Sediment / erosion / perimeter control devices made from and / or including fibrillated and / or perforated materials

Abstract

Disclosed herein are exemplary embodiments of sediment / erosion / perimeter control devices (e.g., erosion control blankets, nets, meshes, geowebs, geonets, wattles, other geotextiles, etc.) made from fibrillated and / or perforated materials. Also disclosed herein are exemplary methods and systems for producing sediment / erosion / perimeter control devices (e.g., erosion control blankets, nets, meshes, geowebs, geonets, wattles, other geotextiles, etc.) by fibrillating and / or perforating materials.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 751,027 filed Jan. 29, 2025, which is incorporated herein by reference in its entirety.FIELD

[0002] The present disclosure relates to sediment / erosion / perimeter control devices made from and / or including fibrillated and / or perforated materials. The present disclosure also related to methods of making sediment / erosion / perimeter control devices from fibrillated and / or perforated materials.BACKGROUND

[0003] This section provides background information related to the present disclosure which is not necessarily prior art.

[0004] Sediment retention devices and control systems include silt fences, wattles, other geotextiles, filter logs, compost socks, hay bales, check dams, temporary diversion dikes, fiber rolls, nets, blankets, geowebs, geonets, and various types of stormwater inlet protectors. They are a widely used best management practice (BMP) to remove sediment from stormwater runoff as water passes through the BMP.

[0005] Sediment controls may be employed together with erosion controls. Generally, erosion controls are designed to prevent or minimize erosion and thus reduce the need for sediment controls. Sediment controls are generally designed to be temporary measures. But some sediment controls may be used for stormwater management purposes in addition to removing sediment, and at times are left on construction sites indefinitely to biodegrade.

[0006] The term “wattle” is used to describe a wide variety of tubular, cylindrical, and / or low-profile BMPs that have intimate contact with the ground and are designed to help control water direction, remove sediment from water, and aide in controlling or preventing erosion. For example, these devices and systems may be used to keep eroded soil on a construction site so that the eroded soil does not wash off and cause water pollution to a nearby stream, river, lake, sea, etc.DETAILED DESCRIPTION

[0007] The purpose of erosion control is to prevent the movement of topsoil and sediment and to assist vegetation establishment. Some erosion control methods, while protecting the soil, are not considered as environmentally friendly as others.

[0008] Disclosed herein are exemplary embodiments of sediment / erosion / perimeter control devices (e.g., erosion control blankets, nets, meshes, geowebs, geonets, wattles, other geotextiles, etc.) made from and / or including fibrillated and / or perforated materials. Also disclosed herein are exemplary methods and systems for producing sediment / erosion / perimeter control devices (e.g., erosion control blankets, nets, meshes, geowebs, geonets, wattles, other geotextiles, etc.) by fibrillating and / or perforating materials. Exemplary embodiments may include various materials that are fibrillated and / or perforated, such as papers, sheets, fabrics, films, environmentally sustainable materials derived from renewable resources, recycled materials, non-sustainable materials from non-renewable resources, among other fibrillatable and / or perforatable materials that are capable of being fibrillated and / or perforated.

[0009] In some exemplary embodiments, the sediment / erosion / perimeter control devices (e.g., erosion control blankets, nets, meshes, geowebs, geonets, wattles, other geotextiles, etc.) is made from and / or includes fibrillated and / or perforated environmentally sustainable materials, such as papers, sheets, fabrics, recycled materials, other environmentally sustainable materials derived from renewable resources and / or recycled materials, etc. In such exemplary embodiments, the sediment / erosion / perimeter control devices, methods, and systems may advantageously provide a novel approach to creating environmentally friendly erosion control solutions that address varying needs of temporary to permanent soil stabilization, erosion prevention, and other sediment control applications where lightweight, biodegradable, and / or cost-effective solutions are required.

[0010] In exemplary embodiments, a method includes processing a fibrillatable and / or perforatable material (e.g., paper, sheet, fabric, film, environmentally sustainable material, non-sustainable material, etc.) through fibrillation and / or perforation to create a network of strands in a webbed format suitable for use as a standalone sediment / erosion / perimeter control device or as a component of a geotextile, sediment, and / or erosion control device / solution / system.

[0011] The fibrillation and / or perforation may be accomplished mechanically and / or chemically, e.g., via a respective mechanical process and / or chemical treatment. The fibrillation and / or perforation splits or frays the material (e.g., paper, sheet, fabric, film, environmentally sustainable material, non-sustainable material, etc.) into fine interconnected strands. The fibrillated structure is formable into a net, mesh, blanket configured to be usable as a standalone geotextile or a sediment / erosion / perimeter control solution (e.g., blanket, geoweb, geonet, etc.) and / or configured to be incorporated as a component (e.g., an exterior of a wattle, etc.) into a sediment / erosion / perimeter control device usable for a variety of applications requiring high permeability, structural integrity, and flexibility.

[0012] In exemplary embodiments, the fibrillation process may include passing the material (e.g., paper, sheet, fabric, film, environmentally sustainable material, non-sustainable material, etc.) through rollers, cutting devices, ultrasonic slitting, and / or abrasion mechanisms to achieve the desired level of strand formation. The resulting fibrillated material (e.g., net, mesh, blanket, etc.) provides open structures that can trap or retain soil, keep “filler” fibers in place for installation, promote vegetation growth, and facilitate water drainage.

[0013] In some exemplary embodiments, the materials that are fibrillated and / or perforated can be produced from natural fibers, recycled paper, nonwoven and woven geotextiles, biodegradable fabrics, plastic sheets, etc. ensuring environmental sustainability. For example, the fibrillated and / or perforated materials may comprise one or more of jute fibers, sisal fibers, coir fibers, lyocell cellulose based fibers, modal cellulose based fibers, among other eco-friendly, natural, organic and / or plant-based fibers, etc.

[0014] Fibrillation is a process by which fibers or filaments within a material (e.g., papers, sheets, fabrics, films, environmentally sustainable materials, non-sustainable materials, etc.) are separated, frayed, or broken into smaller, finer strands to create a network of interconnected filaments. Fibrillation may be performed to increase the material's texture, strength, surface area, or to make it more porous or flexible. Below are example mechanical processes and chemical processes by which materials (e.g., papers, sheets, fabrics, films, environmentally sustainable materials, non-sustainable materials, etc.) can be fibrillated in exemplary embodiments disclosed herein.

[0015] Beating (mechanical beating) is an example fibrillation process that may be used in exemplary embodiments to provide fibrillated materials (e.g., papers, sheets, fabrics, films, environmentally sustainable materials, non-sustainable materials, etc.). Beating involves passing paper pulp, fabric fibers, etc. through a beater, which includes rotating blades or drums. In paper-making, beating may done during pulp preparation. For fabrics, beating can involve a similar action on loose fibers or during finishing. The beating action applies mechanical forces such as shear, compression, and friction to the fibers, causing them to break apart into smaller fibrils. The friction between the fibers and the machine parts causes the fibers to split and fibrillate, creating finer, interconnected strands. Outcome: the result is a fibrous, more open and porous material with increased surface area. For paper, this leads to better bonding and smoother surfaces. For fabrics, this enhances texture and softness.

[0016] Refining (paper refining or textile carding) is an example fibrillation process that may be used in exemplary embodiments to provide fibrillated materials (e.g., papers, sheets, fabrics, films, environmentally sustainable materials, non-sustainable materials, etc.). Paper refining includes using a machine called a refiner to physically separate and cuts fibers. Textile carding includes passing fibers through a set of rotating rollers or combs. In refining, fibers are subjected to mechanical stress between rotating plates or disks, causing the cellulose fibers to break into finer fibrils. Carding in textiles uses fine teeth or combs to separate and align the fibers, causing them to break into smaller pieces and become more entangled. Outcome: in both the paper refining and textile carding processes, fibers become finer and more entangled, forming a network of interconnected microfibers. This increases the strength, flexibility, and texture of paper, fabric, other material, etc.

[0017] High-pressure water jetting (hydroentanglement) is an example fibrillation process that may be used in exemplary embodiments to provide fibrillated materials (e.g., papers, sheets, fabrics, films, environmentally sustainable materials, non-sustainable materials, etc.). Hydroentanglement, also known as spunlacing, uses high-pressure water jets that can create entanglement between fibers in a web of paper, fabric, or other material. Water is sprayed at very high pressure (e.g., often over 1000 psi) onto the material, which breaks apart and fibrillates the fibers. The force of the water splits the fibers into finer strands, which then interlock to form a cohesive fabric, paper, etc. Outcome: this process results in a denser, stronger material with improved flexibility and absorbency and may be used for creating nonwoven fabrics, papers, etc. with enhanced performance in filtration.

[0018] Needle punching is an example fibrillation process that may be used in exemplary embodiments to provide fibrillated materials (e.g., papers, sheets, fabrics, films, environmentally sustainable materials, non-sustainable materials, etc.). Needle punching involves passing fibers through a bed of barbed needles, which repeatedly punch and entangle the fibers. The needles create small perforations in the material, causing fibers to separate and entangle into a dense mat of interconnected strands. The barbed needles cause the fibers to interlock, forming a stronger, more cohesive structure. Outcome: the material becomes a nonwoven fabric material with a felt-like texture, enhanced strength, and stability.

[0019] Roller and cylinder pressing (calendering) is an example fibrillation process that may be used in exemplary embodiments to provide fibrillated materials (e.g., papers, sheets, fabrics, films, environmentally sustainable materials, non-sustainable materials, etc.). Calendering is a mechanical process where paper, fabric, etc. is passed through a series of rollers under high pressure, often at elevated temperatures. The rollers compress the material, applying shear forces that can cause fiber separation and partial fibrillation. The rollers create a smoother surface and, in some cases, induce splitting of the fibers into finer strands. Outcome: the process smooths and densifies the material while also causing partial fibrillation, which can increase its strength and flexibility.

[0020] Grinding and mashing is an example fibrillation process that may be used in exemplary embodiments to provide fibrillated materials (e.g., papers, sheets, fabrics, films, environmentally sustainable materials, non-sustainable materials, etc.). Grinding and mashing involves applying significant mechanical force to crush or mash fibers, typically using grinding machines or presses. The grinding or mashing action physically crushes the fibers, causing them to break into smaller pieces and fibrils. The fibers separate under pressure, forming a web of interconnected strands. Outcome: the material becomes more porous, and the fibrillated fibers create an interwoven network that enhances texture and absorbency.

[0021] Frictional fibrillation (tumbling or frictional tumbling) is an example fibrillation process that may be used in exemplary embodiments to provide fibrillated materials (e.g., papers, sheets, fabrics, films, environmentally sustainable materials, non-sustainable materials, etc.). Tumbling or frictional fibrillation involves placing paper, fabric, etc. in a rotating drum or container along with abrasive materials. The material is tumbled or agitated, applying friction between fibers and between the fibers and the container walls. The constant friction breaks down the fibers into finer strands, causing them to split and fibrillate. This process allows for gradual fiber separation and interlocking. Outcome: the fabric, paper, or other material becomes softer and more flexible, with an increased surface area and improved texture. This process can also be used to enhance the absorbency or strength of the material.

[0022] Ultrasonic fibrillation is an example fibrillation process that may be used in exemplary embodiments to provide fibrillated materials (e.g., papers, sheets, fabrics, films, environmentally sustainable materials, non-sustainable materials, etc.). Ultrasonic fibrillation uses high-frequency sound waves to generate cavitation in a liquid medium surrounding the material. The ultrasonic waves create microscopic bubbles in the liquid. As these bubbles collapse, they create localized shear forces that break the fibers into finer fibrils, causing them to separate and form an interconnected web. Outcome: this process can generate very fine fibrils, resulting in materials with a high surface area and that are ideal for applications such as filtration.

[0023] The example mechanical fibrillation processes (e.g., beating, refining, high-pressure water jetting, needle punching, roller and cylinder pressing (calendering), grinding and mashing, frictional fibrillation (tumbling or frictional tumbling), ultrasonic fibrillation, etc.) create interconnected fibrillated strands in fabric, paper, or other material by applying shear, pressure, friction, or other forces to break down the fibers.

[0024] Oxidation is an example chemical fibrillation process that may be used in exemplary embodiments to provide fibrillated materials (e.g., papers, sheets, fabrics, films, environmentally sustainable materials, non-sustainable materials, etc.). In this example, fibrillation of cellulose in paper, fabric, etc. can be achieved through the use of oxidizing agents, such as hydrogen peroxide or potassium permanganate. The oxidizing agents break down the cellulose fibers by selectively cleaving the glycosidic bonds between glucose units in the cellulose chain, weakening the fiber structure. The oxidizing agents create oxygen-containing functional groups (e.g., hydroxyl or carboxyl groups) that disrupt the crystalline structure of the cellulose. This results in the breaking of individual fibers into smaller fibrils, which then become interconnected. Outcome: the paper, fabric, or other material develops a more open, fluffy texture, and the fibers become more hydrophilic, improving absorption properties and flexibility.

[0025] Enzymatic fibrillation is an example fibrillation process that may be used in exemplary embodiments to provide fibrillated materials (e.g., papers, sheets, fabrics, films, environmentally sustainable materials, non-sustainable materials, etc.). In this example, enzymatic treatments involve the use of cellulase enzymes to break down cellulose fibers selectively. These enzymes catalyze the hydrolysis of cellulose into shorter chains or fragments, which can then fibrillate to form interconnected networks. The cellulase enzymes hydrolyze the β-1,4-glycosidic bonds in cellulose. The enzyme attacks specific regions of the cellulose fiber, weakening it and causing the fibers to split into fine fibrils that create an interwoven structure. Outcome: the material becomes softer and more flexible, and the fibers form a three-dimensional structure that is often used to enhance the material's ability to hold liquid (such as in tissue paper or absorbent products).

[0026] Acid hydrolysis is an example fibrillation process that may be used in exemplary embodiments to provide fibrillated materials (e.g., papers, sheets, fabrics, films, environmentally sustainable materials, non-sustainable materials, etc.). Acidy hydrolysis includes using sulfuric acid or hydrochloric acid to treat paper, fabric, or other material made of cellulose. The acid breaks down the cellulose fibers, causing them to fibrillate. The acid breaks the hydrogen bonds and weakens the amorphous regions of the cellulose, causing the fibers to separate into fibrils. In some cases, concentrated sulfuric acid can also produce a gel-like substance as it breaks down the cellulose, which can lead to the formation of microfibrils. Outcome: the acid hydrolysis fibrillation process can lead to increased surface area and porosity, making the material suitable for applications like filtration, reinforced composite materials, high-strength paper, etc.

[0027] Alkaline treatment (mercerization) is an example fibrillation process that may be used in exemplary embodiments to provide fibrillated materials (e.g., papers, sheets, fabrics, films, environmentally sustainable materials, non-sustainable materials, etc.). Mercerization includes the treatment of cotton, fabric, or other cellulose-based materials with a strong alkaline solution, typically sodium hydroxide (NaOH) to induce fibrillation. The alkaline solution swells the cellulose fibers and causes the amorphous regions to dissolve or loosen, which allows the individual fibrils to separate and become interwoven. While mercerization is usually done for improving the luster and strength of the fibers, mercerization can also result in partial fibrillation under certain conditions. Outcome: the fabric or other material becomes stronger, more lustrous, and more dimensionally stable, with a smoother surface and enhanced dye uptake. A degree of fibrillation can also occur, contributing to a softer feel or improved performance in certain textile applications.

[0028] Exemplary embodiments may also include combined mechanical and chemical approaches to fibrillate materials (e.g., papers, sheets, fabrics, films, environmentally sustainable materials, non-sustainable materials, etc.). For example, a mechanical fibrillation assisted by chemical treatment may be used in exemplary embodiments to provide fibrillated materials (e.g., papers, sheets, fabrics, films, environmentally sustainable materials, non-sustainable materials, etc.). For example, a cellulose-based material might be mechanically beaten or subjected to high-pressure water jets, while simultaneously being treated with a chemical agent such as sodium hydroxide or urea. The mechanical beating or high-pressure jets help to separate and break down the fibers, and the chemical agents weaken the fiber structure to facilitate fibrillation. The mechanical process physically forces the fibers apart, while the chemicals ensure that the fibers can easily form the fine, interconnected strands. Outcome: This hybrid method (mechanical fibrillation assisted by chemical treatment) can produce highly fibrillated materials with fine networks of cellulose fibers that enhance properties like strength, absorbency, and surface area.

[0029] Supercritical fluid treatment is an example fibrillation process that may be used in exemplary embodiments to provide fibrillated materials (e.g., papers, sheets, fabrics, films, environmentally sustainable materials, non-sustainable materials, etc.). This example process includes the use of supercritical fluids (e.g., carbon dioxide (CO2), etc.) that can be combined with chemical treatments to fibrillate fibers. Supercritical CO2 has unique properties that allow it to dissolve certain substances and interact with cellulose fibers in ways that can lead to fibrillation. In the presence of supercritical CO2, cellulose fibers undergo swelling and partial dissolution, making them more prone to fibrillation when mechanically treated or when exposed to chemical agents like alkalis or oxidizing agents. Outcome: the cellulose fibers break into finer fibrils, creating a porous, interconnected structure. This supercritical fluid treatment method can be particularly useful for creating highly porous or biocompatible materials.

[0030] Advantageously, exemplary sediment / erosion / perimeter control devices, methods, and systems disclosed herein may include or provide one or more (but not necessarily any or all of) the following advantages:

[0031] cost-effective production using readily available paper or fabric materials;

[0032] lightweight sediment and erosion control solutions suitable for temporary or permanent erosion control applications;

[0033] enhanced performance through customizable fibrillation, ensuring improved (e.g., optima;, etc.) strength and permeability based on the end application; and / or

[0034] versatile application in soil stabilization, revegetation, slope protection, and construction projects.

[0035] By way of example, fibrillated and / or perforated materials disclosed herein (e.g., papers, sheets, fabrics, films, environmentally sustainable materials, non-sustainable materials, etc.) may be used in a sediment / erosion / perimeter control device as disclosed in U.S. patent application Ser. No. 18 / 818,250 filed Aug. 28, 2024 and / or in U.S. patent application Ser. No. 18 / 818,282 filed Aug. 28, 2024, which are incorporated herein by reference in their entirety. For example, fibrillated and / or perforated materials disclosed herein may be used in:

[0036] a wattle;

[0037] a wattle integrated with a silt fence such that the silt fence and the wattle are an integrated, singular, or unitary product;

[0038] a wattle that is integrated with a scour pad such that the scour pad and the wattle are an integrated, singular, or unitary product; and / or

[0039] a hygroexpandable sediment / erosion / perimeter control device.

[0040] In exemplary embodiments, fibrillated and / or perforated materials disclosed herein are used in a wattle as disclosed in U.S. patent application Ser. No. 18 / 818,250. In such exemplary embodiments, the wattle (broadly, sediment / erosion / perimeter control device) comprises a water permeable exterior (e.g., netting, etc.) defined by the fibrillated and / or perforated material (e.g., papers, sheets, fabrics, films, environmentally sustainable materials, non-sustainable materials, etc.). An infill is encapsulated within an interior defined by the water permeable exterior of the wattle. The wattle is reconfigurable between at least a first configuration via compression of the infill in which the wattle has a first size, shape, volume, and / or weight, and a second configuration in which the wattle has a second size, shape, volume, and / or weight substantially larger than the corresponding first size, shape, volume, and / or weight that the sediment / erosion / perimeter control device has in the first configuration. More specifically, the wattle may be compressible into the first configuration via compression of the infill, and expandable from the first configuration to the second configuration via expansion of the infill when the infill absorbs water passing through the water permeable exterior of the wattle. The infill may comprise a cellulose-based sponge infill, a hygroexpandable infill, an infill configured to be compressible and expandable upon absorption of water, an infill configured to be chemically activatable to thereby reconfigure the wattle from the first configuration into the second configuration, a natural infill, a non-natural infill, a synthetic infill, an organic, plant-based, and / or environmentally friendly infill, a cellulose-based material, and / or a sponge.

[0041] Various aspects of the invention according to the present disclosure include, but are not limited to, the aspects listed in the following numbered clauses.

[0042] Clause 1. A sediment / erosion / perimeter control device comprising a fibrillated and / or perforated material(s).

[0043] Clause 2. The sediment / erosion / perimeter control device of clause 1, wherein the fibrillated and / or perforated material(s) comprises a fibrillated and / or perforated environmentally sustainable material(s).

[0044] Clause 3. The sediment / erosion / perimeter control device of clause 1 or 2, wherein the fibrillated and / or perforated material(s) comprises a fibrillated and / or perforated paper(s), sheets(s), fabric(s), and / or film(s).

[0045] Clause 4. The sediment / erosion / perimeter control device of any one of clauses 1 to 3, wherein the fibrillated and / or perforated material(s) comprises: a mechanically fibrillated material(s); a chemically fibrillated material(s); or a material fibrillated via mechanical fibrillation assisted by chemical treatment.

[0046] Clause 5. The sediment / erosion / perimeter control device of any one of clauses 1 to 4, wherein the fibrillated and / or perforated material(s) is split or frayed, via mechanical and / or chemical fibrillation, into relatively fine interconnected strands of the material(s).

[0047] Clause 6. The sediment / erosion / perimeter control device of any one of clauses 1 to 5, wherein the fibrillated and / or perforated material(s) is configured to create a network of strands in a webbed format suitable for use as a standalone sediment / erosion / perimeter control device or as a component of a sediment / erosion / perimeter control system.

[0048] Clause 7. The sediment / erosion / perimeter control device of any one of clauses 1 to 6, wherein the fibrillated and / or perforated material(s) is configured to provide open structures that can trap or retain soil, keep “filler” fibers in place for installation, promote vegetation growth, and facilitate water drainage.

[0049] Clause 8. The sediment / erosion / perimeter control device of any one of clauses 1 to 7, wherein the fibrillated and / or perforated material(s) comprises a fibrillated and / or perforated environmentally sustainable material(s) such that the sediment / erosion / perimeter control device is configured to provide an environmentally friendly erosion control solution that addresses varying needs of temporary to permanent soil stabilization, erosion prevention, and other sediment control applications.

[0050] Clause 9. The sediment / erosion / perimeter control device of any one of clauses 1 to 8, wherein the sediment / erosion / perimeter control device is an erosion control blanket, a net, a mesh, a geoweb, a geonet, and / or a geotextile.

[0051] Clause 10. The sediment / erosion / perimeter control device of any one of clauses 1 to 8, wherein the sediment / erosion / perimeter control device is a wattle including:

[0052] a water permeable exterior defined by the fibrillated and / or perforated material(s); and an infill encapsulated within an interior defined by the water permeable exterior of the wattle.

[0053] Clause 11. The sediment / erosion / perimeter control device of any one of clauses 1 to 8, wherein the sediment / erosion / perimeter control device comprises: a wattle; a wattle integrated with a silt fence such that the silt fence and the wattle are an integrated, singular, or unitary product; or a wattle that is integrated with a scour pad such that the scour pad and the wattle are an integrated, singular, or unitary product.

[0054] Clause 12. A method of using the sediment / erosion / perimeter control device of any one of clauses 1 to 11.

[0055] Clause 13. A method of manufacturing the sediment / erosion / perimeter control device of any one of clauses 1 to 11, the method comprising fibrillating and / or perforating a material(s) to thereby provide the fibrillated and / or perforated material(s) for the sediment / erosion / perimeter control device.

[0056] Clause 14. The method of clause 13, wherein fibrillating and / or perforating a material(s) comprises: mechanically fibrillating and / or perforating the material(s); chemically fibrillating and / or perforating the material(s); or fibrillating and / or perforating the material(s) via mechanical fibrillation assisted by chemical treatment.

[0057] Clause 15. The method of clause 13 or 14, wherein fibrillating and / or perforating a material(s) comprises passing the material(s) through one or more rollers, cutting devices, ultrasonic slitting, and / or abrasion mechanism(s) to achieve a desired level of strand formation in the material(s).

[0058] Clause 16. The method of any one of clauses 13 to 15, wherein fibrillating and / or perforating a material(s) comprises separating, fraying, and / or breaking fibers or filaments within the material(s) into smaller, finer strands to create a network of interconnected filaments.

[0059] Clause 17. The method of any one of clauses 13 to 16, wherein fibrillating and / or perforating a material(s) comprises embossing the material(s) to create perforations in a web of the material(s).

[0060] Clause 18. The method of any one of clauses 13 to 17, wherein fibrillating and / or perforating a material(s) comprises mechanically manipulating the material(s) to thereby fibrillate and / or perforate the material.

[0061] Clause 19. The method of any one of clauses 13 to 18, wherein fibrillating and / or perforating a material(s) comprises subjecting the material(s) to: a beating (mechanical beating) fibrillation process; refining (paper refining or textile carding) fibrillation process; a high-pressure water jetting (hydroentanglement) fibrillation process; a need punching fibrillation process; a roller and cylinder pressing (calendering) fibrillation process; a grinding and mashing fibrillation process; frictional fibrillation (tumbling or frictional tumbling) fibrillation process; and / or an ultrasonic fibrillation process.

[0062] Clause 20. The method of any one of claims 13 to 19, wherein fibrillating and / or perforating a material(s) comprises subjecting the material(s) to: an oxidation chemical fibrillation process; an enzymatic fibrillation process; an acid hydrolysis fibrillation process; an alkaline treatment (mercerization) fibrillation process; a mechanical fibrillation assisted by chemical treatment process; a fibrillation process including subjecting the material(s) to mechanically beating and / or high-pressure water jets while simultaneously treating the material(s) with a chemical agent such as sodium hydroxide or urea; and / or a supercritical fluid treatment fibrillation process.

[0063] Clause 21. A sediment, erosion, or perimeter control device comprising a fibrillated and / or perforated material that defines a water-permeable structure configured to trap or retain soil, facilitate water drainage, and promote vegetation growth.

[0064] Clause 22. The device of clause 21, wherein the fibrillated and / or perforated material comprises paper, sheet, fabric, or film.

[0065] Clause 23. The device of clause 21 or 22, wherein the fibrillated and / or perforated material comprises an environmentally sustainable material selected from natural fibers, recycled paper, biodegradable fabrics, and combinations thereof.

[0066] Clause 24. The device of any one of claims 21 to 23, wherein the fibrillated and / or perforated material comprises fibers selected from jute, sisal, coir, lyocell, modal, cellulose-based fibers, and combinations thereof.

[0067] Clause 25. The device of any one of clauses 21 to 24, wherein the fibrillated and / or perforated material comprises interconnected strands forming a net, mesh, blanket, geoweb, geonet, or geotextile.

[0068] Clause 26. The device of any one of claims 21 to 25, wherein the fibrillated and / or perforated material is obtained by mechanical fibrillation, chemical fibrillation, or mechanical fibrillation assisted by chemical treatment.

[0069] Clause 27. The device of clause 26, wherein the mechanical fibrillation comprises one or more of beating, refining, high-pressure water jetting (hydroentanglement), needle punching, calendering, grinding, frictional tumbling, and ultrasonic fibrillation.

[0070] Clause 28. The device of clause 26, wherein the chemical fibrillation comprises one or more of oxidation, enzymatic treatment, acid hydrolysis, alkaline treatment (mercerization), supercritical fluid treatment, or concurrent chemical treatment with mechanical action.

[0071] Clause 29. The device of any one of clauses 21 to 28, wherein perforation is formed by embossing a web of the material and / or by mechanical manipulation that creates apertures providing target porosity and permeability.

[0072] Clause 30. The device of any one of clauses 21 to 29, wherein the water-permeable structure has open area and strand geometry selected to retain sediment while allowing stormwater flow suitable for temporary to permanent soil stabilization.

[0073] Clause 31. The device of any one of claims 21 to 30, wherein the fibrillated and / or perforated material(s) is split or frayed, via mechanical and / or chemical fibrillation, into relatively fine interconnected strands of the material(s).

[0074] Clause 32. The device of any one of clauses 21 to 31, wherein the fibrillated and / or perforated material(s) is configured to create a network of strands in a webbed format suitable for use as a standalone sediment / erosion / perimeter control device or as a component of a sediment / erosion / perimeter control system.

[0075] Clause 33. The device of any one of clauses 21 to 32, wherein the fibrillated strands exhibit an average node-to-node spacing within a selected range to achieve a predetermined filtration efficiency for stormwater inlet protection.

[0076] Clause 34. The device of any one of clauses 21 to 33, wherein the fibrillated and / or perforated material comprises a blend of plant based fibers and recycled polymer fibers to tune mechanical integrity and biodegradation rate.

[0077] Clause 35. A wattle comprising: a water-permeable exterior comprising the fibrillated and / or perforated material of any one of clauses 21 to 34; and an infill encapsulated within an interior defined by the water-permeable exterior.

[0078] Clause 36. The wattle of clause 35, wherein the wattle is reconfigurable between: a first configuration via compression of the infill; and a second configuration having greater size and / or volume than the first configuration, the wattle being expandable to the second configuration upon the infill absorbing water passing through the exterior.

[0079] Clause 37. The wattle of clause 35 or 36, wherein the infill comprises a cellulose based sponge, a hygroexpandable infill, a chemically activatable infill, or a plant based or recycled infill.

[0080] Clause 38. The wattle of any one of clauses 35 to 37, wherein the water permeable exterior comprises a fibrillated net or mesh having interconnected strands dimensioned to retain the infill fibers during installation while permitting stormwater infiltration

[0081] Clause 39. The wattle of any one of clauses 35 to 38, wherein: the wattle is integrated with a silt fence as an integrated, singular, or unitary product; or the wattle is integrated with a scour pad as an integrated, singular, or unitary product.

[0082] Clause 40. The wattle of any one of clauses 35 to 39, wherein the infill expands by at least a selected percentage upon water absorption, thereby increasing an installation footprint height for flow interception.

[0083] Clause 41. An erosion control blanket, net, mesh, geoweb, geonet, or geotextile comprising the fibrillated and / or perforated material of any one of clauses 21 to 34, the material forming an open-structure web configured to stabilize soil, retain sediment, and promote revegetation.

[0084] Clause 42. The product of clause 41, wherein the open-structure web has strand width, node spacing, and aperture size selected to provide a target permeability for slope protection or channel lining applications.

[0085] Clause 43. The product of clause 41 or 42, wherein the fibrillated and / or perforated material is biodegradable to enable site-left-in-place applications.

[0086] Clause 44. The product of any one of clauses 41 to 43, wherein the open structure web includes graduated aperture zones to provide variable permeability across the product width.

[0087] Clause 45. A method of controlling sediment or erosion at a site, the method comprising placing the device of any one of clauses 21 to 34, the wattle of any one of clauses 35 to 40, or the product of any one of clauses 41 to 44 at a ground surface or flow path to intercept runoff, retain sediment, and permit water to pass through the water-permeable structure.

[0088] Clause 46. The method of clause 45, wherein the device is left in place to biodegrade following site stabilization.

[0089] Clause 47. A method of manufacturing a sediment, erosion, or perimeter control device, the method comprising fibrillating and / or perforating a paper, sheet, fabric, film, or cellulose-based material to form a network of interconnected strands providing a water-permeable structure suitable for use as a standalone geotextile or a component of a control device.

[0090] Clause 48. The method of clause 47, wherein fibrillating and / or perforating comprises passing the material through one or more rollers, cutting devices, ultrasonic slitting tools, and / or abrasion mechanisms to achieve a desired strand formation.

[0091] Clause 49. The method of clause 47 or 48, wherein the method further comprises embossing the material to form perforations in a web.

[0092] Clause 50. The method of any one of clauses 47 to 49, wherein fibrillating comprises one or more of beating, refining, hydroentanglement, needle punching, calendering, grinding, frictional tumbling, and ultrasonic fibrillation.

[0093] Clause 51. The method of any one of clauses 47 to 50, wherein fibrillating comprises oxidation, enzymatic treatment, acid hydrolysis, alkaline treatment, supercritical fluid treatment, or concurrent chemical treatment with mechanical action.

[0094] Clause 52. The method of any one of clauses 47 to 51, further comprising integrating the fibrillated and / or perforated material as an exterior of a wattle, optionally pre-filled with a hygroexpandable or cellulose-based sponge infill.

[0095] Clause 53. The method of any one of clauses 47 to 52, wherein fibrillating comprises mechanical fibrillation assisted by chemical treatment that includes exposing a cellulose based web to sodium hydroxide or urea during beating or hydroentanglement.

[0096] Example embodiments are provided so that this disclosure will be thorough and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. In addition, advantages and improvements that may be achieved with one or more exemplary embodiments of the present disclosure are provided for purpose of illustration only and do not limit the scope of the present disclosure, as exemplary embodiments disclosed herein may provide all or none of the above mentioned advantages and improvements and still fall within the scope of the present disclosure.

[0097] Specific dimensions, specific materials, and / or specific shapes disclosed herein are example in nature and do not limit the scope of the present disclosure. The disclosure herein of particular values and particular ranges of values for given parameters are not exclusive of other values and ranges of values that may be useful in one or more of the examples disclosed herein. Moreover, it is envisioned that any two particular values for a specific parameter stated herein may define the endpoints of a range of values that may be suitable for the given parameter (i.e., the disclosure of a first value and a second value for a given parameter can be interpreted as disclosing that any value between the first and second values could also be employed for the given parameter). For example, if Parameter X is exemplified herein to have value A and also exemplified to have value Z, it is envisioned that parameter X may have a range of values from about A to about Z. Similarly, it is envisioned that disclosure of two or more ranges of values for a parameter (whether such ranges are nested, overlapping, or distinct) subsume all possible combination of ranges for the value that might be claimed using endpoints of the disclosed ranges. For example, if parameter X is exemplified herein to have values in the range of 1-10, or 2-9, or 3-8, it is also envisioned that Parameter X may have other ranges of values including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3, 3-10, and 3-9.

[0098] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. For example, when permissive phrases, such as “may comprise”, “may include”, and the like, are used herein, at least one embodiment comprises or includes the feature(s). As used herein, the singular forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,”“comprising,”“including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

[0099] When an element or layer is referred to as being “on”, “engaged to”, “connected to” or “coupled to” another element or layer, it may be directly on, engaged, connected, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,”“directly engaged to”, “directly connected to” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,”“adjacent” versus “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0100] The term “about” when applied to values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If, for some reason, the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring or using such parameters. For example, the terms “generally”, “about”, and “substantially” may be used herein to mean within manufacturing tolerances.

[0101] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer, or section. Terms such as “first,”“second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of the example embodiments.

[0102] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements, intended or stated uses, or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. A sediment, erosion, or perimeter control device comprising a fibrillated and / or perforated material that defines a water-permeable structure configured to trap or retain soil, facilitate water drainage, and promote vegetation growth.

2. The device of claim 1, wherein the fibrillated and / or perforated material comprises paper, sheet, fabric, or film.

3. The device of claim 1, wherein the fibrillated and / or perforated material comprises an environmentally sustainable material selected from natural fibers, recycled paper, biodegradable fabrics, and combinations thereof.

4. The device of claim 1, wherein the fibrillated and / or perforated material comprises fibers selected from jute, sisal, coir, lyocell, modal, cellulose-based fibers, and combinations thereof.

5. The device of claim 1, wherein the fibrillated and / or perforated material comprises interconnected strands forming a net, mesh, blanket, geoweb, geonet, or geotextile.

6. The device of claim 1, wherein the fibrillated and / or perforated material is obtained by mechanical fibrillation, chemical fibrillation, or mechanical fibrillation assisted by chemical treatment.

7. The device of claim 6, wherein:the mechanical fibrillation comprises one or more of beating, refining, high-pressure water jetting (hydroentanglement), needle punching, calendering, grinding, frictional tumbling, and ultrasonic fibrillation; orthe chemical fibrillation comprises one or more of oxidation, enzymatic treatment, acid hydrolysis, alkaline treatment (mercerization), supercritical fluid treatment, or concurrent chemical treatment with mechanical action.

8. The device of claim 1, wherein perforation is formed by embossing a web of the material and / or by mechanical manipulation that creates apertures providing target porosity and permeability.

9. The device of claim 1, wherein the water-permeable structure has open area and strand geometry selected to retain sediment while allowing stormwater flow suitable for temporary to permanent soil stabilization.

10. The device of claim 1, wherein the fibrillated and / or perforated material(s) is configured to create a network of strands in a webbed format suitable for use as a standalone sediment / erosion / perimeter control device or as a component of a sediment / erosion / perimeter control system.

11. A wattle comprising:a water-permeable exterior comprising the fibrillated and / or perforated material of claim 1; andan infill encapsulated within an interior defined by the water-permeable exterior.

12. The wattle of claim 11, wherein the wattle is reconfigurable between:a first configuration via compression of the infill; anda second configuration having greater size and / or volume than the first configuration, the wattle being expandable to the second configuration upon the infill absorbing water passing through the exterior.

13. The wattle of claim 11, wherein the infill comprises a cellulose-based sponge, a hygroexpandable infill, a chemically activatable infill, or a plant-based or recycled infill.

14. The wattle of claim 11, wherein the water-permeable exterior comprises a fibrillated net or mesh having interconnected strands dimensioned to retain the infill fibers during installation while permitting stormwater infiltration.

15. The wattle of claim 11, wherein:the wattle is integrated with a silt fence as an integrated, singular, or unitary product; orthe wattle is integrated with a scour pad as an integrated, singular, or unitary product.

16. The wattle of claim 11, wherein the infill expands upon water absorption, thereby increasing an installation footprint height for flow interception.

17. An erosion control blanket, net, mesh, geoweb, geonet, or geotextile comprising the fibrillated and / or perforated material of claim 1, the material forming an open-structure web configured to stabilize soil, retain sediment, and promote revegetation.

18. The product of claim 17, wherein the fibrillated and / or perforated material is biodegradable to enable site-left-in-place applications.

19. A method of manufacturing a sediment, erosion, or perimeter control device, the method comprising fibrillating and / or perforating a paper, sheet, fabric, film, or cellulose-based material to form a network of interconnected strands providing a water-permeable structure suitable for use as a standalone geotextile or a component of a control device.

20. The method of claim 19, wherein:fibrillating and / or perforating comprises passing the material through one or more rollers, cutting devices, ultrasonic slitting tools, and / or abrasion mechanisms to achieve a desired strand formation; and / orthe method further comprises embossing the material to form perforations in a web.

21. The method of claim 19, wherein:fibrillating comprises one or more of beating, refining, hydroentanglement, needle punching, calendering, grinding, frictional tumbling, and ultrasonic fibrillation; orfibrillating comprises oxidation, enzymatic treatment, acid hydrolysis, alkaline treatment, supercritical fluid treatment, or concurrent chemical treatment with mechanical action.

22. The method of claim 19, wherein the method comprises integrating the fibrillated and / or perforated material as an exterior of a wattle, optionally pre-filled with a hygroexpandable or cellulose-based sponge infill.

23. The method of claim 19, wherein fibrillating comprises mechanical fibrillation assisted by chemical treatment that includes exposing a cellulose-based web to sodium hydroxide or urea during beating or hydroentanglement.