The present invention relates to devices for controlling flow of surface waters, in particular for blocking the flow of flood waters.
For controlling the flow of surface waters in the same way as sand bags are used, barriers may be provided by putting within a water-permeable non-woven polymer fabric sleeve a water absorbent material that, upon contact with sufficient water, swells up to 20 or more times its initial size. When such a barrier is manufactured, the water absorbent material is put within the flat-tubular fabric sleeve as a powder or sheet. See U.S. Pat. No. 9,297,134 “Self-Expanding Barrier for Control of Surface Water Flow,” which is commonly owned with this present application. Preferred barriers have a D-shape front lobe and a rear lobe that inhibits overturning of the barrier during use.
Prior to use, the absorbent contained within the sleeve of a barrier is dry. Thus, only a small interior volume is needed to contain the absorbent and any associated carrier sheet or pouch, etc. That enables the barrier to be stored and shipped in a compact flat or folded condition. To put a barrier in condition for use, the absorbent must be contacted with water sufficient to cause it to expand substantially. This may be done in any manner, including in one or more exemplary modes: (a) the user sprays water on the barrier or wets it by submersion at the time of placement; (b) the user drops a barrier in a puddle or other mass of water; (c) rain wets the barrier after placement; and (d) surface water approaches and infiltrates an in-place barrier.
Prior to use, an invention barrier is substantially flat and light in weight; it has a small cross section area interior cavity within which is contained water-absorbent substance. For a two lobe barrier, the water absorbent material is preferably in the form of a cellulose sheet that is captured by lengthwise stitching that separates the front lobe and rear lobe.
A preferred fabric for embodiments of the invention is a non-woven plastic polymer material, in particular a commercial material comprising needle-punched nonwoven polypropylene textile. See the Description below for more detail about the fabric. The barrier needs to have a fineness of openings such that the gelatinous mass of swelled up absorbent is retained within the barrier during use.
While different color fabrics can be used, as described in the '134 patent, different colors of the same kind of fabric impart differing durability to a barrier, with respect to sunlight/ultraviolent degradation of the swelled-up water absorbent material, in particular SAP, during use. Black and brown colors are preferred. But such dark color barriers may be poorly visible in darkened areas where barriers are used.
During use, an expanded barrier may be dragged about or otherwise handled, which can result in cutting or tearing damage to the barrier fabric and failure of the barrier. The necessity of having a water permeable low-cost material that retains the gelatinous mass limits fabric choice.
An object of the invention is to provide a barrier containing a water absorbent/swelling substance, which barrier has improved resistance to damage without comprising the ability to compactly store the barrier when dry prior to use, or the ability to dry the barrier after use. Another object is to provide a barrier which is highly visible for safety reasons.
The invention is referred to as an encased barrier. An embodiment of the invention comprises a sleeve made of porous fabric material, such as 0.3 mm thick water-permeable nonwoven geotextile, which is encased within a sheath made of mesh material. Contained within the sleeve prior to use is a substance that absorbs water upon contact, preferably a super-absorbent polymer (SAP) in powder or sheet form. The sheath is sufficiently flexible to permit the water absorbent substance to expand in volume, enabling the encased barrier to change from a typically flat object (suitable for easy shipping or storage) to a bulky three dimensional object suited for impeding the flow of surface waters. The sleeve is preferably fully enclosed or encompassed within the sheath, but embodiments may include a sheath that only partially encases a sleeve.
The sheath can protect the sleeve when the encased barrier of the invention is dragged across a rough surface, such as a driveway. The fabric of the sleeve is preferably made of black or brown sunlight-resisting polypropylene, and the fabric of the sheath preferably has an orange or other attention-catching color. In comparison, it would be a disadvantage to use a sleeve having a bright or light color because experiments show (as described in U.S. Pat. No. 9,297,134) that such kind of material has inferior durability.
The sleeve fabric has small openings, sufficient to contain the gelatinous expanded water absorbent polymer. In comparison, the sheath material has openings that are too large to contain the gelatinous polymer. In embodiments of the invention, the sheath comprises a polyester mesh and the fraction open area of the sheath is-will range from about 25 percent to about 60 percent; more preferably between about 36 percent and about 48 percent open area. When the sheath open area is greater than the upper limit, there is a tendency for the sleeve to be inadequately protected from abrasion, etc., and for the encased barrier to be less visible to a viewer. When the sheath open area is less than the lower limit, the flow of water or water vapor through the sheath can be impeded, in particular, increasing the time for a used barrier to be dried.
An exemplary invention sheath is made of woven polyester material and is about 0.5 mm thick. And it has a plurality of same-size holes arranged on a regular pattern, such as oval openings arranged rectilinear pattern with successive lines in staggered offset. And each hole has an area that is approximately equivalent to a round hole having a diameter of about 4 to 5 mm.
The foregoing and other objects, features and advantages of the present invention will become more apparent from the following description of preferred embodiments and accompanying drawings.
The present invention comprises a gelatinous mass that is contained within a tubular sleeve made of water permeable fabric having fine openings. The sleeve (which may be very much like one of the barriers described in the '134 patent) is contained within a sheath (or “case”) that has openings for passage of water. Thus, an article of the present invention, is referred to as an encased barrier. Embodiments of the present invention comprise an interior portion that is functionally in accord with barriers described in U.S. Pat. No. 9,297,134 “Self-Expanding Barrier for Control of Surface Water Flow”, issued Mar. 29, 2016 (the '134 patent” hereafter), the disclosure of which is hereby incorporated by reference. Just below, a barrier without a sheath is described first. Then, encased barrier embodiments in accord with the present invention are described.
An exemplary barrier 20 of the two-lobe type is shown in use in the perspective view of
The present invention may also comprise barriers having other shapes and other internal configurations, and may contain other types and forms of absorbent material. Barriers may also have other uses than those described here.
The absorbent used within a barrier of the present invention may comprise other known or future substitutes which are equivalents to those absorbent materials that are described here and in Patent '134 and elsewhere in the art. The absorbent for the barrier may be a so-called super absorbing polymer (SAP), which is generally a hydrogel. SAP is familiar in commerce, for instance in the fabrication of diapers for babies, feminine care pads, meat pads, and other commercial water absorbing devices. A familiar SAP is comprised of polymerized acrylic acid in combination with sodium hydroxide, with an initiator, forming sodium polyacrylate when wetted. The resultant mass is gelatinous. As known in the technical literature, other materials may be used for SAP, including polyacrylamide copolymer, ethylene maleic anhydride copolymer, cross-linked carboxymethylcellulose, polyvinyl alcohol copolymers, cross-linked polyethylene oxide, and starch grafted copolymer of polyacrylonitrile. See also the teachings of Watanabe et al. U.S. Pat. No. 7,258,904, the disclosure of which is hereby incorporated by reference.
While thread-stitching is mostly referred to with respect to forming barriers, alternative means may be used in making barriers. For example, riveting, stapling, adhesives, ultrasonic welding, and thermal fusion welding, may be used instead of or in combination with, stitching, and in combination with each other.
A fabric used in embodiments of the sleeve of the present invention is a non-woven plastic polymer material. In particular, a commercial material comprising needle-punched nonwoven polypropylene textile weighing about 92 grams per square meter (2.7 ounces per square yard) and having a thickness of about 0.3 mm (0.012 inches). Other non-woven fabrics such as Dupont™ spunbonded polypropylene fabric may be used. Commercial fabrics which are often buried in soil for drainage and filtration purposes, familiarly called geotextiles, may be used. Useful geotextiles have permittivity as measured by ASTM 4491 standard in the range 1-2 seconds−1.
Other kinds of commercial porous fabrics made from polyolefins other than polypropylene may be used, provided the fabric has sufficient porosity to enable water to infiltrate the interior of the barrier in easy fashion. At the same time, the effective sizing of the pores of a useful fabric will be small enough to prevent significant escape of the gelatinous mass of the swelled up SAP under normal use. The preferred non-woven fabrics do not elongate substantially, if and when the SAP expands sufficient to strain the fabric. Elongation of a fabric could be about 4 percent or less.
In embodiments of the present invention a barrier like one of those just described—or having alternative other configurations—is encased within a tough water permeable sheath. Thus, it is referred to as an encased barrier (or simply a barrier), and the inner fabric structure is called the sleeve. Preferably, the sheath has an attention getting color, such as OSHA safety orange, which color contrasts with a dark color of nonwoven fabric that is preferentially used, in accord with the teachings of the '134 patent.
The encased barrier 200 is shown in its dry as-manufactured condition in
Consistent with the description above relating to barriers that do not have sheaths, prior to contact with water, an encased barrier will be a substantially flattened tubular structure. In the generality of the invention, an encased barrier may comprise a barrier having one, two, or more lobes. Barriers of the present invention may have other shapes and forms, as are referred to herein, known in the art, or as may exist in the future.
A barrier like that of the
The partial cross section through the end of barrier 200 at
As described in more detail below, an exemplary sheath is a mesh material that has openings sufficiently large so that, compared to a same-size sleeve having no encasement, there is a lack of substantial adverse effect on capacity of water to contact the sleeve particularly if the water should be applied by spraying rather than flooding. The sheath used for an encased barrier comprises a mesh material which is flexible and thin, so that when a barrier that is arranged for use, as shown for example in or
An exemplary sheath of the present invention will provide a tough and visible surface while at the same time allowing easy flow of water from the exterior of the barrier into and through the nonwoven fabric sleeve. A sheath useful in the invention is comprised of woven polyester material of the kind provided as product PG12 mesh by Apex Mills of Inwood, N.Y., having a weight of 3.6 ounces per square yard and an approximate thickness of 0.5 mm (0.020 inch). Meshes of the present invention may weigh more or less than the PG12 mesh on a unit area basis, and meshes may be formed of other materials than polyester, including such as polyolefins. Other meshes may comprise flexible film/sheet that has punched holes.
The pattern for the PG12 mesh is shown in planar view in
The openings of mesh 280 in
A mesh of the present invention desirably comprises a material which is flexible and bendable so the product can be packaged as a flattened tubular structure, and/or folded along its length, without suffering a crease or set that later impedes the effectiveness of a barrier when a swollen-up barrier sets on a flat surface such as the surface of an automobile driveway, to block water flow; or when the barrier is laid against a vertical surface such as a wall or doorway; or when the barrier mates with other barriers when stacked, as sand bags are commonly stacked.
“Open area” is that portion of the surface area of sheath material which allows the passage of water. Alternately stated, it is the area of the holes in the sheath. “Percent open area” is the unit open area of the holes as a fraction of a unit total area of sheath. Sheaths of the present invention will range from about 25 percent to about 60 percent open area; more preferably between about 36 percent and about 48 percent open area. Of course, sleeve material will be visible to a viewer anywhere there are openings in the sheath. So, the fraction of a barrier external surface which is presented to a viewer as being sleeve material is the same as the fraction of the sheath which is open area.
When the sheath has the foregoing broader range of opening areas, simple calculation leads to there being between about 40 and about 75 percent of a unit area of barrier external surface presented as structural fabric which comprises the sheath. That range will be between about 24 and about 52 percent when the sheath has foregoing narrower range of openings stated in the preceding paragraph.
When the external surface sheath material fraction is less than the foregoing lower limits, the protection provided by the sheath to the sleeve (from abrasion) and any perceived change in color/visibility (due to the sheath being a bright/visible color) will both be lessened. When the sheath material external surface fraction is above the foregoing upper limits, the flow of water to the sleeve through the sheath can be lessened. In particular, the capacity of a swelled up barrier to be dried may be impeded.
Nonwoven permeable polymeric fabrics useful in the present invention are often referred to as geotextiles, in particular when they are used in connection with soil engineering. Such fabrics are comprised of interwoven and adhered together small resilient fibers which may have been needle punched. Nonwoven fabrics do not have defined openings or a repeating pattern, comparable to the openings of meshes mentioned here. Nonwoven polymeric fabrics which are used to form the sleeve of a barrier may be compared to each other by measuring their capacity to flow water, expressed as permittivity.
Thus, insofar as applicant knows, non-woven fabrics are not easily characterizable with respect to percent open area, as are meshes. However, a geotextile may be characterized as having an Apparent Opening Size (AOS). AOS indicates the diameter of the approximate largest particle that passes through a particular geotextile. For example, a Dupont spun bonded nonwoven fabric SF20 has an AOS of 0.595 mm and fabric SF65 has an AOS of 0.09 mm. Although it is somewhat conceptually imperfect to compare an AOS (which relates to passage of a solid) to a mesh opening (which in the present context relates to passage of a liquid), it would nonetheless appear that, with respect to gelatinous material, a sheath material (mesh) of the present invention has openings each of which is several times larger, i.e., 6 to up to maybe 40 times larger, in size than the openings that characterize a non-woven fabric of a sleeve. It hardly needs to be stated, but the holes of exemplary meshes would not contain the gelatinous mass of absorbent.
Returning again to discussion of the fraction open area of sheaths: To summarize some of what is said above, the function of the nonwoven sleeve is to allow water to pass into the sleeve concavity, and to prevent escape of the gelatinous water-saturated absorbent. The function of the sheath, while surrounding the sleeve, is to let water pass through the sheath to contact the exterior of the sleeve (and to let water escape from the sleeve when a barrier is being dried), while encompassing and physically protecting the sleeve and enabling improved visibility.
Since, as mentioned elsewhere, it is desirable to have a dark color sleeve, visibility is enhanced if the sheath of an encased barrier is made of a bright visible color. However, the effective visibility of an encased barrier is diminished if the percent open area is significantly greater than the maximum(s) stated above. That is because, particularly at a distance, to the eye the bright color of a sheath can be diminished by seeing it merged with the darker color of a sleeve material which is visible through the mesh openings of the sheath. That leads one to want a small open area.
Further, if the percent open area is greater than the maximums recited above (and assuming large open area correlates with larger individual openings), local portions of the sleeve may, due to swelling of the absorbent, protrude through openings of the sheath. Where the sleeve protrudes (or where stones and the like can intrude), the sleeve can be more vulnerable than otherwise to damage. That leads one to want small open area. The sheath also will add strength to the article as a whole, offering the possibility of using a thinner sleeve fabric should such be desired.
On the other hand, when the percent open area is small, while visibility of a bright sheath and resistance to abrasion damage may be better, the passage of water through the sheath, to the sleeve, can be impeded. That can perhaps be more significant for those users which seek to dry out the absorbent after a use.
An exemplary sheath, for example, one made of aforesaid Apex Mills fabric is made of woven material that provides the desired resistance to abrasion. The woven fabric is in differentiation to a mesh sheath made of a plastic film which has punched openings. The preferred Apex Mills invention fabrics present as a somewhat coarse woven materials having spaces between the woven fibers that define the fabric. Those spaces can allow flow of water or water vapor through the fabric structure itself. That is, an exemplary sheath is water permeable irrespective of openings in the sheath material. That adds somewhat to the ability for water and water vapor to move between the absorbent and the atmosphere external to the encased barrier.
To summarize some of what is said above, the function of the nonwoven sleeve is to allow water to pass through the sleeve, into the sleeve concavity, while preventing escape of the gelatinous water-saturated absorbent. The function of the sheath is to let water pass through to contact the exterior of the sleeve (and to escape from the sleeve when the barrier is being dried) while physically protecting the sleeve and enabling improved visibility.
While the invention has been described in terms of tubular barriers, in the generality of the invention, encased barriers may have other shapes, including rectanguloid and semi-spherical, etc. For such products, the non-woven fabric structure holding the water absorbent material shall be considered equivalent to a sleeve as described herein. While the invention has been characterized in terms of use of polymeric materials, fabrics made of natural fibers may be substituted.
The invention, with explicit and implicit variations and advantages, has been described and illustrated with respect to several embodiments. Those embodiments should be considered illustrative and not restrictive. Any use of words such as “preferred” and variations suggest a feature or combination which is desirable but which is not necessarily mandatory. Thus, embodiments lacking any such preferred feature or combination may be within the scope of the claims which follow. Persons skilled in the art may make various changes in form and detail of the invention embodiments which are described, without departing from the spirit and scope of the claimed invention.
This application claims benefit of provisional patent application Ser. No. 62/927,660, filed Oct. 29, 2019
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