Oil absorbent layered fabric sheet

Claim 1

A method for removing oil from the surface of a body of water, said method including the steps of (a) placing on the surface of said body of water a layered sheet substantially comprised of natural fabric fibers to absorb oil between the layers in said sheet, said sheet being formed by (i) blending at a first selected temperature binder fibers with natural fabric fibers to produce a mixture of said binder and natural fibers in random orientation, said natural fibers having a melting temperature greater than said first selected temperature, and containing a water repellent material naturally occurring in said material, said binder fibers having a bonding temperature at which said binder fibers soften and adhere to said natural fibers, said bonding temperature being greater than 130° F., greater than said selected blending temperature, and less than said melting temperature of said natural fibers, (ii) feeding said mixture of fibers into processing--carding means to produce a web having a thickness in the range of 0.001 inch to 0.1 inch, and comprised principally of parallel elongate strands of thread, (iii) transporting at a second selected temperature said web to a lapping machine to be cross lapped into a sheet having a plurality of overlaid cross lapped web layers, and a thickness greater than the thickness of said web, (iv) cross lapping at a third selected temperature said web with said lapping machine to form said sheet, (v) directing said sheet between a pair of opposed rollers to compress said sheet, (vi) needle punching said compressed sheet to displace at least some of said natural fibers such that each of said displaced natural fibers extends between a pair of said layers and contacts natural fibers in said pair of said layers, (vii) transporting at a fourth selected temperature said needle punched sheet to apparatus for heating said sheet to said bonding temperature, said bonding temperature being less than said melting temperature of said natural fibers, and greater than said first, second, third and fourth selected temperatures, (viii) heating said sheet with said heating apparatus to a temperature equal to or greater than said bonding temperature to cause said binder fibers to soften and adhere to said natural fibers such that at least certain of said displaced natural fibers are each bonded by said softened binder fibers to and interconnect one of said natural fibers in one of said layers with another of said natural fibers in another of said layers, said water repellent material of said natural fibers remains in said fibers, and, cooling said batt to harden said softened binder fibers, said cooled batt being oleophillic and absorbing oil to locations intermediate said layers, and buoyant and able to absorb at least seven times the weight of said batt in oil without submerging in water, and, said natural fibers in said batt being hydrophobic; (b) removing said sheet from said body of water; and, (c) compressing said sheet to squeeze oil from between said layers in said sheet.

Claim 2

A method for removing oil from the surface of a body of water, said method including the steps of (a) placing on the surface of said body of water a layered sheet substantially comprised of natural fabric fibers to absorb oil between the layers in said sheet, said sheet being formed by (i) blending at a first selected temperature binder fibers with natural fabric fibers to produce a mixture of said binder and natural fibers in random orientation, said natural fibers having a melting temperature greater than said first selected temperature, and containing a water repellent material naturally occurring in said material, said binder fibers having a bonding temperature at which said binder fibers soften and adhere to said natural fibers, said bonding temperature being greater than 130° F., greater than said selected blending temperature, and less than said melting temperature of said natural fibers, (ii) feeding said mixture of fibers into processing--carding means to produce a web having a thickness in the range of 0.001 inch to 0.1 inch, and comprised principally of parallel elongate strands of thread, (iii) transporting at a second selected temperature said web to a lapping machine to be cross lapped into a sheet having a plurality of overlaid cross lapped web layers, and a thickness greater than the thickness of said web, (iv) cross lapping at a third selected temperature said web with said lapping machine to form said sheet, (v) directing said sheet between a pair of opposed rollers to compress said sheet, (vi) needle punching said compressed sheet to displace at least some of said natural fibers such that each of said displaced natural fibers extends between a pair of said layers and contacts natural fibers in said pair of said layers, (vii) transporting at a fourth selected temperature said needle punched sheet to apparatus for heating said sheet to said bonding temperature, said bonding temperature being less than said melting temperature of said natural fibers, and greater than said first, second, third and fourth selected temperatures, (viii) heating said sheet with said heating apparatus to a temperature equal to or greater than said bonding temperature to cause said binder fibers to soften and adhere to said natural fibers such that at least certain of said displaced natural fibers are each bonded by said softened binder fibers to and interconnect one of said natural fibers in one of said layers with another of said natural fibers in another of said layers, said water repellent material of said natural fibers remains in said fibers, and, cooling said batt to harden said softened binder fibers, said cooled batt being oleophillic and absorbing oil to locations intermediate said layers, and buoyant and able to absorb at least seven times the weight of said batt in oil without submerging in water, and, said natural fibers in said batt being hydrophobic; (b) removing said sheet from said body of water; and, (c) compressing said sheet to squeeze oil from between said layers in said sheet.