United States Patent [19J
`Holton
`
`111111111111111111111111111111111111111111111111111111111111111111111111111
`US006021598A
`[11] Patent Number:
`[45] Date of Patent:
`
`6,021,598
`Feb.8,2000
`
`[54] POURABLE GRANULAR PAPER MULCH
`COMPOSITION
`
`[75]
`
`Inventor: Charles J. Holton, Haslett, Mich.
`
`[73] Assignee: Ampro Industries, Inc., Bradley, Mich.
`
`[21] Appl. No.: 08/994,774
`
`[22] Filed:
`
`Dec. 19, 1997
`
`5,195,465
`5,209,186
`5,215,041
`5,358,607
`5,396,731
`5,429,741
`5,456,733
`5,672,434
`5,916,027
`5,942,029
`
`............................ 119/172
`
`3/1993 Webb et a!.
`5/1993 Dewing .
`6/1993 Krahenbuhl .
`10/1994 Ellis .
`3/1995 Byrne .
`7/1995 Webb eta!. .
`10/1995 Hamilton, Jr ..
`9/1997 Dalebroux eta!. ....................... 47/9 X
`6/1999 Spittle ........................................... 47/9
`8/1999 Spittle ....................................... 47/9 X
`
`Int. Cl? ....................................................... AOlG 7/00
`[51]
`[52] U.S. Cl. .................................................... 47/9; 119/172
`[58] Field of Search ................................... 47/9; 119/172;
`502/7, 401
`
`Primary Examiner-Michael 1. Carone
`Assistant Examiner-Jeffrey L. Gellner
`Attorney, Agent, or Firm-Price, Heneveld, Cooper, Dewitt
`& Litton
`
`[56]
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`5/1955 Sugar eta!. .
`2,708,418
`8/1966 Aswell.
`3,269,824
`8/1974 White.
`3,828,731
`1!1978 Thomas.
`4,067,140
`4,278,047
`7/1981 Luca.
`4,409,925 10/1983 Brundrett et a!. .
`4,458,629
`7/1984 Gerber.
`4,570,573
`2/1986 Lohman.
`4,619,862 10/1986 Sokolowski et a!. .
`6/1987 Lojek eta!..
`4,676,196
`4,721,059
`1!1988 Lowe eta!..
`4,931,139
`6/1990 Phillips.
`1!1992 Webb eta!. ............................ 210/631
`5,082,563
`5,188,064
`2/1993 House.
`5,192,587
`3/1993 Rondy.
`
`[57]
`
`ABSTRACT
`
`A pourable, granular paper mulch product including a granu(cid:173)
`lar solid comprising at least about 85% paper by weight and
`at least about 6% water by weight, and having a settled
`density of at least about 15 pounds per cubic foot is prepared
`by comminuting paper, mixing the comminuting paper with
`water to form a pulp, extruding the pulp through a die
`orifice, chopping the extrudate to a length of less than about
`1/s inch to form granules, and drying the granules to achieve
`a final moisture content of from about 6% to about 13% by
`weight. The granular paper mulch product exhibits excellent
`flow characteristics, and can be easily applied to a damaged
`area of lawn such as by pouring the patch composition
`directly from a box.
`
`8 Claims, No Drawings
`
`SCOTTS EXHIBIT 1005
`
`

`

`6,021,598
`
`1
`POURABLE GRANULAR PAPER MULCH
`COMPOSITION
`
`FIELD OF THE INVENTION
`This invention relates to paper mulch compositions for 5
`repairing damaged areas of an existing lawn.
`
`10
`
`2
`A lawn patch product which has been especially devel(cid:173)
`oped for restoring damaged areas in an existing lawn is a
`fluffy mulch product comprised of very finely shredded
`paper (usually dyed green) which is mixed with grass seed
`and fertilizer. This product is usually sold in a plastic bag,
`and is applied by hand. The application technique involves
`tearing a suitable amount of the mixture from the fluffy mass
`of material, carefully placing it by hand over a bare spot
`which is to be restored, and adding water. A disadvantage
`with this fluffy lawn patch product is that it is generally
`necessary to add the water immediately after the product has
`been applied to the lawn to prevent it from being carried
`away by wind. A further disadvantage with the fluffy mulch
`product is that it is relatively unsuitable for use in restoring
`patches of lawn which have been damaged by dog urine. The
`15 soil in such areas already has a high urea content. Therefore,
`any additional fertilizer, rather than being beneficial, is
`unnecessary and may be harmful to germination and growth
`of grass seedlings.
`Despite efforts to provide products especially developed
`20 for restoring small damaged areas in an existing lawn, there
`nevertheless remains a need for a mulch product which can
`be more easily and quickly applied, without any special
`equipment, to relatively small areas of an existing lawn,
`such as areas damaged by dog urine, or divots on a golf
`25 course.
`
`BACKGROUND OF THE INVENTION
`As is the case with large lawn seed beds, it is also
`generally desirable to apply a mulch or seed cover material
`over relatively small areas of lawn which are in need of
`restoration, such as areas which have been damaged by dog
`urine, salt burn, utility work, molds, etc., in order to provide
`a favorable environment for seed germination and seedling
`development. The mulch or seed cover should desirably
`stabilize the soil and seed against water and wind erosion,
`moderate temperature fluctuations at the soil surface to
`protect germinating seeds and seedlings from temperature
`induced injury, reduce evaporation from the soil surface to
`provide a humid environment in and directly above the soil
`surface, and dissipate the energy of falling water droplets
`from rainfall and irrigation to prevent crust formation at the
`soil surface and concomitant reduced water infiltration rates.
`In addition to meeting all of the above objectives, it is
`desirable that the mulch be absorbent, easy to apply, free of
`weed seeds and other objectionable materials which could
`harm the soil, seeds or seedlings, and be capable of provid(cid:173)
`ing a relatively uniform seed bed cover. Desirably, the mulch
`or seed bed cover will be substantially biodegradable, and
`will not need to be removed after the grass begins to grow.
`Many of the mulch products which have been commonly 30
`used over relatively large grass seed beds are particularly
`unsuitable for repair of small damaged areas or patches.
`Aside from the normal disadvantages associated with using
`typical seed covers, such as the difficulty associated with
`uniformly spreading, and later removing, hay and straw, and
`the tendency of straw to contain weed seeds, it is also
`inconvenient to separately acquire, handle and apply grass
`seed and hay or straw in the relatively small quantities which
`would be needed for repairing dead patches in an existing
`lawn.
`Other common grass seed covers such as hydro-mulch
`products would be entirely impractical for small scale patch(cid:173)
`ing applications on account of the expensive equipment
`which would be needed, and because of the difficulty which
`may be associated with directing hydro-mulch applications
`over relatively small areas. Additionally, hydro-mulch mate- 45
`rials come in 50 pound bales which are difficult, or almost
`impossible to break up, and apply to a small area.
`Dry mulch pellets which are designed to swell, expand
`and disintegrate upon being exposed to water (rain or
`irrigation) can be uniformly spread over relatively large
`areas using various conventional lawn material spreaders.
`However, it is not practical or convenient to use a lawn
`spreader to spread dry mulch pellets over small damaged
`patches in an existing lawn. Also, it is not possible to achieve
`uniform application of the dry mulch pellets over a small 55
`and/or irregularly shaped patch using a conventional
`spreader without also spreading the pellets over undamaged
`areas, which results in waste and may be harmful to those
`portions of the existing lawn which do not need to be
`reseeded. The dry mulch pellets can be uniformly spread by
`hand over only the damaged areas of an existing lawn, but 60
`this requires a great deal of effort and care. Another disad(cid:173)
`vantage with using dry mulch pellets for repairing damaged
`patches on an existing lawn is that the pellets and grass seeds
`must be applied separately because a mixture of dry mulch
`pellets and grass seeds will quickly separate, with the grass 65
`seeds falling to the bottom of any container holding such a
`mixture.
`
`35
`
`This invention provides a paper mulch product and a
`method for making a paper mulch product which can be
`easily applied to small areas of an existing lawn which are
`in need of restoration. The paper mulch product, upon
`application to an area of lawn which is to be restored,
`provides an environment for promoting seed germination
`and seedling development. The paper mulch product
`achieves the desired attributes of stabilizing the soil against
`water and wind erosion, moderating temperature fluctua-
`tions at the soil surface, reducing evaporation and dissipat(cid:173)
`ing the energy of falling water droplets. Further, the paper
`mulch product of this invention is biodegradable and does
`40 not need to be removed after the grass begins to grow.
`The paper mulch product comprises a granular solid
`comprising at least about 85% paper by weight and at least
`about 6% water by weight, with the granular solid having a
`settled density of at least about 15 pounds per cubic foot.
`The method for preparing the paper mulch product
`includes the steps of comminuting paper to form particles
`having a maximum dimension of from about Y4 inch to about
`1 inch in any direction, mixing the comminuted paper with
`water to form a pulp, extruding the pulp through a die
`orifice, chopping the extrudate to a length of less than about
`1/s inch to form granules, and drying the granules to achieve
`a final moisture content of from about 6% to about 13% by
`weight.
`
`SUMMARY OF THE INVENTION
`
`DESCRIPTION OF THE PREFERRED
`EMBODIMENTS
`
`The paper mulch products in accordance with the pre(cid:173)
`ferred embodiments of this invention are primarily com(cid:173)
`prised of cellulose fibers derived from paper. Generally, any
`available source of paper may be used in preparing a paper
`mulch product in accordance with this invention, including
`newspaper, office stationary, and the like. However, the
`products of this invention are most preferably prepared from
`waste newspaper. Newspaper, especially recycled
`newspaper, is preferred because of its naturally high absorp(cid:173)
`tion capacity for water, because of its availability, and
`because of its environmental acceptability and biodegrad(cid:173)
`ability. Additionally, an added benefit is that newspaper, or
`
`50
`
`

`

`6,021,598
`
`3
`other waste paper, can be recycled and utilized in the
`preparation of an effective, environmentally acceptable,
`paper mulch product, rather than occupying space in a
`landfill.
`The recycled or used newspaper, or other paper, used in
`preparing the mulch product is first sorted, such as by hand,
`to remove any foreign objects which are not acceptable in
`the finished product. High powered magnets are used to
`remove any metal items such as staples, paper clips, etc. A
`metal detector is used to ensure that all unacceptable metal
`objects have been removed. The paper is then conveyed to
`a primary hammermill or shredder, where the paper is
`shredded or chopped into strips which are approximately 2
`to 3 inches wide. Thereafter, the shredded strips of paper are
`conveyed to a secondary shredder which chops the paper
`into fragments having a maximum dimension of approxi(cid:173)
`mately 1 inch in any direction. The chopped up paper is then
`conveyed to a final shredder in which the paper is shredded
`or ground to produce paper fragments having a maximum
`dimension of approximately % inch in any direction. A
`surfactant and a dye are preferably added to the ground
`paper in the final shredder. From the final shredder, the finely 20
`chopped paper is blown to a holding tank from which it is
`metered to a conditioning mill. At the conditioning mill,
`steam and water are added to raise the moisture content of
`the ground paper to a range from about 35% to about 45%
`by weight. The use of steam to raise the moisture content of 25
`the chopped paper is desirable because it tends to help break
`down the paper and provides a product which will break
`apart more quickly and disperse more evenly over the
`ground after application and wetting. With the addition of
`water and steam to the chopped paper, a pulp is formed at the 30
`conditioning mill. From the conditioning mill, the pulp is
`conveyed to a pellet mill. At the pellet mill, the pulp is
`extruded through a die having a plurality of die orifices, and
`the extrudates exiting the die orifices are chopped to a length
`of less than about 1/s inch to form granules. The temperature
`of the pulp in the pellet mill is approximately from about
`110° F. to 120° F., preferably about 115° F. From the pellet
`mill, the granules are conveyed to a cooling and aspirating
`area where water is removed. The granules are dried in the
`cooling and aspirating area to achieve a final moisture
`content of from about 6% to about 13% by weight, and more 40
`preferably from about 6% to about 8%.
`As stated above, a surfactant is preferably added to the
`paper mulch product to improve the absorption properties of
`the granules. Specifically, by adding a surfactant to the paper
`mulch product, the granules thereof are capable of more 45
`quickly absorbing water and disintegrating to provide a
`more uniform seed bed cover after the product is wetted with
`water (by rainfall or irrigation). Any of a variety of surfac(cid:173)
`tants (surface-active agents) may be acceptable for use in the
`paper mulch product of this invention, including anionic 50
`surfactants, such as those having carboxylate, sulfonate,
`sulfate or phosphate solubilizing anionic groups; nonionic
`surfactants, such as polyoxyethylene surfactants, carboxylic
`acid esters, carboxylic amides, and polyalkylene oxide block
`copolymers; cationic surfactants, such as amines, 2-alkyl-
`1-(2-hydroxyethyl)-2-imidazolines, and quaternary ammo(cid:173)
`nium salts; and amphoteric surfactants such as imidazo(cid:173)
`linium derivatives prepared from 2-alkyl-1-(2-
`hydroxyethyl)-2-imidazolines and sodium chloracetate. A
`preferred surfactant for use in preparing the paper mulch
`product of this invention is a product sold by Technical 60
`Products, Inc., Louisville Ky. under the name "Surfonic
`N-95" and having the chemical name Poly(oxy-1,2-
`ethanediyl), alpha-(nonylphenyl)-omega-hydroxy. Surfonic
`N-95 is known to decompose faster than cross-linked poly(cid:173)
`mers.
`The amount of surfactant which is added to the paper
`mulch product should be sufficient to provide a surfactant
`
`4
`content of from about 0.1 to about 0.5% by weight, and more
`preferably from about 0.15 to about 0.35% by weight.
`Amounts of surfactant below approximately 0.1% by weight
`are generally undesirable because they do not suitably
`5 excellerate or supplement the natural absorbing character(cid:173)
`istics of paper, especially newspaper. Amounts of surfactant
`above about 0.5% by weight are generally undesirable
`because they do not provide any appreciable added benefit.
`As stated above, a dye is preferably added to the paper
`mulch product in an amount sufficient to impart an aestheti-
`10 cally acceptable green color to the granules. A suitable
`amount of green dye is generally added, based on the total
`weight of the mulch. Most preferably, a dye or a combina(cid:173)
`tion of dyes are used which will impart to the mulch product
`a color which resembles that of actual grass, e.g., a Kelly
`15 green color. A suitable amount of dye for imparting the
`desired green color is, for example, about 1 pound per 400
`pounds of paper. However, this amount can be higher or
`lower depending upon the particular dye or dyes being used,
`the properties of the particular paper or papers being used,
`and the color which is desired.
`As stated above, a combination of steam and water are
`added to the chopped paper fragments to form a pulp which
`can be extruded through a die orifice. The relative amount of
`steam and water are selected to achieve a pulp having a
`moisture content of from about 35 to 45% by weight and a
`temperature of about 110 to 120° F. The relatively high
`moisture content helps lubricate the pellet mill. When the
`pulp is conveyed to the pellet mill at the above mentioned
`temperature and moisture ranges, a granular paper mulch
`product which is well suited for easy application to small
`areas of an existing lawn which require restoration is
`achieved.
`Suitable pellet mills for use in the practice of this inven-
`tion include the "series 3000" pellet mills sold by California
`Pellet Mill Co., Crawfordsville, Ind. The die orifices pref(cid:173)
`erably have a relatively constant diameter entrance portion
`and a tapered exit portion having a diameter which continu-
`ously increases towards the exit end of the orifice. For
`example, a suitable orifice size is one which has a total
`length of approximately 2 Y2 inches, including a constant
`diameter entrance portion having a length of approximately
`1.25 inches and a diameter of approximately 1/s inch, and a
`tapered exit portion which is approximately 1.25 inches long
`and whose diameter continuously increases from 1/s inch to
`0.265 inches at the exit.
`The pellet mill is provided with a plurality of knives
`which chop the extrudates exiting the die orifices to a desired
`length. Rotary pellet mills are typically provided with either
`one or two knives. The length of the pellets are determined
`by such factors as the rotational rate of the die in the pellet
`mill, the number of knives, the angular displacement
`between the knives (when more than one knife is used), and
`the distance between the outer surface of the die from which
`the extrudate emerges and the knife blade. In order to form
`the granular paper mulch products of this invention, it has
`been found desirable to use at least two knives in the pellet
`mill, and more preferably from 4 to 8 knives, with about 6
`being presently preferred. If too few knives are used, the
`pellets tend to be too long and too inconsistent in size (i.e.,
`have an undesirably large size distribution). If too many
`knives are used, the resulting product has an undesirable
`fluffiness and low density. Fluffy products of this type are
`undesirable because they do not exhibit good flow properties
`and therefore cannot be easily poured from a container for
`easy application onto a relatively small area of an existing
`lawn which has been damaged. The position of the knives
`are adjusted so that the cutting edge of the knife blade is
`65 approximately from 1.1t6 inch to approximately Y4 inch from
`the outer surface of the die from which the extrudates
`emerge.
`
`35
`
`55
`
`

`

`6,021,598
`
`10
`
`5
`The paper mulch product which results from the method
`described above has a granular appearance. The expression
`"granular" as used herein refers to a product which has a
`settled bulk or apparent density similar to a conventional
`pellet product, but in which the dimensions of the product
`are smaller than that of conventional pellets. Generally, the
`individual grains of the granular product of this invention
`have various sizes and shapes. However, the individual
`granules of the granular product of this invention should
`generally have a maximum dimension of less than 1/s inch in
`any direction. The granular products of this invention should
`typically have a settled density of at least 15 pounds per
`cubic foot, preferably at least 20 pounds per cubic foot, and
`more preferably at least 25 pounds per cubic foot. Settled
`density refers to the bulk or apparent density of the product
`after it has been subjected to sufficient vibration to cause
`settling thereof.
`The granular solid product comprising paper, a small
`amount of water (e.g., from about 6% to about 13% by
`weight), and desirably containing a suitable amount of
`surfactant (i.e., from about 0.1 to about 0.5% by weight) and
`an amount of a dye which is effective to impart an aestheti(cid:173)
`cally acceptable green color to the product, may be sold in
`various suitable containers, such as boxes or bags, to the
`ultimate user, who may mix the granular product with grass
`seeds prior to application. For example, the owners and/or
`operators of golf courses generally prefer to use their own
`blend of grass seeds. Accordingly, the owners and/or opera(cid:173)
`tors of golf courses will find it desirable to purchase the
`granular paper mulch product alone, and mix the granular
`product with a blend of grass seeds which is preferred. 30
`Alternatively, the granular paper mulch product may be
`premixed with grass seeds and packaged in suitable con(cid:173)
`tainers such as boxes or bags for sale to consumers, such as
`homeowners, who prefer the convenience of a premix.
`Because of the relatively small size of the granular product,
`it may be premixed with grass seeds and sold to consumers 35
`in that form without any appreciable separation of the seeds
`from the granular mulch.
`The paper mulch products of this invention have the
`advantage that they exhibit excellent flow properties and can
`be easily poured from a container, such as directly from the 40
`box in which the product is shipped, stored and displayed for
`retail sale. In one form, the product may be sold as a granular
`solid comprising paper containing a small amount of water,
`and optionally containing a small amount of surfactant
`and/or dye, without any additives or grass seed. This neat 45
`granular solid product can be mixed with grass seed or
`seeds, and with fertilizer and/or other additives if desired
`prior to application. Owners and operators of golf courses
`will find this form particularly desirable for preparing lawn
`patch compositions for repairing small areas of a golf course 50
`which has been damaged, such as by divots.
`In another form, the granular solid may be premixed with
`grass seed or seeds to form a patch composition which can
`be applied directly from the container in which it is sold to
`a damaged area of lawn. A patch composition containing the 55
`granular solid and grass seed or seeds, without fertilizer or
`other additives, is particularly useful for repairing small
`areas of a lawn damaged by dog urine.
`
`6
`In another form, the paper mulch product may be sold as
`a premixed composition containing the granular solid, grass
`seed or seeds, fertilizer, and other conventional additives if
`desired. The paper mulch products containing grass or grass
`5 seeds and fertilizer may be used for restoring areas of a lawn
`which have been damaged by various causes (other than dog
`urine) such as damage due to utility work, molds, etc.
`Application of the paper mulch products of this invention
`is relatively simple. First, it is generally desirable to remove
`any dead grass and to loosen the soil slightly such as with a
`rake. Thereafter, the paper mulch products of this invention
`are simply poured out of a container onto the damaged area
`of a lawn. Because of the excellent flow properties of the
`paper mulch products of this invention, application is easier
`than application of conventional fluffy lawn patch compo-
`15 sitions which must be placed over the damaged area, rather
`than poured over the damaged area. Also, because the paper
`mulch products of this invention have a higher density than
`commercially available fluffy paper mulch products, they
`are not as likely to be blown away by wind, and it is
`20 generally not necessary to wet the paper mulch products of
`this invention immediately after application, as is the case
`with conventional fluffy lawn patch compositions.
`The above description is considered that of the preferred
`embodiment(s) only. Modifications of the invention will
`25 occur to those skilled in the art and to those who make or use
`the invention. Therefore, it is understood that the
`embodiment(s) shown in the drawings and described above
`are merely for illustrative purposes and not intended to limit
`the scope of the invention, which is defined by the following
`claims as interpreted according to the principles of patent
`law, including the doctrine of equivalents.
`What is claimed is:
`1. A paper mulch product comprising:
`a granular solid comprising at least about 85% paper by
`weight, from about 6% to about 13% water by weight,
`and a surfactant in an amount of from about 0.1% to
`about 0.5% by weight, the granular solid having a
`settled density of at least about 15 pounds per cubic
`foot.
`2. The paper mulch product of claim 1, wherein the
`granular solid is comprised of granules having an average
`maximum dimension of about 1/s or less.
`3. The paper mulch product of claim 1, wherein the
`granular solid has a surfactant content of from about 0.15%
`to about 0.35% by weight.
`4. The paper mulch product of claim 1 in which the
`granular solid contains an amount of dye which is effective
`to impart a green color to the granules.
`5. The paper mulch product of claim 1, wherein the
`granular solid has a water content of from about 6% to about
`8% by weight.
`6. The paper mulch product of claim 1 further comprising
`grass seeds mixed with the granular solid.
`7. The paper mulch product of claim 1 further comprising
`fertilizer mixed with the granular solid.
`8. The paper mulch product of claim 1 further comprising
`grass seed and fertilizer mixed with the granular solid.
`
`* * * * *
`
`