Geosynthetic articles, systems comprising same, and methods of using same

Abstract

An erosion control subsystem is disclosed. The erosion control subsystem includes a first portion having a first densified fiber batt, first portion having a first water permittivity. The erosion control subsystem includes a second portion adjacent the first portion, the second portion having a second densified fiber batt, the second portion having a second water permittivity. The first water permittivity is greater than the second water permittivity.

Description

GEOSYNTHETIC ARTICLES, SYSTEMS COMPRISING SAME, AND METHODS OF USING SAMECROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and the benefit of the filing date of U.S. Provisional Patent Application No. 63 / 594,155, filed October 30, 2023, the entirety of which is hereby incorporated by reference herein.FIELD

[0002] This disclosure relates to system and articles for providing surface coverings having regions with different permittivity.BACKGROUND

[0003] Soil erosion is a significant issue that has conventionally been managed with hard armoring such as riprap rock or with concrete, but is increasingly being addressed with geosynthetic materials (man-made materials used to improve soil conditions) to stabilize the soil while vegetative growth takes place to provide the primary protection against the erosion.SUMMARY

[0004] Disclosed herein, in one aspect, is an erosion control subsystem including a first portion having a first densified fiber batt, first portion having a first water permittivity. The erosion control subsystem further includes a second portion adjacent the first portion, the second portion having a second densified fiber batt, the second portion having a second water permittivity. The first water permittivity is greater than the second water permittivity.

[0005] Methods of using the erosion control subsystems are also disclosed.

[0006] Additional advantages of the disclosed apparatuses, systems, and methods will be set forth in part by the description that follows. The advantages of the disclosed systems and methods will be realized and attained by means of the elements and combinations particularly- pointed out in the claims. It is to be understood that both the foregoing general description and following detailed description are explanatory only and are not restrictive to the disclosure and claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] These and other features of the preferred embodiments of the invention will become more apparent in the detailed description in which reference is made to the appended drawings wherein:

[0008] FIG. 1 is a schematic to view of an exemplary erosion control subsystem as disclosed herein.

[0009] FIG. 2 is a schematic side view of the exemplary erosion control subsystem of FIG. 1 in one aspect.

[0010] FIG. 3 is a schematic side view of the exemplar)’ erosion control subsystem of FIG. 1 in another aspect.

[0011] FIG. 4A is a schematic side view of the exemplary' erosion control subsystem of FIG. 1 in yet another aspect. FIG. 4B is a schematic side view of the exemplary erosion control subsystem of FIG. 1 in still another aspect.

[0012] FIG. 5 is a schematic side view of the exemplary’ erosion control subsystem of FIG. 1 in still another aspect.

[0013] FIG. 6 is a schematic side view of a tongue and groove interlock of the exemplary erosion control subsystem of FIG. 1.

[0014] FIG. 7 is a schematic top view of an exemplary erosion control subsystem as disclosed herein.

[0015] FIG. 8 is a schematic diagram of a system for forming a densified fiber batt as disclosed herein.

[0016] FIG. 9 is a schematic top view7of an exemplary7erosion control system as disclosed herein.

[0017] FIG. 10 is a schematic diagram showing a system for manufacturing an exemplary erosion control system as disclosed herein.

[0018] FIG. 11 is a schematic diagram showing a portion of a system for manufacturing an exemplary erosion control system as disclosed herein.DETAILED DESCRIPTION

[0019] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. It is to be understood that this invention is not limited to the particular methodology and protocols described, as such may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention.

[0020] Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which the invention pertains having the benefit of the teachings presented in the foregoing description and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

[0021] As used herein the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. For example, use of the term “a portion” can refer to one or more of such portions, and so forth.

[0022] All technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs unless clearly indicated otherwise.

[0023] Ranges can be expressed herein as from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It w ill be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. Optionally, in some aspects, when values are approximated by use of the antecedent “about,” it is contemplated that values within up to 20%, up to 15%, up to 10%,up to 5%, or up to 1% (above or below) of the particularly stated value can be included within the scope of those aspects. Similarly, in some optional aspects, when values are approximated by use of the terms ‘'substantially7’ or "generally,” it is contemplated that values within up to 15%, up to 10%, up to 5%, or up to 1% (above or below) of the particular value can be included within the scope of those aspects. When used with respect to an identified property or circumstance, “substantially” or "generally" can refer to a degree of deviation that is sufficiently small so as to not measurably detract from the identified property or circumstance, and the exact degree of deviation allowable may in some cases depend on the specific context.

[0024] As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

[0025] As used herein, the term “at least one of’ is intended to be synonymous with “one or more of.” For example, “at least one of A, B and C” explicitly includes only A, only B, only C, and combinations of each.

[0026] The word “or” as used herein means any one member of a particular list and, unless context dictates otherw ise, can also include any combination of members of that list.

[0027] As used herein, the term “permittivity ” means “the quantity of water that would pass through a material under a given head over a particular cross-sectional area.” Permittivity is an indicator of the quantity of water that can pass through a material in an isolated condition. In particular, “permittivity” as used herein, refers to permittivity perpendicular to a thickness of a material. For example, for a sheet of material having a planar surface, the permittivity7can be measured perpendicular to the planar surface. Permittivity can be measured according to ASTM D4491 / D4491M-22.

[0028] As used herein, unless context dictates otherwise, the different densified fiber batts, such as first and second densified fiber batts, can be understood to include both: (1) unitarily formed densified fiber batts, where a unitary fiber batt is densified to provide both the first and second densified fiber batts; and (2) separate fiber batts that are individually densified to provide the first and second densified fiber batts.

[0029] It is to be understood that unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; and the number or type of aspects described in the specification.

[0030] The following description supplies specific details in order to provide a thorough understanding. Nevertheless, the skilled artisan would understand that the apparatus, system, and associated methods of using the apparatus can be implemented and used without employing these specific details. Indeed, the apparatus, system, and associated methods can be placed into practice by modifying the illustrated apparatus, system, and associated methods and can be used in conjunction with any other apparatus and techniques conventionally used in the industry.Overview

[0031] Geosynthetic materials offer an anchor for the root mass of vegetative growth so that such vegetative growth has opportunity to grow. Use of geosynthetic materials can permit vegetative growth to grow in order to stabilize soil and prevent erosion. Conventional geosynthetic materials are provided as woven mats and stitched mats, but there are significant limitations to their design and performance. Conventional geosynthetic materials are limited in densify range, are limited in thickness range, are unwieldy to handle and transport, have more creep than is acceptable in many stabilization projects, and cannot provide stratified layers for different performance at different depths within the system. Accordingly, an improved geosynthetic material and system is desirable.

[0032] Disclosed herein are geosynthetic materials comprising one or more densified fiber batts and systems, such as a subsystem, comprising the geosynthetic materials that can be used for water management such as erosion control. The geosynthetic materials and systems disclosed herein can be used in environmental containment applications to stabilize slopes and manage water runoff. In further aspects, the geosynthetic materials and systemsdisclosed herein can line channels, protect shorelines, cover parking lots on hills, or armor levees, or similar applications. In further aspects, the geosynthetic material can be configured to control acoustics by reflecting or deflecting sound. In further aspects, the geosynthetic material can be configured to attenuate stound. The acoustic properties can be tailored based on the internal structure, external shape, properties of the material, or any combination thereof.

[0033] The geosynthetic materials can be provided as sheets or roll goods. The geosynthetic materials can be formed from a fiber batt comprising a first plurality7of fibers and a second plurality of fibers, wherein the first plurality of fibers and a second plurality' of fibers have different melt points. In one example, the first plurality of fibers can have a higher melt point than the second plurality of fibers. Alternatively, in other examples, the first plurality of fibers can have a loyver melt point than the second plurality of fibers. The fiber batt can be created through a card or airlay. Then the fiber matt may be (but not necessarily be) entangled yvith a needlepunch loom(s) to form a roll good that is then heated and densified in a press via a pressing step. During the pressing step, the top and / or bottom side of the fiber batt may be embossed for imparting certain performance features, such as a shape, texture, or pattern for affecting water flow and / or controlling acoustics (noise reduction or amplification; reflect, deflect, or absorb sound); a shape, texture, or pattern for engaging earth beneath the fiber batt, or a permittivity, etc. The material may then be cut into sheets or be rolled up depending on end application.

[0034] Benefits of the disclosed geosynthetic materials and systems over existing solutions include: the ability to adjust the density of the material through stratified layers in the material; the ability to have different shear properties between opposite faces may be different; the ability to provide interlocking fits betyveen sheets; the ability to control the thickness of the material; the ability to provide stackable or rollable sheets for more efficient shipping and handling; the ability to incorporate other performance layers such as geogrids; and the ability to adjust water permittivity through densification. The geosynthetic materials and systems can maintain the open entanglement of fibers to allow for vegetative growth into, and through, the material if desired. Geogrids can be formed by a network of overlay elements (optionally, tensile strength elements) that are configured to engage surrounding soil so as to provide reinforcement to the soil. The geogrids disclosed herein can provide stabilityand reinforcement in critical areas where higher tensile strengths and / or lower elongations are needed for the engineering designs.Exemplary Embodiments

[0035] Disclosed herein is an erosion control subsystem comprising: a first portion comprising a first densified fiber batt, wherein the first portion has a first water permittivity; and a second portion adjacent the first portion, the second portion comprising a second densified fiber batt, wherein the second portion has a second water permittivity7, wherein the first water permittivity is greater than the second water permittivity. For example, FIG. 1 shows an erosion control subsystem 10 comprising a first portion 20 comprising a first densified fiber batt 22 and a second portion 30 adjacent the first portion 20, the second portion comprising a second densified fiber batt 32. The first portion 20 has a first water permittivity, the second portion 30 has a second water permittivity7, the first water permittivity7being greater than the second water permittivity.

[0036] In some aspects, the first portion 20 can be coupled to the second portion 30. For example, referring to FIG. 6, in some aspects, the first and second portions can be coupled by an interlocking fit. Optionally, in these aspects, one of the first portion 20 or the second portion 30 of the erosion control subsystem 10 can comprise a tongue, and the other of the first portion 20 or the second portion 30 can define a groove. For example, the first portion 20 can define a groove 28, and the second portion 30 can comprise a tongue 38. (In other aspects, the portions defining the tongue and groove can be reversed.) The interlocking fit can comprise a coupling between the tongue 38 and the groove 28. In some aspects, the erosion control subsystem 10 can comprise a plurality7of square or rectangular sheets. Optionally, in these aspects, the two adjacent edges of each sheet can comprise a respective tongue, and the other two adjacent edges opposite those comprising the tongues can define respective grooves. In this way, the sheets can be assembled in an interlocking grid. In some examples, the tongue 38 and groove 28 may have additional features such as lips or locking tabs or other locking features that may be configured to further secure the locking between adjacent interlocked portions (20, 30) of the erosion control subsystem 10. In other aspects, the erosion control subsystem 10 can comprise sheets of any other appropriate geometric shape without departing from a broader scope of the present disclosure. It is noted that while the term “erosion control subsystem" is used, the applications or uses of the subsystem 10 may also include controlling acoustics (reducing or amplifying sound or noise in anenvironment where the subsystem is installed) in addition to aiding with erosion control and channeling water flow without departing from a broader scope of the present disclosure.

[0037] Accordingly, the erosion control subsystem 10 can be configured to control water or channel water flow by allowing water to pass therethrough in certain regions (e.g., at the first portion 20), while causing water to flow across (or over, i.e., not through) other regions (e.g., at the second portion 20). Further, the erosion control subsystem 10 can permit vegetation to grow in certain regions by allowing the vegetation to pass therethrough and by providing sufficient light penetration.

[0038] In other aspects, the first and second portions 20, 30 of the erosion control subsystem 10 can be unitarily formed. For example, in some aspects, the first and second portions can be formed from a unitary’ fiber batt, and the first and second portions 20, 30 of the erosion control subsystem 10 can comprise different materials in different regions and / or be processed in different regions to form, from the unitary fiber batt, the differing first and second densified fiber batts 22, 32. For example, in some aspects, a unitary' fiber batt can have a first section, comprising a first fiber type or fiber blend, and a second section, comprising a second fiber ty pe or fiber blend. Following densification, the first section can form the first portion 20. and the second section can form the section portion 30. In further or alternative aspects, during densification. a first section can be subject to a relatively lower temperature and / or a lower pressure, and a second section can be subject to a relatively higher temperature and / or a higher pressure so that the first and second sections form, respectively, the first portion 20 with the first fiber batt 22 having the higher permittivity and the second portion 30 with the second fiber batt 32 having the lower permittivity.

[0039] In still other aspects, the first portion 20 and the second portion 30 of the erosion control subsystem 10 can be positioned adjacent each other. For example, in some aspects, the first portion 20 and the second portion 30 can be provided on separate sheets of material and can have respective abutting or adjacent edges 24, 34 (e.g., in contact, or within 1 inch, or within 2 inches, or within 3 inches, or within 5 inches, or within 6 inches). In alternative aspects, the first portion 20 and the second portion 30 of the erosion control subsystem 10 can comprise overlapping edge portions 26, 36, wherein the edge 24 of the first portion 20 extends over or under the second portion 30. In some optional aspects, the first portion 20 and the second portion 30 of the erosion control subsystem 10 can be coupled to each other. In other optional aspects, the first portion 20 and the second portion 30 of the erosion controlsubsystem 10 are not coupled to each other. In still other aspects, the first portion 20 and the second portion 30 can be unitarily formed, wherein the respective abutting edges 24, 34 are defined by change in material properties between the first and second densified fiber batts 22, 32.

[0040] Each portion of the erosion control subsystem 10 can have an upper surface 72 and a lower surface 70. In some aspects, and as shown in FIG. 2. the first portion 20 can have an upper surface 72 that is generally planar. In some optional aspects, the second portion 30 can have an upper surface 72 that is generally planar. Referring also to FIGS. 4 and 5, in other aspects, the second portion 30 can define a channel 40 extending along a channel axis 42. In some aspects, and as shown in FIG. 4A, the channel 40 can be defined by an arcuate upper surface. In other aspects, and as shown in FIG. 4B, the channel 40 can have a generally rectangular cross-section. In still further aspects, the channel 40 can have any suitable cross sectional profile, such as, for example, a trapezoidal or generally trapezoidal profile, as illustrated in FIG. 5. Further, the cross-sectional profile can optionally vary along a length of the channel. More generally, along a vertical axis, the upper surface 72 of the first portion 20 can be positioned above at least part 74 of the upper surface 72 of the second portion 30. It is contemplated that the channel 40 can direct water flow. The channel 40 can prevent or inhibit water in the channel from flowing from the second portion to the first portion.

[0041] In some aspects, the channel 40 can be rigidly formed into the second portion 30. In other aspects, it is contemplated that the second portion 30 can be flexible and can conformably fit into an underlying channel and / or the contour of the underlying channel (e.g., a channel formed in the underlying surface of the earth) over which the second portion 30 is placed. In still other aspects, and as illustrated in FIG. 5, the channel can be formed by a combination of the first portion 20 and the second portion 30. For example, the second portion 30, having the second densified fiber batt 32, can form a portion of the channel subject to a relatively higher amount of flow (e.g.. a bottom of the channel), and the first portion 20 can form a side of the channel. For example, portions having the first densified fiber batt 22 can form the sides of the channel. In this way, the first portion 20 can permit vegetative grow th along the sides of the channel.

[0042] In some aspects, the first portion 20 of the erosion control subsystem 10 can have a length from 3 feet to 12 feet and a width from 2 feet to 8 feet. For example, in some aspects, the first portion can have a length of about 8 feet and a width of about 4 feet. In variousaspects, the first portion can comprise a sheet having a length from 3 feet to 12 feet and a width from 2 feet to 8 feet. For example, in some aspects, the first portion can comprise a sheet having a length of about 8 feet and a width of about 4 feet. In other aspects, the sheet can have a width of up to 16 feet, up to 12 feet, or up to 8 feet. In other aspects, the sheet can have a length of up to 30 feet, up to 20 feet, or up to 16 feet. For example, the sheet can have a width of 8 feet and a length of 16 feet. In various aspects, the first portion 20 can be provided as a roll. In some aspects, the roll can have a width of up to 12 feet. In some aspects, the roll can have a width of up to 20 feet. In some aspects, the roll can have a width of up to 8, or up to 10 feet (e.g., from 8 feet to 10 feet).

[0043] In some aspects, the second portion 30 of the erosion control subsystem 10 can have a length from 3 feet to 12 feet and a width from 2 feet to 8 feet. For example, in some aspects, the second portion 30 can have a length of about 8 feet and a width of about 4 feet. In various aspects, the second portion can comprise a sheet having a length from 3 feet to 12 feet and a width from 2 feet to 8 feet. For example, in some aspects, the second portion 30 can comprise a sheet having a length of about 8 feet and a width of about 4 feet. In other aspects, the sheet can have a width of up to 8 feet. In other aspects, the sheet can have a length of up to 16 feet. For example, the sheet can have a w idth of 8 feet and a length of 16 feet. In various aspects, the second portion 20 can be provided as a roll. In some aspects, the roll can have a width of up to 12 feet. In some aspects, the roll can have a width of up to 20 feet. In some aspects, the roll can have a width of up to 8, or up to 10 feet (e.g., from 8 feet to 10 feet). Accordingly, in various optional aspects, the first and second portions 20, 30 can have the same or similar dimensions (e.g., within 10%, within 5%, or within 1%).

[0044] In some aspects, the first and second portions 20, 30 of the erosion control subsystem 10 can both be provided on a single sheet of material. Optionally, in these aspects, the sheet can consist of the first and second portions 20, 30. In some aspects, the sheet comprising the first and second portions can have a length from 3 feet to 12 feet and a width from 2 feet to 8 feet. For example, in some aspects, the sheet comprising the first and second portions can have a length of about 8 feet and a width of about 4 feet. In other aspects, the sheet can have a width of up to 16 feet, up to 12 feet, or up to 8 feet. In other aspects, the sheet can have a length of up to 30 feet, up to 20 feet, or up to 16 feet. For example, the sheet can have a width of 8 feet and a length of 16 feet. In various aspects, the first and second portions 20. 30 can be provided as a roll. In some aspects, the roll can have a width of up to 12 feet. In someaspects, the roll can have a width of up to 20 feet. In some aspects, the roll can have a width of up to 8, or up to 10 feet (e.g., from 8 feet to 10 feet). In some optional aspects, the first and second portions 20, 30 can each have the same or substantially the same dimensions. In other aspects, the first and second portions can have any suitable relative dimensions to provide a desired structure.

[0045] In some aspects, the first densified fiber batt 22 can comprise fiber having a first denier, and the second densified fiber batt 32 comprises fiber having a second denier that is less than the first denier. In still further aspects, first densified fiber batt 22 can comprise a first blend of fibers having a first average (mean or median) denier, and the second densified fiber batt 32 can comprise a second blend of fibers having a second average (mean or median) denier, with the first average denier being greater than the second denier. The first blend of fibers can have a greater portion of larger fibers (e.g., having a denier of greater than 100), and the second blend of fibers can have a lesser portion of larger fibers (e.g., having a denier of greater than 100). It is contemplated that each of the first and second blends of fibers can include lower denier fibers for processability. That is, the smaller denier fibers can help carry the larger denier fibers through the process because the smaller the denier, the greater the number of fibers for the same total weight. In some optional aspects, the first blend of fibers can have deniers within a range from 15-3000. In some optional aspects, the second blend of fibers can have deniers within a range from 2-200. It is contemplated that fibers with smaller deniers can provide a construction with more fibers per cubic inch, while the larger fibers form a more open bulk that can permit higher waterflow through the material and / or more open space for vegetative growth (e.g., room for the grow th and open space for the sunlight). It is contemplated that coarser fibers can further provide greater UV resistance. For example, larger diameter fibers can be more easily stabilized for longer life.

[0046] In some aspects, the first and second densified fiber batts 22, 32 can be provided with the same blend of fiber denier, and the different permittivity can be provided during densification. This can be advantageous for avoiding use of multiple fiber blends.

[0047] In some aspects, the first densified fiber batt 22 can have a first density7, and the second fiber batt 32 can have a second density that is greater than the first density.

[0048] In some aspects, and with reference to FIG. 7, the erosion control subsystem 10 can further comprise a third portion 50 comprising a third densified fiber batt 52. The thirdportion 50 can have a third water permittivity that is greater than the second water permittivity. In some optional aspects, the third water permittivity can be the same as, or substantially the same as, the first water permittivity. In some aspects, the second portion 30 can be positioned between the first and third portions 20, 50. Optionally, in these aspects, the second portion 30 can define a channel 40. In some optional aspects, the first, second and third portions 20, 30. 50 can be unitarily formed. Optionally, in these aspects, the sheet can consist of the first, second, and third portions 20, 30, 50. In still other aspects, the first and second portions 20, 30 can be unitarily formed, and the third portion 50 can be provided on a separate sheet. In still further aspects, two or more subsystems 10 can be provided adjacent each other, each subsystem 10 having first and second portions 20, 30, so that the second first portion of one subsystem can serve as the third portion 50 of an adjacent subsystem. In some aspects, the subsystem 10 can comprise alternating first and second portions 20, 30. Optionally, in these aspects, two or more of the second portions 30 can define a channel 40, or a portion thereof, so that the subsystem 10 defines a plurality7of channels. In various aspects, the plurality of the channels 40 of the subsystem 10 can be spaced by some or all of the first portions 20 of the subsystem. That is, the second portions 30 can define respective channels 40 or portions thereof, and the first portions 20 between the channels 40 can space the channels. In aspects in which the subsystem 10 comprises a channel 40, the channel can be defined by an arcuate upper surface. In other aspects, and as shown in FIG. 4B, the channel 40 can have a generally rectangular cross-section.

[0049] In some optional aspects, the erosion control subsystem 10 can comprise portions that are not densified. For example, the portions that are not densified can be formed by spaces in a calendar or mold that densifies other regions of a fiber batt.

[0050] In some aspects, the erosion control subsystem 10 can further comprise at least one anchor 60 that extends through the first portion 20 or the second portion 30. The anchor 60 can comprise, for example, a stake that inhibits movement of the erosion control subsystem 10 relative to the underlying surface.

[0051] In some aspects, the first water permittivity7of the first densified fiber batt 22 can be at least two times the second water permittivity of the second densified fiber batt 32. In further aspects, the first water permittivity can be at least ten times the second water permittivity. In further aspects, the first water permittivity can be at least 20, at least 30, at least 50, or at least 100 times the second water permittivity7. In some exemplary7aspects, thesecond portion 30 can be generally water impermeable (e.g., less than 0.05 sec'1). That is, the permittivity of the second portion 30 can be 0 or about 0. In some aspects, the second water permittivity can be from about 0 to about 0.05 sec'1. In some aspects, the first water permittivity can be from about 0.05 sec'1to about 5 sec'1. In some aspects, the second water permittivity can be from about 0 to about 0.01 sec'1. In some aspects, the first water permittivity can be from about 0.01 sec'1to about 5 sec'1. In some aspects, the second water permittivity can be from about 0 to about 0. 1 sec'1. In some aspects, the first water permittivity can be from about 0. 1 sec'1to about 5 sec'1.

[0052] Optionally, the first portion 20 or the second portion 30 can comprise a coating. For example, the second portion 30 can comprise a coating that increases durability or decreases permittivity. In various aspects, the coating can comprise polyurethane, polyuria, bitumen, or a combination thereof. In other aspects, the first portion 20 and the second portion 30 do not comprise (are free of) coatings.

[0053] Referring to FIG. 8, a respective fiber batt 80 that forms each of the first densified fiber batt 22 and the second densified fiber batt 32 can be heated at a first temperature for a first period of time. The heated fiber batt can be subjected to pressure with a surface 232 of a press 230. For example, the press 230 can apply a pressure from about 50 psi to about 400 psi (e.g., from about 50 to about 100, or from about 100 to about 400 psi). The surface 232 of the press 230 can optionally be heated. For example, the surface 232 of the press 230 can be heated to a temperature from about 150 °F to about 600 °F (e.g., from 150 °F to 300 °F, or from 300 °F to 600 °F. In some examples, the heating and pressing can be done subsequently while in other examples, the heating and pressing may be done contemporaneously.Subjecting the heated fiber batt to the surface of the press can form the first densified fiber batt 22 (and, optionally, the second densified fiber batt 32).

[0054] In some aspects, the first densified fiber batt 22 can comprise a first plurality of fibers 90 having a first melting point and a second plurality of fibers 92. At least a portion of the second plurality of fibers 92 can have a second melting point that is lower than the first melting point. In this way, during a densification step during which the fiber batt 80 is heated, the second plurality of fibers, or the portion thereof having the second melting point, can soften (e.g., melt) to bind to the other fibers to form the densified fiber batt 22. In some optional aspects, the portion of the second plurality of fibers that has the second melting point can be an outer portion of the fibers of the second plurality7of fibers. For example, thesecond plurality of fibers can comprise a multi-component fiber, wherein the multicomponent fiber comprises a sheath 94 and a core 96 provided as a sheath core configuration, and wherein the sheath has the second melting point that is lower than the first melting point. In this way, during densification the first portion of the second plurality of fibers can soften and bind to the first plurality of fibers, while the second portion of the second plurality of fibers do not melt. In various optional aspects, the first plurality of fibers comprise polypropylene, and the second plurality of fibers can comprise polyethylene. In other optional aspects, the first plurality of fibers and the second plurality' of fibers can comprise polyethylene terephthalate (PET). In some optional aspects, the first and second plurality of fibers 90, 92 can be entangled.

[0055] The first temperature to which the fiber batt 80 is heated can be greater than the second melting point and lower than the first melting point. For example, in some aspects, such as those in which the first plurality of fibers comprise PET, the first temperature can be about 400 °F. This temperature can be below the melting point of PET but above the second melting point of the second plurality of fibers (or a portion thereof). In some exemplary aspects, the first plurality of fibers can comprise PET and the second plurality of fibers can comprise polypropylene, so the first and second pluralities of fibers melt at different temperatures. In other aspects, the first and second plurality of fibers can comprise the same material (e.g., polyester), but the melting points of the first and second plurality of fibers can differ.

[0056] Similarly, in some aspects, the second densified fiber batt 32 can comprise a first plurality of fibers having a first melting point and a second plurality of fibers. At least a portion of the second plurality of fibers can have a second melting point that is lower than the first melting point. In this way, during a densification step, the second plurality of fibers, or the portion thereof having the second melting point, can soften (e g., melt) to bind to the other fibers to form the densified fiber batt 22. In some optional aspects, the portion of the second plurality of fibers that has the second melting point can be an outer portion of the fibers of the second plurality of fibers. For example, the second plurality of fibers can comprise a multicomponent fiber, wherein the multi-component fiber comprises a sheath and a core provided as a sheath core configuration, and wherein the sheath has the second melting point that is lower than the first melting point. In various optional aspects, the first plurality of fibers comprise polypropylene, and the second plurality of fibers can comprise polyethylene. Inother optional aspects, the first plurality of fibers and the second plurality of fibers can comprise polyethylene terephthalate. In some optional aspects, the first and second plurality of fibers can be entangled.

[0057] In exemplary aspects, the second densified fiber batt 32 can have a density7of at least 500 kg / m3. For example, the second densified fiber batt 32 can have a density from about 500 kg / m3to about 1000 kg / m3. Optionally, the second densified fiber batt 32 can have a density of about 800 kg / m3. Such a density can be suitable for scour areas, as further described herein.

[0058] The first and second densified fiber batts 22. 32 can differ in one or more of the following ways: The fiber denier blend (e.g., the mean or median denier) can differ between the first and second densified fiber batts 22, 32 in order to control openness that affects permittivity7and sunlight penetration. For example, open space can permit sun to penetrate for promoting vegetation growth. In some aspects, the light penetration for the second densified fiber batt can range from about 0% to about 50% according to ASTM D6567, a light penetration test. In some aspects, the light penetration for the first densified fiber batt can range from about 10% to about 100%, or from about 50% to about 90%.

[0059] The first and second densified fiber batts 22, 32 can differ in relative percentage of lowmelt fiber (the second plurality7of fibers having a second melting point that is lower than the first melting point) to support differences in densities. Denser areas can be provided with more of a binder matrix of the lowmelt fibers. The second densified fiber batt 32 can be provided at areas with high water volumetric flow rate (scour areas) and can be configured to mimic the properties of concrete, while lower flow areas can provide less dense areas for the vegetative grow th.

[0060] The first and second densified fiber batts 22. 32 can differ in thickness. Greater thickness can be provided in the less dense areas can provide for better root anchoring, but greater thickness in the scour areas can provide a heavier material. Density7may be controlled by thickness, i.e., highly compressed areas can have higher density7while less compressed areas can have lower density. The density of the subsystem 10 can vary along the subsystem 10 with some areas or portions being denser than the others. Accordingly, the lesser thickness can correspond to a region with higher density, such as, for example a region configured to be a scour area.

[0061] The first and second densified fiber batts 22, 32 can differ in shape (e.g., texture or surface contour, such as forming the channel 40). Use of different shapes can channel / direct water and / or slow water flow.

[0062] Density and thickness can be controlled to provide sufficient shear strength to receive anchors and resist anchors ripping when shear forces are applied (e.g., due to water flow).

[0063] In some aspects, at least one of the first portion or the second portion can comprise an embossed surface. For example, wherein at least one of the first portion or the second portion can have a lower surface 70 that is textured. In this way, the textured lower surface can be configured to enhance shear engagement with ground below the textured lower surface. The lower textured surface can optionally comprise indentations or cups. In some aspects, the cups can have depths from about 1 mm to about 5 mm. In further aspects, the cups can have dimensions (e.g., diameters) from about 0.3 cm to about 2 cm, or about 1 cm.

[0064] In some aspects, at least one of the first portion or the second portion comprises an upper surface 72 that is planar. For example, in some aspects, the upper surface 72 can be smooth. It is contemplated that the smooth upper surface can promote water flow thereacross. This can be advantageous at a location of high water flow (e.g., at a stormwater pipe outlet) to inhibit turbulence that would otherwise apply shear to the erosion control subsystem 10. It is contemplated that, at other areas of the erosion control subsystem 10, where volumetric flow rate of water is lower, the upper surface 72 can have a texture that slows water flow.

[0065] In some aspects, at least one of the first portion 20 or the second portion 30 can comprise an upper surface 72 that is textured with grooves 76 (FIG. 10). The grooves 76 can be oriented parallel to a natural direction of water flow across the erosion control subsystem (e.g., downhill or away from a storm drain outlet) in order to promote water flow in a particular direction. In other aspects, the grooves can be oriented transverse to (e.g. perpendicular to) to a natural direction of water flow across the erosion control subsystem in order to slow or redirect water flow in a particular direction. In other words, the subsystem 10, the portions 20, 30 of the subsystem, and the channels defined by one or more of the portions of the subsystem may be configured to control the direction of the water flow.

[0066] In some aspect, at least one of the first portion 20 or the second portion 30 can comprise a variation in density between the upper surface 72 and the lower surface 70. Forexample, the variation in density can comprise a higher density proximate to the upper surface 72 and a lower density proximate to the lower surface 70. It is contemplated that the lower density can provide a surface that engages the surface (e.g., dirt) below the erosion control subsystem to inhibit movement of the erosion control subsystem.

[0067] In some aspects, the first densified fiber batt 22 can comprise polyester, polyolefin, nylon, or any combination thereof. In some aspects, the second densified fiber batt 32 can comprise polyester, polyolefin, nylon, or any combination thereof.

[0068] In some aspects, the first densified fiber batt 22 can comprise staple fibers. In some aspects, the second densified fiber batt 32 can comprise staple fibers. Each of the first and second densified fiber batts can comprise nonwoven material. In various aspects, the first densified fiber batt 22 and / or the second densified fiber batt 32 can comprise recycled, postindustrial, post-consumer material fibers. In some optional aspects, at least a portion of the fibers of the first densified fiber batt 22 and / or the second densified fiber batt 32 can be configured to biodegrade or dissolve. Such fibers can provide a temporary system to protect a slope / channel until vegetation is grown into place, and then biodegrade or dissolve thereafter.

[0069] In some aspects, the first portion 20 is within 6 inches of the second portion 30. For example, it is contemplated that the first portion and second portion need not have discrete boundaries therebetween. That is, a sheet comprising the first portion 20 and the second portion 30 can have a gradient or a spacing between the first and second portions.

[0070] In some aspects, the first portion 20 of the erosion control subsystem 10 comprises a structure that permits vegetation to grow therethrough. For example, the first portion can have a sufficiently low density that permits vegetation to grow therethrough. Referring to FIG. 7. in some aspects, the first portion 20 and the third portion 50 can permit vegetation to grow through. Optionally, in these aspects, the second portion 30 does not permit vegetation to grow therethrough. Such vegetation can include, for example, grasses and groundcover plants. In further aspects, the vegetation can include trees.Systems and Method of Forming Erosion Control Articles and Subsystem

[0071] FIGS. 10 and 11 show exemplary' systems 200 for forming the densified fiber batts as disclosed herein. Referring to FIG. 10, at least one fiber batt 80 can be provided on a roll210. The fiber batt from the roll 210 can be draw n through a heater 220, such as. for example, an oven. The heated fiber batt can then be pressed in a press 230. The press 230 can densify the fiber batt to form the densified fiber batt 22 (and, in some aspects in which the first and second densified fiber batts 22, 32 are unitarily formed, simultaneously the second densified fiber batt 32).

[0072] The press 230 can further form the texture at each surface of each densified fiber batt (shown as grooves 76). As disclosed herein the upper and lower surfaces can have the same textures or different textures. Further, the texture of each of the upper surface and the lower surface can the same or different at different regions across each surface. Still further, the press 230 can form the shape of the channel 40 (FIGS. 4-5) into the densified fiber batt (e.g.. in the second portion 30). The press 230 can form a channel 40 along a longitudinal axis (material movement axis) of the plurality of fiber batts 80.

[0073] After the press 230 forms the densified fiber batt, the densified fiber batt can be cut into sheets and stacked (FIG. 10) or formed onto rolls 260 via a roller 262 (FIG. 11). Optionally, the system 200 can comprise an accumulator 250 for feeding the roller 262.

[0074] Referring also to FIG. 11, in some aspects, a plurality of fiber batts 80 can be provided on a respective rolls 210. FIG. 11 shows a break where the heater 220 and the press 230 (FIG. 10) have been omitted for compactness. The plurality of fiber batts 80 can be layered to form the densified fiber batt 22 (and, in some aspects in which the first and second densified fiber batts 22, 32 are unitarily formed, simultaneously the second densified fiber batt 32). For example, in some optional aspects, the plurality of fiber batts 80 can be entangled (e.g., via a needle loom 240). The layered and, optionally, entangled plurality of fiber batts 80 can be drawn through the heater 220 and then provided to the press 230. It is contemplated that the different material properties (e.g., variation in densify) across the thickness of the first and second portions can be controlled by the different materials of each layer of the plurality of fiber batts 80.

[0075] It is contemplated that the material properties of the first and second densified fiber batts 22, 32 (e.g., the different permittivities) can be controlled at least in part by a densification step using the press 230. In still further aspects, the material properties of the first and second densified fiber batts 22, 32 (e.g., the different permittivities) can be controlled at least in part by the material properties of the fiber batt(s) 80.Systems and Methods of Using Erosion Control Articles and Subsystem

[0076] Referring to FIG. 9, an erosion control system 100 can comprise a plurality of erosion control subsystems 10 as disclosed herein. Each erosion control subsystem 10 of the plurality of erosion control subsystems can be provided as sheets or rolls, or assemblies comprising sheets rolls.

[0077] In some aspects, along a first axis 102, the erosion control system 100 can comprise alternating first portions and second portions of respective erosion control subsystems.

[0078] In some optional aspects, adjacent erosion control subsystems 10 can be coupled by an interlocking fit. For example, the interlocking fit between adjacent erosion control subsystems can comprise a tongue and groove interlocking fit.

[0079] In some aspects, the erosion control system 100 can form a levee. In some aspects, the erosion control system 100 can be provided on a surface 110 proximate to an outlet 130 of a storm drain. In some aspects, the erosion control system 100 can be provided on a sloped surface. In some aspects, the erosion control system 100 can be provided on a surface of an environmental containment area.

[0080] A method of installing the erosion control system 100 includes positioning each erosion control subsystem 10 over a surface 110. In some optional aspects, an anchor can be inserted through at least one erosion control subsystem 10. For example, an anchor can be placed at each comer of each sheet forming the erosion control subsystem 10. Optionally, an anchor can extend through overlapping portions of adjacent sheets of the erosion control system 100 to couple the adjacent sheets.

[0081] In some optional aspects, adjacent erosion control subsystems 10 can be coupled together with respective interlocking fits.Advantages of Erosion Control Articles and Subsystems Disclosed Herein

[0082] The disclosed geosynthetic materials, erosion control subsystem 10, and erosion control system 100 provide solutions to the limitations of conventional geosynthetic materials and can be adapted to a much broader range of conditions. For example, the exit of stormwater pipes presents extreme water flow and scouring that overwhelms open density solutions. Referring to FIG. 9, the erosion control subsystem 10 can be made denser in theseareas for armoring (using portions 30), and more open at locations away from high flow (e g., optionally, down a channel) where vegetative growth requires lesser density for proper water flow and sunlight to support root growth (at first portions 20). The surface structure in this example could also play a part in improving performance. A flat surface at exit might be needed to prevent turbulence for faster water evacuation, or the surface could be shaped to form small channel groves for directing the water flow. Farther away from the outlet, it can be advantageous to form indentions or cups in the surface to hold soil and provide proper interface so the soil will not be washed away prior to vegetative establishment. In some situations, it can be advantageous to have a flat or channeled upper surface at the outlet water movement and a different lower surface (e.g., a cupped face) for proper interface with the underlying soil to increase shear strength. It can further be advantageous to provide a higher density at an upper portion of the erosion control subsystem, with less water permeability, to promote water movement across the upper portion rather than permeating through, while providing a more open density7near the lower surface for improved interface with the underlying soil.Exemplary Aspects

[0083] In view of the described products, systems, and methods and variations thereof, herein below are described certain more particularly described aspects of the invention. These particularly recited aspects should not however be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the “particular ’ aspects are somehow limited in some way other than the inherent meanings of the language literally used therein.

[0084] Aspect 1 : An erosion control subsystem comprising: a first portion comprising a first densified fiber batt, wherein the first portion has a first water permittivity; and a second portion adj acent the first portion, the second portion comprising a second densified fiber batt, wherein the second portion has a second water permittivity, wherein the first water permittivity is greater than the second water permittivity.

[0085] Aspect 2: The erosion control subsystem of aspect 1, wherein the first portion is coupled to the second portion.

[0086] Aspect 3: The erosion control subsystem of aspect 2, wherein the first and second densified fiber batt are present in a unitary fiber batt.

[0087] Aspect 4: The erosion control subsystem of aspect 2, wherein the first and second portions are coupled by an interlocking fit.

[0088] Aspect 5: The erosion control subsystem of aspect 4, wherein one of the first portion or the second portion comprises a tongue, wherein the other of the first portion or the second portion defines a groove, wherein the interlocking fit comprises a coupling between the tongue and the groove.

[0089] Aspect 6: The erosion control subsystem of any one of the preceding aspects, wherein the first and second portions comprise abutting or adjacent edges.

[0090] Aspect 7: The erosion control subsystem of any one of aspects 1-5, wherein the first and second portions comprise overlapping edge portions.

[0091] Aspect 8: The erosion control subsystem of any one of the preceding aspects, wherein the second portion defines a channel or at least a portion thereof extending along a channel axis.

[0092] Aspect 9: The erosion control subsystem of aspect 8, wherein the first and second portions comprise respective edge portions adjacent each other, wherein the edge portions extend parallel to the channel axis.

[0093] Aspect 10: The erosion control subsystem of aspect 8 or aspect 9, wherein the channel is rigidly formed into the second portion.

[0094] Aspect 11 : The erosion control subsystem of any one of aspects 8-10, wherein each of the first portion and the second portion has an upper surface, wherein the channel is defined at least partially by a region of the upper surface of the second portion that is below the upper surface of the first portion.

[0095] Aspect 12: The erosion control subsystem of any one of aspects 8-11, wherein the channel is configured to inhibit water from flowing from the channel to the first portion.

[0096] Aspect 13: The erosion control subsystem of any one of the preceding aspects, wherein the first portion has a length from 3 feet to 12 feet and a width from 2 feet to 8 feet.

[0097] Aspect 14: The erosion control subsystem of any one of the preceding aspects, wherein the first portion has a length of about 8 feet and a width of about 4 feet.

[0098] Aspect 15: The erosion control subsystem of any one of the preceding aspects, wherein the first portion comprises a sheet having a length from 3 feet to 12 feet and a width from 2 feet to 8 feet.

[0099] Aspect 16: The erosion control subsystem of any one of the preceding aspects, wherein the first portion comprises a sheet having a length of about 8 feet and a width of about 4 feet.

[0100] Aspect 17: The erosion control subsystem of any one of the preceding aspects, wherein the first densified fiber batt comprises a first blend of fibers having a first average denier, wherein the second fiber batt comprises a second blend of fibers having a second average denier that is less than the first average denier.

[0101] Aspect 18: The erosion control subsystem of any one of the preceding aspects, wherein the first densified fiber batt has a first density, wherein the second fiber batt has a second density that is greater than the first density.

[0102] Aspect 19: The erosion control subsystem of any one of the preceding aspects, further comprising a third portion comprising a third densified fiber batt, wherein the third portion has a third water permittivity’, wherein the third water permittivity’ is greater than the second water permittivity.

[0103] Aspect 20: The erosion control subsystem of aspect 19, wherein the third water permittivity is substantially identical to the first water permittivity.

[0104] Aspect 21 : The erosion control subsystem of aspect 19 or aspect 20, wherein the third portion is positioned betw een the first and third portions.

[0105] Aspect 22: The erosion control subsystem of any one of aspects 19-21, wherein the first, second, and third portions are unitarily formed.

[0106] Aspect 23: The erosion control subsystem of any one of aspects 19-21, wherein the first and second portions are unitarily formed, and the third portion is provided on a separate sheet that is positioned adjacent the second portion.

[0107] Aspect 24: The erosion control subsystem of any one of the preceding aspects, further comprising at least one anchor that extends through the first portion or the second portion.

[0108] Aspect 25: The erosion control subsystem of any one of the preceding aspects, wherein the first water permittivity is at least two times the second water permittivity.

[0109] Aspect 26: The erosion control subsystem of any one of the preceding aspects, wherein the first water permittivity is at least ten times the second water permittivity7.

[0110] Aspect 27: The erosion control subsystem of any one of the preceding aspects, wherein second portion is generally water impermeable.

[0111] Aspect 28: The erosion control subsystem of any one of the preceding aspects, wherein the first densified fiber batt comprises a first plurality of fibers having a first melting point and a second plurality of fibers, wherein at least a portion of the second plurality of fibers has a second melting point that is lower than the first melting point.

[0112] Aspect 29: The erosion control subsystem of aspect 28, wherein the at least a portion of the second plurality of fibers that has the second melting point is an outer portion of the fibers of the second plurality of fibers.

[0113] Aspect 30: The erosion control subsystem of aspect 28 or aspect 29. wherein the second plurality of fibers comprises a multi-component fiber, wherein the multicomponent fiber comprises a sheath and a core provided as a sheath core configuration, and wherein the sheath has a second melting point that is lower than the first melting point.

[0114] Aspect 31 : The erosion control subsystem of any one of the preceding aspects, wherein the second densified fiber batt comprises a first plurality of fibers having a first melting point and a second plurality of fibers, wherein at least a portion of the second plurality of fibers has a second melting point that is lower than the first melting point.

[0115] Aspect 32: The erosion control subsystem of aspect 31, wherein the at least a portion of the second plurality of fibers that has the second melting point is an outer portion of the fibers of the second plurality of fibers.

[0116] Aspect 33: The erosion control subsystem of aspect 31 or aspect 32, wherein the second plurality of fibers comprises a multi-component fiber, wherein the multicomponent fiber compnses a sheath and a core provided as a sheath core configuration, and wherein the sheath has a second melting point that is lower than the first melting point.

[0117] Aspect 34: The erosion control subsystem of any one of aspects 28-33, wherein the first plurality of fibers comprise polypropylene, and wherein the second plurality of fibers comprise polyethylene.

[0118] Aspect 35: The erosion control subsystem of any one of aspects 28-33, wherein the first plurality of fibers and the second plurality of fibers comprise polyethylene terephthalate.

[0119] Aspect 36: The erosion control system of any one of aspects 28-35, wherein the first and second plurality of fibers are entangled.

[0120] Aspect 37: The erosion control subsystem of any one of the preceding aspects, wherein at least one of the first portion or the second portion comprises an embossed face.

[0121] Aspect 38: The erosion control subsystem of any one of the preceding aspects, wherein at least one of the first portion or the second portion comprises a lower textured surface that is configured to enhance shear engagement with ground below the lower textured surface.

[0122] Aspect 39: The erosion control subsystem of aspect 38, wherein the lower textured surface comprises indentations or cups.

[0123] Aspect 40: The erosion control subsystem of any one of the preceding aspects, wherein at least one of the first portion or the second portion comprises a planar upper surface.

[0124] Aspect 41 : The erosion control subsystem of any one of the preceding aspects, wherein at least one of the first portion or the second portion comprises an upper surface textured with grooves.

[0125] Aspect 42: The erosion control subsystem of any one of the preceding aspects, wherein at least one of the first portion or the second portion comprises an upper surface, a lower surface, and a variation in density between the upper surface and the lower surface.

[0126] Aspect 43: The erosion control subsystem of aspect 42, wherein the at least one of the first portion or the second portion comprising the variation in density’ comprises a higher density proximate to the upper surface and a lower density proximate to the lower surface.

[0127] Aspect 44: The erosion control subsystem of any one of the preceding aspects, wherein one or both of the first densified fiber batt or the second densified fiber batt comprises polyester, polyolefin, nylon, or any combination thereof.

[0128] Aspect 45 : The erosion control subsystem of any one of the preceding aspects, wherein one or both of the first densified fiber batt or the second densified fiber batt comprises polyester, polyolefin, nylon, or any combination thereof.

[0129] Aspect 46: The erosion control subsystem of any one of the preceding aspects, wherein the first densified fiber batt comprises staple fibers.

[0130] Aspect 47: The erosion control subsystem of any one of the preceding aspects, wherein the second densified fiber batt comprises staple fibers.

[0131] Aspect 48: The erosion control subsystem of any one of the preceding aspects, wherein the first portion is within 6 inches of the second portion.

[0132] Aspect 49: The erosion control subsystem of any one of the preceding aspects, wherein the first portion comprises a structure that permits vegetation to grow therethrough.

[0133] Aspect 50: The erosion control subsystem of aspect 49, wherein the first portion comprises a sufficiently low density that permits vegetation to grow therethrough.

[0134] Aspect 51 : An erosion control system comprising a plurality of erosion control subsy stems as in any one of the preceding aspects.

[0135] Aspect 52: The erosion control system of aspect 51, wherein, along a first axis, the erosion control system comprises alternating first portions and second portions of respective erosion control subsystems.

[0136] Aspect 53: The erosion control system of aspect 51 or aspect 52, wherein adjacent erosion control subsystems are coupled by an interlocking fit.

[0137] Aspect 54: The erosion control system of aspect 53, wherein the interlocking fit between adjacent erosion control subsystems comprises a tongue and groove interlocking fit.

[0138] Aspect 55: A method comprising: installing an erosion control system as in any one of aspects 51-54.

[0139] Aspect 56: The method of aspect 55, wherein installing the erosion control system comprises positioning each erosion control subsystem over a surface.

[0140] Aspect 57: The method of aspect 56, further comprising inserting an anchor through at least one erosion control subsystem.

[0141] Aspect 58: The method of aspect 56, wherein installing the erosion control system comprises coupling together adjacent erosion control subsystems with respective interlocking fits.

[0142] Aspect 59: The method of any one of aspects 56-58, wherein the erosion control system forms a levee.

[0143] Aspect 60: The method of any one of aspects 56-58, wherein the surface is proximate to an outlet of a storm drain.

[0144] Aspect 61 : The method of any one of aspects 56-58, wherein the surface is sloped.

[0145] Aspect 62: The method of any one of aspects 56-58, wherein the surface is an environmental containment area.

[0146] Aspect 63: A method of making an element of an erosion control system, the method comprising: applying heat and pressure to at least one fiber batt to form a first densified fiber batt having a first water permittivity; andapplying heat and pressure to the at least one fiber batt to form a second densified fiber batt having a second water permittivity, wherein the first water permittivity is greater than the second water permittivity.

[0147] Aspect 64: The method of aspect 63. wherein the at least one fiber batt comprises a unitary fiber batt.

[0148] Aspect 65: The method of aspect 63. wherein the at least one fiber batt comprises a first fiber batt and a second fiber batt, wherein the first fiber batt forms the first densified fiber batt, and wherein second the fiber batt forms the second densified fiber batt.

[0149] Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity' of understanding, certain changes and modifications may be practiced within the scope of the appended claims.

Claims

CLAIMSWhat is claimed is:

1. An erosion control subsystem comprising: a first portion comprising a first densified fiber batt, wherein the first portion has a first water permittivity; and a second portion adj acent the first portion, the second portion comprising a second densified fiber batt, wherein the second portion has a second water permittivity, wherein the first water permittivity is greater than the second water permittivity’.

2. The erosion control subsystem of claim 1, wherein the first portion is coupled to the second portion.

3. The erosion control subsystem of claim 2, wherein the first and second densified fiber batt are present in a unitary fiber batt.

4. The erosion control subsystem of claim 2, wherein the first and second portions are coupled by an interlocking fit.

5. The erosion control subsystem of claim 4, wherein one of the first portion or the second portion comprises a tongue, wherein the other of the first portion or the second portion defines a groove, wherein the interlocking fit comprises a coupling between the tongue and the groove.

6. The erosion control subsystem of claim 1, wherein the first and second portions comprise abutting or adjacent edges.

7. The erosion control subsystem of claim 1, wherein the first and second portions comprise overlapping edge portions.

8. The erosion control subsystem of claim 1, wherein the second portion defines a channel _or at least a portion thereof extending along a channel axis.

9. The erosion control subsystem of claim 8, wherein the first and second portions comprise respective edge portions adjacent each other, wherein the edge portions extend parallel to the channel axis.

10. The erosion control subsystem of claim 8, wherein the channel is rigidly formed into the second portion.

11. The erosion control subsystem of claim 8, wherein each of the first portion and the second portion has an upper surface, wherein the channel is defined at least partially by a region of the upper surface of the second portion that is below the upper surface of the first portion.

12. The erosion control subsystem of claim 8, wherein the channel is configured to inhibit water from flowing from the channel to the first portion.

13. The erosion control subsystem of claim 1, wherein the first portion has a length from 3 feet to 12 feet and a width from 2 feet to 8 feet.

14. The erosion control subsystem of claim 1, wherein the first portion has a length of about 8 feet and a width of about 4 feet.

15. The erosion control subsystem of claim 1, wherein the first portion comprises a sheet having a length from 3 feet to 12 feet and a width from 2 feet to 8 feet.

16. The erosion control subsystem of claim 1, wherein the first portion comprises a sheet having a length of about 8 feet and a width of about 4 feet.

17. The erosion control subsystem of claim 1, wherein the first densified fiber batt comprises a first blend of fibers having a first average denier, wherein the second fiber batt comprises a second blend of fibers having a second average denier that is less than the first average denier.

18. The erosion control subsystem of claim 1, wherein the first densified fiber batt has a first density, wherein the second fiber batt has a second density that is greater than the first density.

19. The erosion control subsystem of claim 1, further comprising a third portion comprising a third densified fiber batt, wherein the third portion has a third water permittivity, wherein the third water permittivity is greater than the second water permittivity.

20. The erosion control subsystem of claim 19, wherein the third water permittivity is substantially identical to the first water permittivity.

21. The erosion control subsystem of claim 19, wherein the third portion is positioned between the first and third portions.

22. The erosion control subsystem of claim 19, wherein the first, second, and third portions are unitarily formed.

23. The erosion control subsystem of claim 19, wherein the first and second portions are unitarily formed, and the third portion is provided on a separate sheet that is positioned adjacent the second portion.

24. The erosion control subsystem of claim 1, further comprising at least one anchor that extends through the first portion or the second portion.

25. The erosion control subsystem of claim 1, wherein the first water permittivity is at least two times the second water permittivity.

26. The erosion control subsystem of claim 1, wherein the first water permittivity is at least ten times the second water permittivity.

27. The erosion control subsystem of claim 1, wherein second portion is generally water impermeable.

28. The erosion control subsystem claim 1, wherein the first densified fiber batt comprises a first plurality of fibers having a first melting point and a second plurality of fibers, wherein at least a portion of the second plurality of fibers has a second melting point that is lower than the first melting point.

29. The erosion control subsystem of claim 28, wherein the at least a portion of the second plurality of fibers that has the second melting point is an outer portion of the fibers of the second plurality of fibers.

30. The erosion control subsystem of claim 28, wherein the second plurality of fibers comprises a multi-component fiber, wherein the multi-component fiber comprises a sheath and a core provided as a sheath core configuration, and wherein the sheath has a second melting point that is lower than the first melting point.

31. The erosion control subsystem of claim 1, wherein the second densified fiber batt comprises a first plurality of fibers having a first melting point and a second plurality of fibers, wherein at least a portion of the second plurality of fibers has a second melting point that is lower than the first melting point.

32. The erosion control subsystem of claim 31, wherein the at least a portion of the second plurality of fibers that has the second melting point is an outer portion of the fibers of the second plurality of fibers.

33. The erosion control subsystem of claim 31, wherein the second plurality of fibers comprises a multi-component fiber, wherein the multi-component fiber comprises a sheathand a core provided as a sheath core configuration, and wherein the sheath has a second melting point that is lower than the first melting point.

34. The erosion control subsystem of claim 28, wherein the first plurality of fibers comprise polypropylene, and wherein the second plurality of fibers comprise polyethylene.

35. The erosion control subsystem of claim 28, wherein the first plurality of fibers and the second plurality of fibers comprise polyethylene terephthalate.

36. The erosion control system of claim 28, wherein the first and second plurality of fibers are entangled.

37. The erosion control subsystem of claim 1, wherein at least one of the first portion or the second portion comprises an embossed face.

38. The erosion control subsystem of claim 1, wherein at least one of the first portion or the second portion comprises a lower textured surface that is configured to enhance shear engagement with ground below the lower textured surface.

39. The erosion control subsystem of claim 38, wherein the lower textured surface comprises indentations or cups.

40. The erosion control subsystem of claim 1, wherein at least one of the first portion or the second portion comprises a planar upper surface.

41. The erosion control subsystem of claim 1, wherein at least one of the first portion or the second portion comprises an upper surface textured with grooves.

42. The erosion control subsystem of claim 1, wherein at least one of the first portion or the second portion comprises an upper surface, a lower surface, and a variation in density between the upper surface and the lower surface.

43. The erosion control subsystem of claim 42, wherein the at least one of the first portion or the second portion comprising the variation in density comprises a higher density proximate to the upper surface and a lower density proximate to the lower surface.

44. The erosion control subsystem of claim 1, wherein one or both of the first densified fiber batt or the second densified fiber batt comprises polyester, polyolefin, nylon, or any combination thereof.

45. The erosion control subsystem of claim 1, wherein one or both of the first densified fiber batt or the second densified fiber batt comprises polyester, polyolefin, nylon, or any combination thereof.

46. The erosion control subsystem of claim 1, wherein the first densified fiber batt comprises staple fibers.

47. The erosion control subsystem of claim 1, wherein the second densified fiber batt comprises staple fibers.

48. The erosion control subsystem of claim 1, wherein the first portion is within 6 inches of the second portion.

49. The erosion control subsystem of claim 1, wherein the first portion comprises a structure that permits vegetation to grow therethrough.

50. The erosion control subsystem of claim 49, wherein the first portion comprises a sufficiently low density7that permits vegetation to grow therethrough.

51. An erosion control system comprising a plurality of erosion control subsystems as in any one of the preceding claims.

52. The erosion control system of claim 51, wherein, along a first axis, the erosion control system comprises alternating first portions and second portions of respective erosion control subsystems.

53. The erosion control system of claim 51, wherein adjacent erosion control subsystems are coupled by an interlocking fit.

54. The erosion control system of claim 53, wherein the interlocking fit between adjacent erosion control subsystems comprises a tongue and groove interlocking fit.

55. A method comprising: installing an erosion control system as in claim 51.

56. The method of claim 55, wherein installing the erosion control system comprises positioning each erosion control subsystem over a surface.

57. The method of claim 56, further comprising inserting an anchor through at least one erosion control subsystem.

58. The method of claim 56, wherein installing the erosion control system comprises coupling together adjacent erosion control subsystems with respective interlocking fits.

59. The method of claim 56, wherein the erosion control system forms a levee.

60. The method of claim 56, wherein the surface is proximate to an outlet of a storm drain.

61. The method of claim 56, wherein the surface is sloped.

62. The method of claim 56, wherein the surface is an environmental containment area.

63. A method of making an element of an erosion control system, the method comprising: applying heat and pressure to at least one fiber batt to form a first densified fiber batt having a first water permittivity; and applying heat and pressure to the at least one fiber batt to form a second densified fiber batt having a second water permittivity, wherein the first water permittivity is greater than the second water permittivity.

64. The method of claim 63, wherein the at least one fiber batt comprises a unitary7fiber batt.

65. The method of claim 63, wherein the at least one fiber batt comprises a first fiber batt and a second fiber batt, wherein the first fiber batt forms the first densified fiber batt, and wherein second the fiber batt forms the second densified fiber batt.

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