.05-0.25 parts synthetic to natural fibers to
`create an intimately mixed. mechanically-bonded fiber
`mulch; and
`
`45
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`50
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`55
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`65
`
`

`
`5.741.832
`
`5
`dispersing into said fiber mulch a polymeric water absor—
`bent to increase the mulch water absorption capacity.
`2. The fiber mulch production process of claim 1 in which
`said water absorbent is a powder.
`3. The fiber mulch production process of claim 2 in which 5
`said water absorbent is dispersed mechanically into said
`fiber mulch.
`
`6
`4. The fiber mulch production process of claim 1 further
`including passing said imimagdy mjxgd_ m5chanjCa[1y_
`bondcd fiber mulch through a rotary fan to ful-mgr mix said
`mulch.