MULTIPLE LAYER WALL WATER STORAGE CHAMBERS
A storm water and septic system using plastic galleries that have multiple layers provided having differing hardness characteristics, the exterior layer having a lower hardness rating than an inner layer; and a multi-layer gallery where the inner layer is treated to be resistance to degradation to a selected chemical that would otherwise degrade polyethylene. The gallery may further be provided with an interior layer having defined dielectric properties such that a fluid level measurement can be made of fluid in the galleries.
The present invention relates to pre-molded galleries utilized for storm-water and septic systems, which minimize the damage that may potentially be inflicted to the chamber during installation and use.
BACKGROUND OF THE INVENTIONStorm water and septic systems have been in wide use for many years, including for example, pre-molded polyethylene galleries. An advantage to utilizing these galleries is that they are lightweight, easy and quick to install and relatively inexpensive.
Pre-molded polyethylene galleries have increasingly been utilized for leaching and drainage systems. Such a system is disclosed in U.S. Pat. No. 5,087,155 to DiTullio (“the '155 patent”), the disclosure of which is incorporated by reference, which discloses a drainage and leaching field system comprising vacuum-molded polyethylene galleries that are designed to be connected and locked together in and end-to-end fashion.
The galleries disclosed in the '151 patent comprise a single pre-molded polyethylene layer with an arch-shaped configuration having upstanding ribs running transverse to the length of the gallery. The ribs provide compressive strength to the gallery where, often it is desired to install the galleries under parking areas and under roadways. However, because the galleries are made of only a single layer the rocks and or debris falling into or on the gallery during, for example, installation, can cause damage to the gallery. Additionally, where the galleries are exposed to, for example, a warm or hot caustic such as may be encountered at a chemical treatment plant, the structural integrity of the gallery can be compromised if the chemical causes damage to the walls of the gallery. Additionally, it is virtually impossible to determine a level of fluid in the gallery without direct visualization of the interior of the gallery.
U.S. Pat. No. 6,854,925 to DiTullio (“the '925 patent”), the disclosure of which is also incorporated by reference, discloses a multi-layer plastic gallery including a first exterior layer forming a smooth continuous surface along a substantial length of the gallery; a second middle layer forming a plurality of spaced apart upstanding ribs along a length of the gallery; and a third interior layer forming a smooth continuous surface along a second substantial length of the gallery. The '925 patent further discloses that one benefit of the configuration is that it allows for a low-friction surface on the interior walls for the quick removal of storm water runoff. While the smooth inner wall does present a reduced friction surface, the problem of providing a gallery capable of withstanding damage due to, for example, rocks or other heavy objects impacting the surface of the gallery during installation is still a factor.
For example, while providing a multi-layer walled structure will provide additional strength to the gallery, the exterior layer and possibly the middle corrugated support layer may become damaged (e.g. cracked) if a large object impacts the exterior of the gallery. Additionally, the galleries disclosed in the '925 patent do not allow or provide for a remote determination of a level of fluid in the gallery without direct visualization or the insertion of an instrument to perform the measurement.
SUMMARY OF THE INVENTIONWhat is desired therefore, is a gallery that minimizes any damage that may occur to the gallery due to impact of a relatively heavy object against the gallery, such as a rock.
It is also desired to provide a gallery that minimizes any damage that may occur to the gallery during use caused from the exposure of the gallery to a corrosive chemical, such as for example, a warm or hot caustic.
It is still further desired to provide a gallery that allows for the remote measurement of a fluid level in the gallery without the need for direct visualization or the need for insertion of an external or internally mounted sensor.
These and other objects are achieved in one embodiment by the provision of a gallery having at least two layers where an exterior layer is provided having a lower hardness rating than a stiffer inner layer. This configuration provides the distinct advantage that if a relatively large or heavy object impacts the exterior surface of the gallery, rather than cracking or shattering, the exterior layer is provided to absorb the impact and protect the harder or stiffer inner layer. It is contemplated that the inner layer can be provided as a stiffer and/or harder layer having higher strength characteristics to ensure stability for the drainage system when buried. It is contemplated that both the exterior and inner layers may comprise a polyethylene material, however, the inner layer may be treated to increase the hardness of the polyethylene, such as for example, with talc.
While the gallery is provided having at least two layers, the layers may be co-extruded to form a unitary sheet that may then be formed into a gallery. The extruded unitary sheet may then be inserted into a mold to form a chamber. While the embodiment is described as comprising at least two co-extruded layers, it is contemplated that numerous layers may be used and/or co-extruded to form a single unitary sheet for use in forming chambers.
In another embodiment, it is contemplated that the gallery may be provided with a first layer comprising a corrugated polyethylene material, and a protective inner layer that is treated to resist chemicals that are corrosive to polyethylene. For example, the inner layer may comprise a polyethylene material that is treated to resist a warm or hot caustic that would normally cause damage to the polyethylene material. The protective inner layer could be provided as a relatively thin layer that substantially follow the contour of the corrugated first layer, or could comprise a relatively thin layer that presents a smooth interior surface. In any event, the layer would be treated to resist degradation due to exposure to a particular chemical. In this manner, the corrugated first layer that provides structural stability to the gallery will not be compromised due to exposure to a caustic substance.
In yet another embodiment, a gallery is provided comprising a material having dielectric or magnetic properties. For example, it is know to determine the Dielectric Constant (DC) of a material for various purposes. In this application, a DC conductivity measurement may be used to measure the level of a liquid in the gallery. The DC of a material is a ratio of how much Radio Frequency energy will pass through it compared to that amount that will pass through empty space (DC=1.0). Therefore, polyethylene plastic (DC=2.2 at 68° F. in a solid state) will pass 2.2 times as much R.F. energy as will a vacuum. Accordingly, DC conductivity measurements using R.F./admittance and pulse wave technology can be used for liquid level measurements.
Accordingly, it is contemplated that a gallery having an inner polyethylene layer can be used to determine the level of a liquid residing in the gallery at a particular temperature by performing a DC conductivity measurement. It is contemplated that an inner layer may be used on one or more galleries coupled to together in an end-to-end fashion and/or in various columns and rows to determine a liquid level throughout the gallery field. The dielectric measurement could be used to generate a level signal indicative of a level of fluid in the gallery, which could be sent to either a local or remote location for monitoring.
The gallery may be provided as an elongated arched body including multiple layers where a top portion or at least an upper surface of the body is provided having a relatively light color, such as for example, white. In this manner, when the galleries are maintained exposed to heating sources, such as the sun for prolonged periods of times, rather than absorbing large amounts of energy that heat the gallery and thereby cause the gallery to become more pliable, a larger amount of energy is deflected away from the gallery. This allows the gallery to maintain its shape and stiffness as the temperature is not dramatically increased.
Still further, a metallic portion may be positioned in the gallery, which may advantageously be located at a top portion of the gallery. In this manner, when the galleries are buried, the metallic portion allows an individual to locate the buried galleries by simply using a metal detector.
In one advantageous embodiment a multi-layer gallery having an elongated arched body and first and second ends, the elongated arched body forming an elongated arched interior space with an open bottom for liquid to flow therethrough is provided comprising a first exterior layer having a hardness (H1) that extends the substantially the length of the gallery and a second inner layer forming a plurality of spaced apart upstanding ribs along a length of the gallery, the second layer having a hardness (H2). The gallery is provided such that the hardness (H1) of the first exterior layer is lower than the hardness (H2) of the second inner layer. The gallery further comprises a connecting mechanism located at the first and second end of the multi-layer gallery for connecting the gallery together with another gallery in an end-to-end relationship, the connecting mechanism comprising a starting rib located at the first end of the gallery, and an end rib located at the second end of the gallery, such that a first gallery and a second gallery may be connected together by overlapping a starting rib of the first gallery over an end rib of the second gallery.
In another advantageous embodiment a multi-layer polyethylene gallery having an elongated arched body and first and second ends, the elongated arched body forming an elongated arched interior space with an open bottom for liquid to flow therethrough is provided comprising a first exterior layer forming a plurality of spaced apart upstanding ribs along a length of the gallery and a second inner layer extending substantially the length of the gallery. The gallery is provided such that the second inner layer is treated to resist degradation by a selected substance that is caustic to polyethylene so that the multi-layer polyethylene gallery can be used to disperse substances that may be harmful to polyethylene without degradation to the gallery. The gallery further comprises a connecting mechanism located at the first and second end of the multi-layer gallery for connecting the gallery together with another gallery in an end-to-end relationship, the connecting mechanism comprising a starting rib located at the first end of the gallery, and an end rib located at the second end of the gallery, such that a first gallery and a second gallery may be connected together by overlapping a starting rib of the first gallery over an end rib of the second gallery.
In still another advantageous embodiment a multi-layer gallery having an elongated arched body and first and second ends, the elongated arched body forming an elongated arched interior space with an open bottom for liquid to flow therethrough is provided comprising a first exterior polyethylene layer forming a plurality of spaced apart upstanding ribs along a length of the gallery and a second inner polyethylene layer having a know Dielectric Constant (DC) at a given temperature. The gallery further comprises a DC conductivity measurement of the second inner polyethylene layer that is indicative of a level of liquid in the gallery at a given point in time and a level signal generator receiving the DC conductivity measurement and generating a level signal corresponding to the level of liquid in the gallery. The gallery still further comprises a connecting mechanism located at the first and second end of the multi-layer gallery for connecting the gallery together with another gallery in an end-to-end relationship, the connecting mechanism comprising a starting rib located at the first end of the gallery, and an end rib located at the second end of the gallery, such that a first gallery and a second gallery may be connected together by overlapping a starting rib of the first gallery over an end rib of the second gallery.
In yet another advantageous embodiment a multi-layer gallery having an elongated arched body and first and second ends, the elongated arched body forming an elongated arched interior space with an open bottom for liquid to flow therethrough is provided comprising a first exterior layer having a hardness (H1) that extends the substantially the length of the gallery and a second inner layer forming a plurality of spaced apart upstanding ribs along a length of the gallery, the second layer having a hardness (H2). The gallery is provided such that the hardness (H1) of the first exterior layer is lower than the hardness (H2) of the second inner layer. The gallery further comprises a third interior layer extending substantially the length of the gallery where the third interior layer is treated to resist degradation by a selected substance that is caustic to polyethylene such that the multi-layer polyethylene gallery can be used to disperse substances that may be harmful to polyethylene without degradation to the gallery. The gallery still further comprises a connecting mechanism located at the first and second end of the multi-layer gallery for connecting the gallery together with another gallery in an end-to-end relationship, the connecting mechanism comprising a starting rib located at the first end of the gallery, and an end rib located at the second end of the gallery, such that a first gallery and a second gallery may be connected together by overlapping a starting rib of the first gallery over an end rib of the second gallery.
In still another advantageous embodiment a multi-layer gallery having an elongated arched body and first and second ends, the elongated arched body forming an elongated arched interior space with an open bottom for liquid to flow therethrough is provided comprising a first exterior layer having a hardness (H1) that extends the substantially the length of the gallery and a second inner layer forming a plurality of spaced apart upstanding ribs along a length of the gallery, the second layer having a hardness (H2). The gallery is provided such that the hardness (H1) of the first exterior layer is lower than the hardness (H2) of the second inner layer. The gallery further comprises a third interior polyethylene layer having a know Dielectric Constant (DC) at a given temperature. The gallery still further comprises a DC conductivity measurement of the third interior polyethylene layer that is indicative of a level of liquid in the gallery at a given point in time and a level signal generator receiving the DC conductivity measurement and generating a level signal corresponding to the level of liquid in the gallery. The gallery yet further comprises a connecting mechanism located at the first and second end of the multi-layer gallery for connecting the gallery together with another gallery in an end-to-end relationship, the connecting mechanism comprising a starting rib located at the first end of the gallery, and an end rib located at the second end of the gallery, such that a first gallery and a second gallery may be connected together by overlapping a starting rib of the first gallery over an end rib of the second gallery.
Other objects of the invention and its particular features and advantages will become more apparent from consideration of the following drawings and accompanying detailed description.
Referring now to the drawings, wherein like reference numerals designate corresponding structure throughout the views.
It is contemplated that exterior layer 16 is provided having a lower hardness rating than a stiffer inner layer 18. In this manner, if during installation a relatively heavy object where to impact the gallery 10, the object would contact exterior layer 16, which is provided with a lower hardness rating so as to bend or give to avoid cracking or shattering. The inner layer 18, however, can be provided having higher strength characteristics to ensure stability for the drainage system during loading. Both the exterior layer 16 and inner layer 18 may comprise a polyethylene material, however, inner layer 18 may be treated with, for example, talc, to increase the hardness of the polyethylene.
It should be noted that gallery 10 may be provided comprising both exterior layer 16 and inner layer 18, however these layers may be co-extruded to form a unitary sheet to then be formed into gallery 10. While at least two co-extruded layers are described here, it is contemplated that additional layers may be used and/or co-extruded to form a single unitary sheet for use in forming gallery 10.
To that end, the end wall 32 may be either integral to the gallery 10 as depicted in
Referring to
In one embodiment, gallery 40 may be provided with perforations 60, distributed along the length of the elongated section 42. It is further contemplated that, while not illustrated in connection with
It is still further contemplated that the embodiment described in connection with either
It is further contemplated that a top portion 13, 43 of the arched body 12, 42 may be provided having a white color so as to reflect a relatively large portion of the energy from sunlight away from the gallery 10, 40 so as to reduce heating of the body 12, 42.
The gallery 10, 40 may also be provided with a metallic portion 15, 45 positioned on the elongated arched body 12, 42. In this manner, when the galleries 10, 40 are buried, the metallic portion 15, 45 allows an individual to locate the buried galleries 10, 40 by simply using a metal detector.
Although the invention has been described with reference to a particular arrangement of parts, features and the like, these are not intended to exhaust all possible arrangements or features, and indeed many other modifications and variations will be ascertainable to those of skill in the art.
Claims
1. A multi-layer gallery having an elongated arched body and first and second ends, the elongated arched body forming an elongated arched interior space with an open bottom for liquid to flow therethrough, the multi-layer gallery comprising:
- a first exterior layer having a hardness (H1) that extends the substantially the length of the gallery;
- a second inner layer forming a plurality of spaced apart upstanding ribs along a length of the gallery, said second layer having a hardness (H2);
- said hardness (H1) of said first exterior layer being lower than the hardness (H2) of said second inner layer; and
- a connecting mechanism located at the first and second end of the multi-layer gallery for connecting the gallery together with another gallery in an end-to-end relationship, the connecting mechanism comprising a starting rib located at the first end of the gallery, and an end rib located at the second end of the gallery, such that a first gallery and a second gallery may be connected together by overlapping a starting rib of the first gallery over an end rib of the second gallery.
2. The multi-layer gallery of claim 1 wherein said starting rib is larger than the end rib.
3. The multi-layer gallery of claim 1 further comprising an end wall located at the second end of the gallery.
4. The multi-layer gallery of claim 3 wherein said end wall is integral to the gallery.
5. The multi-layer gallery of claim 3 wherein said end wall is detachably connectable to the second end of the gallery.
6. The multi-layer gallery of claim 1 wherein said first exterior layer is formed as a smooth exterior layer overlaying said second inner layer.
7. The multi-layer gallery of claim 1 wherein a top portion of the arched body is provided having a white color.
8. The multi-layer gallery of claim 1 further comprising a metallic portion positioned on the elongated arched body such that the body may be detected when buried.
9. A multi-layer polyethylene gallery having an elongated arched body and first and second ends, the elongated arched body forming an elongated arched interior space with an open bottom for liquid to flow therethrough, the multi-layer gallery comprising:
- a first exterior layer forming a plurality of spaced apart upstanding ribs along a length of the gallery;
- a second inner layer extending substantially the length of the gallery;
- said second inner layer treated to resist degradation by a selected substance that is caustic to polyethylene such that the multi-layer polyethylene gallery can be used to disperse substances that may be harmful to polyethylene without degradation to the gallery; and
- a connecting mechanism located at the first and second end of the multi-layer gallery for connecting the gallery together with another gallery in an end-to-end relationship, the connecting mechanism comprising a starting rib located at the first end of the gallery, and an end rib located at the second end of the gallery, such that a first gallery and a second gallery may be connected together by overlapping a starting rib of the first gallery over an end rib of the second gallery.
10. The multi-layer gallery of claim 9 wherein said starting rib is larger than the end rib.
11. The multi-layer gallery of claim 10 further comprising an end wall located at the second end of the gallery.
12. The multi-layer gallery of claim 11 wherein said end wall is integral to the gallery.
13. The multi-layer gallery of claim 11 wherein said end wall is detachably connectable to the second end of the gallery.
14. The multi-layer gallery of claim 9 wherein said second inner layer is formed as a smooth inner layer overlaying an inner surface of said first exterior layer.
15. The multi-layer gallery of claim 9 wherein a top portion of the arched body is provided having a white color.
16. The multi-layer gallery of claim 9 further comprising a metallic portion positioned on the elongated arched body such that the body may be detected when buried.
17. A multi-layer gallery having an elongated arched body and first and second ends, the elongated arched body forming an elongated arched interior space with an open bottom for liquid to flow therethrough, the multi-layer gallery comprising:
- a first exterior polyethylene layer forming a plurality of spaced apart upstanding ribs along a length of the gallery;
- a second inner polyethylene layer having a know Dielectric Constant (DC) at a given temperature;
- a DC conductivity measurement of the second inner polyethylene layer that is indicative of a level of liquid in the gallery at a given point in time;
- a level signal generator receiving the DC conductivity measurement and generating a level signal corresponding to the level of liquid in the gallery; and
- a connecting mechanism located at the first and second end of the multi-layer gallery for connecting the gallery together with another gallery in an end-to-end relationship, the connecting mechanism comprising a starting rib located at the first end of the gallery, and an end rib located at the second end of the gallery, such that a first gallery and a second gallery may be connected together by overlapping a starting rib of the first gallery over an end rib of the second gallery.
18. The multi-layer gallery of claim 17 wherein said level signal generator is coupled to a computer and said level signal is transmitted to said computer.
19. The multi-layer gallery of claim 18 wherein said computer is coupled to a network.
20. The multi-layer gallery of claim 17 wherein said starting rib is larger than the end rib.
21. The multi-layer gallery of claim 17 further comprising an end wall located at the second end of the gallery.
22. The multi-layer gallery of claim 21 wherein said end wall is integral to the gallery.
23. The multi-layer gallery of claim 21 wherein said end wall is detachably connectable to the second end of the gallery.
24. The multi-layer gallery of claim 17 wherein a top portion of the arched body is provided having a white color.
25. The multi-layer gallery of claim 17 further comprising a metallic portion positioned on the elongated arched body such that the body may be detected when buried.
26. A multi-layer gallery having an elongated arched body and first and second ends, the elongated arched body forming an elongated arched interior space with an open bottom for liquid to flow therethrough, the multi-layer gallery comprising:
- a first exterior layer having a hardness (H1) that extends the substantially the length of the gallery;
- a second inner layer forming a plurality of spaced apart upstanding ribs along a length of the gallery, said second layer having a hardness (H2);
- said hardness (H1) of said first exterior layer being lower than the hardness (H2) of said second inner layer;
- a third interior layer extending substantially the length of the gallery;
- said third interior layer treated to resist degradation by a selected substance that is caustic to polyethylene such that the multi-layer polyethylene gallery can be used to disperse substances that may be harmful to polyethylene without degradation to the gallery; and
- a connecting mechanism located at the first and second end of the multi-layer gallery for connecting the gallery together with another gallery in an end-to-end relationship, the connecting mechanism comprising a starting rib located at the first end of the gallery, and an end rib located at the second end of the gallery, such that a first gallery and a second gallery may be connected together by overlapping a starting rib of the first gallery over an end rib of the second gallery.
27. A multi-layer gallery having an elongated arched body and first and second ends, the elongated arched body forming an elongated arched interior space with an open bottom for liquid to flow therethrough, the multi-layer gallery comprising:
- a first exterior layer having a hardness (H1) that extends the substantially the length of the gallery;
- a second inner layer forming a plurality of spaced apart upstanding ribs along a length of the gallery, said second layer having a hardness (H2);
- said hardness (H1) of said first exterior layer being lower than the hardness (H2) of said second inner layer;
- a third interior polyethylene layer having a know Dielectric Constant (DC) at a given temperature;
- a DC conductivity measurement of the third interior polyethylene layer that is indicative of a level of liquid in the gallery at a given point in time;
- a level signal generator receiving the DC conductivity measurement and generating a level signal corresponding to the level of liquid in the gallery; and
- a connecting mechanism located at the first and second end of the multi-layer gallery for connecting the gallery together with another gallery in an end-to-end relationship, the connecting mechanism comprising a starting rib located at the first end of the gallery, and an end rib located at the second end of the gallery, such that a first gallery and a second gallery may be connected together by overlapping a starting rib of the first gallery over an end rib of the second gallery.
Type: Application
Filed: Jul 11, 2008
Publication Date: Jan 14, 2010
Inventor: Robert J. DiTullio (Warren, CT)
Application Number: 12/171,884
International Classification: B65D 88/54 (20060101);