Amcol International Corporation

Craig M Mattern

Jerald W Darlington, Jr

Richard W Carriker

Mark William Clarey

Natalie A Dotlich

Natali A Dotlich

In accordance with the method of manufacture described herein, it has been found that by applying a polymerization catalyst or polymerization initiator directly to a liquid-absorbent or liquid adsorbent (hereinafter collectively referred to as 'liquid-sorbent') substrate, preferably a porous geotextile in sheet material form, to form a polymerization-initiating substrate or sheet material, a monomer that is subsequently embedded in the liquid-sorbent substrate will be completely contacted by the polymerization catalyst or polymerization initiator for complete polymerization of the embedded monomer to form embedded polymer solids, without the monomer partially polymerizing before contacting the substrate. It has been found that complete polymerization of the monomer while in contact with the substrate achieves best results in retention of embedded and interlocked polymer solids. Preferably only the polymerization catalyst or polymerization initiator, and optionally a cross-linker for the monomer, is applied to the porous substrate prior to embedding the monomer into the substrate. In another embodiment, the cross-linker is embedded into the substrate together with the polymerization catalyst and/or polymerization initiator.

Polymer-filled sheet material

By applying a polymerization catalyst or polymerization initiator directly to a liquid-absorbent or liquid-adsorbent (hereinafter collectively referred to as &ldquo;liquid-sorbent&rdquo;) substrate, preferably a porous geotextile in sheet material form, to form a polymerization-initiating substrate or sheet material, a slurry of a monomer and a water-absorbent clay that is subsequently embedded in the porous substrate will have its monomer content sufficiently contacted by the polymerization catalyst or polymerization initiator for complete polymerization of the embedded monomer to form embedded polymer solids and clay, without the monomer partially polymerizing before contacting the substrate. It has been found that polymerization of the monomer while in contact with the substrate achieves best results in retention of embedded and interlocked polymer and clay solids. Preferably only the polymerization catalyst or polymerization initiator, and optionally a cross-linker for the monomer, and/or a polymer neutralizing agent, together with any carrier, such as water or an organic solvent, are applied to the liquid-sorbent substrate prior to embedding the monomer into the substrate. In another embodiment, the cross-linker and/or the polymer neutralizing agent are embedded into the substrate together with the polymerization catalyst and/or polymerization initiator.

Growing community of inventors

West Chicago, IL, United States of America

Craig M Mattern