Pre-stressed concrete industrial tanks have been in use for decades. They are often used to store many types of materials and liquids. For example, they have been shown to be efficacious as mill water treatment tanks, reservoirs, water tanks, chemical processing basins, pulp storage chests, and effluent tanks. The strength of these types of tanks have allowed for increased size and capacity.
Enclosed large tanks are vented to protect against build-up of pressure or vacuum under the roof due to gas or liquid flow within the tank. It is not uncommon for debris and other material to find ingress through the vents and cause blockages in the overflow valves. It is also not uncommon for overflow valves to malfunction. For this reason overflow spouts are typically installed on industrial tanks to allow the liquids and other material therein to exit the tank if it becomes overfull. Overflow spouts are often installed at the upper edge of the tank dome and are one of the last components installed on a tank.
Overflow spouts are usually concrete and are incorporated into the material of the tank along the upper edge of the tank dome or roof. These can be heavy and, if damaged, can be difficult to repair or replace. There is a need for an improved overflow spout that is easier to install and, if necessary, to repair or replace without extensive reconstruction.
In accordance with the invention, the problems associated with installing an overflow spout on large concrete pre-stressed tanks is solved by a modular overflow spout that can be installed in stages on a tank. The overflow spout includes an overflow cover that can be joined with a curb assembly. An overflow spout of the subject invention can be manufactured from concrete or similar materials, but can also be manufactured from other materials, which can be less heavy than concrete. Advantageously, the overflow cover can be removed from the curb assembly for repair or replacement without disturbing the curb assembly or the structure of the tank roof.
The curb assembly can include an inner curb having one or more walls that can be joined to an outer curb that has an upper curb flange and a lower curb flange. The outer curb can be positioned within the tank outlet so that the lower curb flange can be cast, integrated, attached, consolidated, or otherwise incorporated with the tank roof or dome. The upper curb flange is located above the tank outlet and can be operably connected to the overflow cover. The angle of the outer curb can be adjusted during incorporation with the tank outlet to accommodate roofs with different pitches. The overflow cover can be attached to or seated on the curb assembly, specifically to the upper curb flange. Advantageously, the ability to adjust the angle and height of the curb assembly, relative to a spring line of the tank, can ensure that the overflow cover is at the proper orientation when joined to the curb assembly. The incorporation of at least the lower curb flange into the roof also provides the advantage of later installing the inner curb and overflow cover onto the adjusted outer curb. Alternatively, the inner curb can be attached to and installed simultaneously with the outer curb. The modularity of the overflow spout also allows for removing and replacing at least the overflow cover without reconstruction of the tank or tank outlet.
It should be noted that this Brief Summary is provided to generally introduce the reader to one or more select concepts described below in the Detailed Disclosure in a simplified form. This Summary is not intended to identify key and/or required features of the claimed subject matter. Other aspects and further scope of applicability of the present invention will also become apparent from the detailed descriptions given herein. It should be understood, however, that the detailed descriptions, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent from such descriptions. The invention is defined by the claims below.
In order that a more precise understanding of the above recited invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. The drawings presented herein may not be drawn to scale and any reference to dimensions in the drawings or the following description is specific to the embodiments disclosed. Any variations of these dimensions that will allow the subject invention to function for its intended purpose are considered to be within the scope of the subject invention. Thus, understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered as limiting in scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
Embodiments of the subject invention pertain to overflow spouts on tanks used for storing liquids and other materials. More specifically, the subject invention provides one or more embodiments of a modular overflow spout, or similar device, comprising components that can be installed separately or in stages as part of a tank outlet. The components can be adjoined, interlocked, and removably attached.
The following description will disclose that the subject invention is particularly useful in the field of municipal tanks, in particular municipal tanks with a concrete roof. A person with skill in the art will, however, be able to recognize numerous other uses that would be applicable to the devices and methods of the subject invention. While the subject application describes, and many of the terms herein relate to, a use for covering overflow outlets in tanks, other uses and modifications apparent to a person with skill in the art and having benefit of the subject disclosure are contemplated to be within the scope of the present invention.
In the description that follows, a number of terms used in the field of tank design are utilized. In order to provide a clear and consistent understanding of the specification and claims, including the scope to be given such terms, the following definitions are provided.
As used herein, the term “weir edge” refers to the edge of an overflow spout above which fluid will overflow. On a fluid filled tank, the weir edge is the edge to which the fluid can rise and overflow.
As used herein, the term “spring line” refers to the point at which the roof meets the walls of a tank.
As used herein, the terms “about,” “substantially,” or “approximately” refer to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, an object that is “substantially” in a given position including but not limited to vertical, horizontal, above, below, or adjacent to or aligned with another object, would mean that the object is either completely in that position or nearly completely in that position. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context. However, generally speaking the nearness of completion will be so as to have the same overall result as if absolute and total completion were obtained. Thus, it should be understood that absolute accuracy is not required with respect to those aspects for the invention to operate.
Also, as used herein, and unless otherwise specifically stated, the terms “operable communication,” “operable connection,” “operably connected,” “cooperatively engaged” and grammatical variations thereof mean that the particular elements are connected in such a way that they cooperate to achieve their intended function or functions. The “connection” or “engagement” may be direct, or indirect, physical or remote.
It is to be understood that the Figures and descriptions of embodiments of the present invention have been simplified to illustrate elements that are relevant for a clear understanding of the invention, while eliminating, for purposes of clarity, other elements that may be well known. Those of ordinary skill in the art will recognize that other elements may be desirable and/or required in order to implement the present invention. However, because such elements are well known in the art, and because they do not facilitate a better understanding of the present invention, a discussion of such elements is not provided herein.
As used herein, terms indicating relative direction or orientation, including but not limited to “upper”, “lower”, “top”, “bottom”, “vertical”, “horizontal”, “outer”, “inner”, “front”, “back”, and the like, are intended to facilitate description of the present invention by indicating relative orientation or direction in usual use, and are not intended to limit the scope of the present invention in any way to such orientations or directions.
Reference will be made to the attached Figures on which the same reference numerals are used throughout to indicate the same or similar components. With reference to the attached Figures, which show certain embodiments of the subject invention, it can be seen in the Figures that embodiments of a modular overflow spout 50 of the subject invention comprise an overflow cover 100 that engages with a curb assembly 200. The overflow cover can have a canopy 102 with a tank-side opening 105 and an exterior opening 110 with a conduit 108 there between to accommodate overflow through a tank outlet 25 in the tank 20 roof. There can be a full or partial cover plate 120 around the tank side opening at or near the bottom end of the overflow cover. The curb assembly 200 can have an inner curb 205 and an outer curb 250. The inner curb can comprise one or more walls 206 with a top end and a bottom end. The outer curb can be incorporated with the tank outlet 25 and provide a structure to which the inner curb can be attached to form an overflow channel 210 through the curb assembly inside the tank outlet 25. The angle or orientation of one or more components of the curb assembly can be adjusted relative to each other and/or to a spring line on the tank, so that the overflow cover is at the correct orientation when placed thereon. When an overflow spout is installed on a tank roof 20, overflow from the tank moves through the tank outlet, through the overflow channel and the conduit, continuous therewith, to exit the exterior opening. Thus, the overflow spout provides a path for overflow to move through the tank outlet to the exterior opening. In certain embodiments, the inner curb and outer curb when installed on a tank roof define the tank outlet and tank side opening. Each of these general components can have one or more sub-components, which will be discussed in detail below.
A canopy can have any suitable external configuration that can cover the tank outlet and permit the release of overflow from the tank.
The overflow cover 100 can be affixed to a curb assembly 200, such that the upper opening 208 in the curb assembly aligns with or is otherwise continuous with an overflow channel 210 in the curb assembly that is further open to or in fluid communication with the tank-side opening 105 of the canopy and the tank outlet. This continuity allows fluid or other material in the tank to flow from the tank outlet 25, through the curb assembly, towards the tank-side opening 105, through the conduit 108 in the canopy and out of the exterior opening 110.
In one embodiment, the bottom of the canopy 102 of the overflow cover 100 is affixed to the curb assembly 200. In an alternative embodiment, the overflow cover 100 includes a cover plate 120. The cover plate can be attached at or about the bottom of the canopy. In one specific embodiment, the cover plate is attached around at least a portion of the bottom of the canopy, as shown, for example in
In a further embodiment, the cover plate 120 is operably connected to an upper curb flange 255 of the outer curb 250, to form a joint 135 there between. In a still further embodiment, the cover plate and upper curb flange 255 are substantially coplanar, which can facilitate their attachment. In yet a further embodiment, the cover plate, or some portion thereof, extends or radiates from the bottom of the canopy a sufficient distance to facilitate attachment to the upper curb flange 255. Thus, the width (W) of the cover plate, or some portion thereof, can be different from the width (W) of the upper curb flange. In an alternative embodiment, the width (W) of the cover plate is approximately equal to the width (W) of the upper curb flange. An example of this is shown in
While the cover plate 120 and the upper curb flange 255 can be seated directly on top of or adjacent to one another, it can be beneficial to utilize a gasket 140 in the joint 135 formed between them to improve seating, inhibit friction, and mitigate leakage. It can be beneficial for a gasket to be weather-resistant. In one embodiment, a gasket is one or more viscous, liquid, moldable, or otherwise, non-solid substance or material applied to one or both surfaces. The substance or material can harden, cure, solidify or otherwise form a gasket between the surfaces. In another embodiment, a gasket is a preformed or pre-molded solid, semi-solid, or pliable device positioned between the upper outer curb and the cover plate. A non-limiting example would be a neoprene or similar type of preformed gasket that can be placed in one or more sections between the upper curb flange and the cover plate. Some combination of a pre-formed gasket and a substance or material that forms a gasket can also be utilized.
To facilitate seating of the cover plate 120 on the upper curb flange 250, there can be a full or partial rim 130 on the cover plate. The rim can be directed towards the tank outlet or the curb assembly 200 or away from the canopy. When seating an overflow cover with a cover plate onto a curb assembly with an upper curb flange thereon, the rim can assist in guiding and/or aligning the cover plate so that it seats or fits onto on the curb frame with the cover plate properly aligned over the upper curb flange. The rim can also cover and provide some protection to the joint 135 and, if present, a gasket 140 within the joint 135. In one embodiment, the cover upper curb flange and/or the top of the inner curb are surrounded or entirely covered under the rim. One example of this is shown in
The overflow cover 200 can also be supported on the curb assembly 200. The curb assembly can have an inner curb 205 that can be attached within the outer curb 250. The outer curb can have at least one wall brace 270 with a lower curb flange 260 at least partially surrounding the outside of the wall brace at or near the bottom opening 209 and the upper curb flange 255 at least partially surrounding the wall brace at or near the upper opening 208. The wall brace can have the upper opening 208 and the bottom opening 209 joined by an overflow channel 210 there between. The upper curb flange and the lower curb flange can extend out or radiate from the wall brace. In one embodiment, the width (W) of the upper curb flange and the lower curb flange is the same, such as shown, for example, in
In one embodiment, at least the lower curb flange is incorporated into the structure of a tank 20, such that it is cast, integrated, attached, consolidated, or otherwise incorporated with the tank roof or dome, such as shown, for example in
Overflow from a tank can initially pass through the overflow channel in the curb assembly to the conduit 108 in the overflow cover 100. The advantageous modularity of embodiments of an overflow spout 50 allows, but does not require, the outer curb 250 to be installed separately from the inner curb and the overflow cover 100. Furthermore, the overflow cover and inner curb can be removed and/or replaced without disturbing or removing the lower curb flange or the tank structure. Alternatively, the inner curb and outer curb can be joined and the entire curb assembly can be integrated or incorporated with the tank outlet. With this method of installation, the overflow cover 100 can also be removed without disturbing or removing the inner curb or the curb assembly.
An inner curb 205 can comprise one or more walls that can be operably connected to an outer curb 250. The one or more walls can define the overflow channel 210 through the inner curb.
Many large tanks have curved or domed roofs, which can cause the tank outlet 25 to also be angled or tilted on the roof. Ideally, an overflow spout can be positioned or oriented based on the angle or curvature of the domed roof. In one embodiment, the orientation of the outer curb 250 can be adjusted relative to the tank outlet and/or the tank edge or spring line 27 when incorporated into the tank, so that the upper end and the upper curb flange 255 will be at an angle conducive for the support, attachment, and orientation of the overflow cover. Likewise, the inner curb can be affixed to the outer curb in a manner conducive to the support, attachment, and orientation of the overflow cover. In one embodiment, the top of the inner curb 205 is at the same height or is level with the top of the outer curb 250, one example of which is shown in
The bottom end of the inner curb 205 can extend further than the bottom of the outer curb. In a further embodiment, the bottom end of the one or more walls 206 of the inner curb 205 are configured to be complimentary with the angle, curvature, or other shape of the roof interior, such that the bottom end of the one or more walls of the inner curb is parallel to or level with the interior edge 29 of the tank outlet.
To inhibit debris, animals, insects, and other material from entering a tank through the outlet spout 50, a protective barrier 300 can be placed over the overflow cover exterior opening 110. In one embodiment, a protective cover is a screen that is cooperatively engaged with the exterior opening. In one embodiment, the screen has a frame 310 in which a screen or mesh 315 is secured to allow passage of water and gases. The frame can be mechanically secured so as to cover the exterior opening. In a further embodiment, the exterior opening comprises a bumper 115 against which the frame is removably attached. The bumper can be located anywhere on or within the exterior opening. In one embodiment, the bumper is arranged within the exterior opening such that the protective cover, when attached, does not extend past the outer edge 117 of exterior opening. The protective cover can be mechanically attached to the bumper. The bottom of the frame 310 can rest on or about the weir edge of the tank outlet or the overflow cover. To facilitate the movement of water over the weir edge 112, the bottom of the frame be configured with a curved or bent footer 320 that is directed into the exterior opening 110 and at least partially overlaps and/or abuts the weir edge. Water passing over the footer can exert a downward force that inhibits the protective cover from being pushed out of the exterior opening.
Installation of a modular overflow spout 50 initially comprises placement of the inner curb 205 by incorporation or integration into the tank roof. Next, the outer curb 250 is operably attached and placed simultaneously for incorporation or integration into the tank roof. During initial placement, the position or orientation of both inner and outer curbs, relative to the tank spring line 27, can be adjusted so that the overflow cover is operably connected to the upper curb flange 255 with the weir edge 112 about 3 inches above the top of the wall (T.O.W.). Adjustment of the lower curb flange can also ensure that the overflow cover is positioned at the correct angle or orientation when the cover plate 120 is attached to the upper curb flange 255. For example, it can be beneficial for the exterior opening 110 to be at about a substantially vertical orientation relative to the weir edge of the tank outlet 28. Alternatively, the inner curb can be operatively connected to the outer curb after the outer curb is incorporated into the tank roof.
The modularity of an overflow spout provides the advantage of installing the components thereof separately. The modularity also provides the advantage of utilizing any of a variety of one or more materials for the components. Typical overflow spouts on tanks are cast from concrete as a monolithic structure. According to the embodiments of the subject invention, the components of an overflow spout can advantageously be cast and installed separately. It can also be more advantageous for an overflow spout to be manufactured from lighter materials for easier installation. For example, the components of an overflow spout can be formed from fiberglass, plastic, nylon, wood, ceramics, metals, or any other material with sufficient strength and durability. In one embodiment, the components of an overflow spout are manufactured from the same material. In a specific embodiment, the components of an overflow spout are manufactured from fiberglass with a gelcoat finish. In an alternative embodiment, one or more components are manufactured from a different material than one or more other components. For example, an outer curb can be manufactured from Ultra High Performance Concrete (UHPC) or other concrete material that can be incorporated into the tank structure. Other components can be manufactured from fiberglass or any other material suitable for connection to the UHPC outer curb. In a further embodiment, one or more gaskets or other protective material or object is positioned between components of different materials to facilitate adjoining and operable connection thereof.
Municipal tanks require overflow outlets for release of liquid, such as water, when they become overfull. Overflow spouts are used to cover and protect these overflow outlets to inhibit dirt, animals, insects, and other debris from entering the tank. The embodiments of the subject invention provide unique and advantageous modular overflow spouts with components that can be installed separately. The inner curb, combined with the outer curb with an outer curb flange provides the ability to adjust the position and angle of the overflow spout for maximum efficiency. Other components can then be placed on the outer curb in the correct orientation. Should components need to be repaired or replaced, they can be removed from the outer curb without disturbing the tank structure.
The examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application.
This application claims the benefit of U.S. Provisional Application Ser. No. 63/010,709, filed Apr. 16, 2020, the disclosure of which is hereby incorporated by reference in its entirety, including all figures, tables and amino acid or nucleic acid sequences.
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63010709 | Apr 2020 | US |