Geomembrane and method of manufacture

Abstract

A geomembrane comprising a unitary structure fabricated by co-extrusion including a center core, a thermoplastic adhesive layer secured on one side of the center core, and a textured layer secured on the opposite side of the center core. The geomembrane is utilized in the manufacture of a liner for earthen constructions by employing the thermoplastic layer of the geomembrane to secure the geomembrane to a geosynthetic clay liner.

Description

TECHNICAL FIELD

[0001] This invention relates generally to geomembranes of the type utilized in the fabrication of liners for earthen constructions such as landfills, canals, ponds, etc., and more particularly to an improved geomembrane comprising a unitary structure fabricated by co-extrusion.

BACKGROUND AND SUMMARY OF THE INVENTION

[0002] Ground water contamination is a primary environmental concern. One method of controlling ground water contamination comprises the lining of landfills, canals, ponds, and similar earthen constructions with a liner comprising a geosynthetic clay liner and an underlying geomembrane. In this manner seepage from the lined construction into the underlying ground water is prevented.

[0003] More particularly, liners for landfills, canals, ponds, and similar earthen constructions may comprise a layer of bentonite. The upper surface of the bentonite layer is secured by a layer of woven polypropylene. A layer of non-woven polypropylene textile is positioned below the bentonite layer. A geomembrane is secured to the lower surface of the non-woven polypropylene textile which may be provided with a textured lower surface to prevent shifting of the liner relative to the underlying construction.

[0004] Heretofore the fabrication of liners in which a geomembrane is secured beneath a geosynthetic clay liner has been complicated by the necessity of applying a glue layer to the upper surface of the geomembrane in order to secure the geomembrane to the geosynthetic clay liner. The application of the glue layer has required a separate manufacturing step which has typically been carried out at a remote location. The cost of manufacturing the liner is therefore substantially increased.

[0005] The present invention comprises an improved geomembrane and method of manufacture which overcomes the foregoing and other difficulties which have long since characterized the prior art. More particularly, the present invention comprises an improved geomembrane construction which is directly bondable to a geosynthetic clay liner to complete the construction of a liner for landfills, canals, ponds, and similar constructions. In accordance with the preferred embodiment of the invention, the geomembrane comprises a unitary structure including an adhesive layer and a barrier layer which are fabricated by co-extrusion. The geomembrane of the present invention may further include a third co-extruded layer which may be textured.

[0006] By means of the present invention the fabrication of liners for earthen constructions such as landfills, canals, ponds, and the like is greatly simplified. The improved geomembrane of the present invention is directly bondable to a geosynthetic clay liner to complete the construction of the liner, thereby eliminating the necessity of a separate adhesive application step. The use of the invention also results in an improved liner construction wherein the possibility of separation of the geomembrane from the remaining components of the liner is substantially eliminated.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] A more complete understanding of the invention may be gained by reference to the following Detailed Description when presented in conjunction with the accompanying Drawings, wherein:

[0008] FIG. 1 is a diagrammatic illustration of the installation of a liner in a landfill, canal, pond, or similar earthen construction;

[0009] FIG. 2 is a sectional view illustrating a liner for landfills, canals, ponds, and similar construction incorporating the geomembrane of the present invention;

[0010] FIG. 3 is an exploded view of the liner of FIG. 2 further illustrating the invention;

[0011] FIG. 4 is a sectional view illustrating a first embodiment of the method of the present invention; and

[0012] FIG. 5 is a sectional view illustrating a second embodiment of the method of the present invention.

DETAILED DESCRIPTION

[0013] Referring now to the Drawings, and particularly to FIG. 1 thereof, the use of a liner incorporating the geomembrane of the present invention is diagrammatically illustrated. An excavation 10 is formed in the earth. The excavation 10 may ultimately comprise a landfill, a canal, a pond, or similar earthen construction. A trench 12 is formed along the sides of the excavation 10, it being understood that the configuration of the trench 12 depends upon the configuration of the excavation 10. A liner 14 incorporating the geomembrane of the present invention is provided in rolls. The liner 14 is unrolled in overlapping strips utilizing an appropriate vehicle 16. Each end of each strip comprising the liner 14 extends into the trench 12. Following installation of the liner 14, backfill 18 is installed in trench 12 to secure the liner in place.

[0014] Referring to FIG. 2, liner 14 includes a geosynthetic clay liner 20 and a geomembrane 22 comprising the present invention. The geosynthetic clay liner 20 comprises a clay layer 24 which may comprise bentonite. The clay layer 24 is retained by a layer of woven polypropylene fabric 26 extending across the upper surface thereof. A layer of non-woven polypropylene material 28 extends across the lower surface of the clay layer 24.

[0015] The geomembrane 22 of the liner 14 is further illustrated in FIG. 3. The geomembrane 22 comprises a two layer construction, including a thermoplastic adhesive layer 30 and a barrier layer 32. The geomembrane 22 may also include a third layer 34, which may be textured as shown. In accordance with the invention, the geomembrane 22 comprises a unitary structure fabricated by co-extrusion.

[0016] The adhesive layer 30 of the geomembrane 22 may be formed from any of the following materials:

[0017] Ethylene Vinyl Acetate(EVA)

[0018] Ionomer

[0019] Ethylene Methyl Acrylate(EMA)

[0020] Ethylene Acrylic Acid(EAA)

[0021] Ethylene Methyl Acrylic Acid(EMAA)

[0022] Ethylene Ethyl Acrylate(EEA)

[0023] Polyethylene with density below 0.915 gm/cc

[0024] Polyolefins, copolymers and terpolymers of polyolefins with melt points below the melt point of the barrier layer 32.

[0025] The barrier layer 32 and the third layer 34, if used, may be formed from any of the following materials:

[0026] High Density Polyethylene

[0027] Linear Low Density Polyethylene

[0028] Low Density Polyethylene

[0029] Ultra Low Density Polyethylene

[0030] Very Low Density Polyethylene

[0031] Polypropylene

[0032] Polypropylene copolymers and terpolymers

[0033] Polyethylene with natural density between 0.880 and 0.950 gm/cc.

[0034] Any of the following techniques may be used to provide a textured surface on the third layer, if desired:

[0035] Use of chemical blowing agents

[0036] Use of compressed gas blowing agents including nitrogen

[0037] Use of post extrusion texturing process such as lamination, spray-on, or embossing.

[0038] FIG. 4 illustrates a first embodiment of the method of the present invention. A conventional co-extrusion die 36, of the type used to make cast co-extrusions, receives a molten thermoplastic adhesive which will eventually form the adhesive layer of the geomembrane 22 through an inlet 38. Molten thermoplastic material which eventually will form the barrier layer 32 of the geomembrane 22, is received through inlet 40. If the geomembrane 22 is to include a third layer, molten thermoplastic material which eventually will form the layer 34 of the geomembrane 22, is received through inlet 42. The materials received through the inlets of the die 36 are directed through a combining adapter 44 and are co-extruded to form the geomembrane 22 of the present invention.

[0039] FIG. 5 illustrates a second embodiment of the method of the present invention. A blown film co-extrusion die 46 receives molten thermoplastic adhesive material which eventually will comprise the adhesive layer 30 of the geomembrane 22 through a cylindrical inlet 48. Molten thermoplastic material, which eventually will form the core 32 of the geomembrane 22, is received through a cylindrical inlet 50. If the geomembrane is to include a third layer, molten thermoplastic material, which eventually will form the layer 34 of the geomembrane 22, is received through inlet 52. Within the die 46, the materials received through the inlets are co-extruded to form a blown film comprising the geomembrane 22 of the present invention.

[0040] Referring again to FIG. 2, the geomembrane of the present invention is hot as it leaves the die 36 or the die 46. Therefore, immediately following the manufacture thereof, the geomembrane 22 may be secured to the outer surface of the non-woven polypropylene textile layer 28 comprising the geosynthetic clay liner 20. The adhesive layer 30 of the geomembrane 22 adhesively secures the geomembrane 22 to the non-woven polypropylene material layer 28 thereby securely joining the geomembrane 22 of the present invention to the geosynthetic clay liner 20. The use of the adhesive layer 30 to secure the geomembrane 22 to the geosynthetic clay liner 20 assures complete bonding between the geomembrane 22 and the geosynthetic clay liner 20 thereby preventing separation during use.

[0041] Alternatively, the geomembrane 22 may be cooled following its manufacture. The geomembrane is then formed into rolls for transport to a separate assembly location. The geomembrane is unrolled and the adhesive layer thereof is heated to facilitate bonding of the geomembrane 22 to the geosynthetic clay liner 20.

[0042] Although preferred embodiments of the invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications, and substitutions of parts and elements without departing from the spirit of the invention.

Claims

1. For use in the manufacture of liners for earthen constructions, a geomembrane comprising a unitary construction formed by co-extrusion and including a thermoplastic barrier layer and a thermoplastic adhesive layer secured on one side of the barrier layer.

2. The geomembrane according to claim 1 wherein the adhesive layer is formed from a material selected from the group including: ethylene vinyl acetate (EVA) ionomer ethylene methyl acrylate (EMA) ethylene acrylic acid (EAA) ethylene ethyl acrylate (EEA) and ethylene methyl acrylic acid (EMAA).

3. The geomembrane according to claim 1 wherein the adhesive layer is formed from polyethylene having a density less than 0.915 gm/cc.

4. The geomembrane according to claim 1 wherein the adhesive layer is formed from a material selected from the group including polyolefins, copolymers of polyolefins, and terpolymers of polyolefins, said material having a melting point below that of the barrier layer.

5. The geomembrane according to claim 1 wherein the thermoplastic barrier layer is formed from a material selected from the group including: high density polyethylene linear low density polyethylene low density polyethylene ultra low density polyethylene p1 very low density polyethylene polypropylene copolymers of polypropylene, and terpolymers of polypropylene.

6. The geomembrane according to claim 1 wherein the barrier layer is formed from polyethylene having a natural density of between about 0.880 and about 0.950 gm/cc.

7. The geomembrane according to claim 1 wherein the barrier layer comprises high density polyethylene and the thermoplastic adhesive layer comprises ethylene-vinyl acetate.

8. For use in the manufacture of liners for earthen constructions, a geomembrane comprising a unitary construction formed by co-extrusion and including a thermoplastic barrier layer, a thermoplastic adhesive layer secured on one side of the barrier layer, and a third thermoplastic layer secured on the opposite side of the barrier layer.

9. The geomembrane according to claim 8 wherein the adhesive layer is formed from a material selected from the group including: ethylene vinyl acetate (EVA) ionomer ethylene methyl acrylate (EMA) ethylene acrylic acid (EAA) ethylene ethyl acrylate (EEA) and ethylene methyl acrylic acid (EMAA).

10. The geomembrane according to claim 8 wherein the adhesive layer is formed from polyethylene having a density less than 0.915 gm/cc.

11. The geomembrane according to claim 8 wherein the adhesive layer is formed from a material selected from the group including polyolefins, copolymers of polyolefins, and terpolymers of polyolefins, said material having a melting point below that of the barrier layer.

12. The geomembrane according to claim 8 wherein the thermoplastic barrier layer is formed from a material selected from the group including: high density polyethylene linear low density polyethylene low density polyethylene ultra low density polyethylene very low density polyethylene polypropylene copolymers of polypropylene, and terpolymers of polypropylene.

13. The geomembrane according to claim 6 wherein the barrier layer is formed from polyethylene having a natural density of between about 0.880 and about 0.950 gm/cc.

14. The geomembrane according to claim 8 wherein the thermoplastic third layer is formed from a material selected from the group including: high density polyethylene linear low density polyethylene low density polyethylene ultra low density polyethylene very low density polyethylene polypropylene copolymers of polypropylene, and terpolymers of polypropylene.

15. The geomembrane according to claim 8 wherein the third layer is formed from polyethylene having a natural density of between about 0.880 and about 0.950 gm/cc.

16. The geomembrane according to claim 5 wherein the third thermoplastic layer comprises a thermoplastic material initially having a blowing agent therein which is released following co-extrusion of the geomembrane to form a textured surface thereof.

17. The geomembrane according to claim 5 wherein the barrier layer comprises high density polyethylene, the thermoplastic adhesive layer comprises ethylene-vinyl acetate, and the third thermoplastic layer comprises high density polyethylene initially having a blowing agent mixed therein which is released following the co-extrusion of the geomembrane to form the textured surface.

18. A method of fabricating a geomembrane for use in manufacturing liners for earthen constructions including the steps of: providing a quantity of thermoplastic material; providing a quantity of thermoplastic adhesive material; co-extruding the quantity of thermoplastic material and the quantity of thermoplastic adhesive material to form a unitary construction comprising a barrier layer formed from the thermoplastic material and an adhesive layer formed from the thermoplastic adhesive material secured to one side of the barrier layer.

19. The method according to claim 18 wherein the step of providing a quantity of thermoplastic material is carried out by providing a quantity of a material selected from the group including: high density polyethylene linear low density polyethylene low density polyethylene ultra low density polyethylene very low density polyethylene polypropylene copolymers of polypropylene, and terpolymers of polypropylene.

20. The method according to claim 18 wherein the step of providing a quantity of a thermoplastic adhesive material is carried out by providing a quantity of a material selected from the group including: ethylene vinyl acetate (EVA) ionomer ethylene methyl acrylate (EMA) ethylene acrylic acid (EAA) ethylene ethyl acrylate (EEA) and ethylene methyl acrylic acid (EMAA).

21. The method according to claim 18 wherein the step of providing a quantity of thermoplastic material is carried out by providing a quantity of high density polyethylene and wherein the step of providing a quantity of thermoplastic adhesive material is carried out by providing a quantity of ethylene-vinyl acetate.

22. A method of fabricating a geomembrane for use in manufacturing liners for earthen constructions including the steps of: providing a first quantity of thermoplastic material; providing a quantity of thermoplastic adhesive material; providing a second quantity of thermoplastic material having a blowing agent mixed therein; co-extruding the first quantity of thermoplastic material, the quantity of thermoplastic adhesive material, and the quantity thermoplastic material to form a unitary construction comprising a barrier formed from the first quantity thermoplastic material, an adhesive layer formed from the thermoplastic adhesive material secured to one side of the center core and a layer formed from the second quantity of thermoplastic material adhesively secured to the opposite side of the center core.

23. The method according to claim 22 wherein the step of providing a first quantity of thermoplastic material is carried out by providing a quantity of a material selected from the group including: high density polyethylene linear low density polyethylene low density polyethylene ultra low density polyethylene very low density polyethylene polypropylene copolymers of polypropylene, and terpolymers of polypropylene.

24. The method according to claim 22 wherein the step of providing a quantity of a thermoplastic adhesive material is carried out by providing a material selected from the group including: ethylene vinyl acetate (EVA) ionomer ethylene methyl acrylate (EMA) ethylene acrylic acid (EAA) ethylene ethyl acrylate (EEA) and ethylene methyl acrylic acid (EMAA).

25. The method according to claim 22 wherein the step of providing a second quantity of thermoplastic material is carried out by providing a quantity of a material selected from the group including: high density polyethylene linear low density polyethylene low density polyethylene ultra low density polyethylene very low density polyethylene polypropylene copolymers of polypropylene, and terpolymers of polypropylene.

26. The method according to claim 22 wherein the step of providing a first quantity of thermoplastic material is carried out by providing a quantity of high density polyethylene, wherein the step of providing a quantity of thermoplastic adhesive material is carried out by providing a quantity of ethylene-vinyl acetate, and wherein the step of providing a second quantity of thermoplastic material is carried out by providing a quantity of high density polyethylene having a blowing agent mixed therein.

27. A liner for earthen constructions comprising: a. a geosynthetic clay liner including a clay layer, a first layer of geotextile extending across one side of the clay layer, and a second layer of geotextile extending across the other side of the clay layer; b. a geomembrane comprising a unitary construction formed by co-extrusion and including a thermoplastic barrier core layer, a thermoplastic adhesive layer secured on one side of the barrier layer, and a textured thermoplastic layer secured on the opposite side of the barrier layer; the layer of thermoplastic adhesive material comprising the geomembrane being adhesively secured to the second layer of geotextile comprising the geosynthetic clay liner.

28. The liner according to claim 27 wherein the barrier layer of the geomembrane is formed from a material selected from the group including: high density polyethylene linear low density polyethylene low density polyethylene ultra low density polyethylene very low density polyethylene polypropylene copolymers of polypropylene, and terpolymers of polypropylene.

29. The liner according to claim 27 wherein the thermoplastic adhesive layer of the geomembrane is formed from a material selected from the group including: ethylene vinyl acetate (EVA) ionomer ethylene methyl acrylate (EMA) ethylene acrylic acid (EAA) ethylene ethyl acrylate (EEA) and ethylene methyl acrylic acid (EMAA).

30. The liner according to claim 27 wherein the textured thermoplastic layer of the geomembrane comprises a thermoplastic material initially having a blowing agent mixed therein which is released following co-extrusion of the geomembrane to form the textured surface thereof.

31. The liner according to claim 27 wherein the barrier layer of the geomembrane comprises high density polyethylene, the thermoplastic layer comprises ethylene-vinyl acetate, and the textured layer of the geomembrane comprises high density polyethylene initially having a blowing agent mixed therein which is released following the co-extrusion of the geomembrane to form the textured surface.