METHOD OF MANUFACTURING AN IRRIGATION IMPLEMENT

Abstract

A method of manufacturing an irrigation implement may include receiving tubing. The tubing may be conventional plastic irrigation tubing. The tubing may be cut to form a first end of an irrigation implement. The tubing may be cut to form a second end of the irrigation implement. Either the first end or the second end of the tubing may be pinched in forming the irrigation implement. The pinched end of the tubing may be sealed in forming the irrigation implement. In an embodiment, the pinched end may be heat sealed to form the irrigation implement.

Description

RELATED APPLICATIONS

This is a divisional application of copending U.S. patent application having Ser. No. 15/042,037 filed on Feb. 11, 2016; the contents of which are hereby incorporated by reference in their entirety.

BACKGROUND

Irrigation, especially in dry or arid geographies, is particularly important to commercial plant and tree growers, such as wineries. Wineries, and other commercial growers, may have thousands of plants located on several or many acres. As commercial growers are faced with the cost of water, there is a need to be efficient with irrigation of plants and trees, such as grapevines. And, in the case of growing plants in drought stricken areas, such as California, avoiding evaporation of water while irrigating the plants is very desirable.

Commercial growers may need miles of irrigation “spaghetti” tubing, thousands of connectors and fittings, and thousands of irrigation implements to irrigate individual plants and trees on a property. The cost of the irrigation implements on a per unit basis may have a significant impact in profitability for growers. If, for example, 5,000 irrigation implements are needed for a winery, the cost for the irrigation implements may be cost prohibitive.

Different irrigation implements or mechanisms have different configurations. Some irrigation implements have a tapered portion or spike member at the bottom to form an irrigation stake with openings or emitters along the sides of the irrigation stake to enable water to saturate soil surrounding the irrigation stake to water roots of a plant or tree. The problems with the irrigation stake are that (i) manufacturing costs are high because of the multiple sections and assembly required to produce the irrigation stake, (ii) the water can saturate soil areas not necessarily desirable, and (iii) emitters both below and above the surface of the soil in which the irrigation stakes are positioned may allow moisture to more easily evaporate from the soil and irrigation stake.

One existing commercially available irrigation is an irrigation stake formed of plastic material, and can cost two dollars or more per unit. The irrigation stake is over 2 feet long. In operation, the irrigation stake is driven into the ground near a plant or tree. A water tube is inserted into the stake to cause water to enter the stake that then leaks water through emitters or openings at the bottom of the stake into the soil. Because the stake has many emitters, evaporation may occur or water may leak into soil that unnecessarily receives the water.

Another type of irrigation implement includes a flexible, spongy material that is about 18 inches long and extends from an irrigation tube. This irrigation implement provides for releasing water along the spongy material. However, the spongy material, when buried in the soil proximate a plant or tree, may become clogged with biological matter, and evaporation from the spongy material may also be restricted. Because of the configuration of the spongy material, water is released along the length of the spongy material, and, therefore, may release in soil locations that are unnecessary and will evaporate more readily than desirable. Moreover, manufacturing the irrigation mechanism requires assembly to fixably attach an irrigation tube to the spongy material, thereby increasing cost of the irrigation implement. To install the irrigation implement, the flexible, spongy material has to be buried, which can be time consuming and difficult to avoid crimping or otherwise damaging the flexible, spongy material. Hence, an irrigation implement that (i) is low cost, (ii) increases watering efficiency (e.g., better water placement in the soil and reduced evaporation), and (iii) is easy to install is needed.

SUMMARY

A low-cost, hi-efficiency irrigation implement may provide commercial growers with a better option for irrigating plants than existing irrigation implements. The irrigation implement may be a single element formed from common plastic irrigation tubing. Alternatively, non-plastic material may be utilized. The irrigation implement may include an open end and a self-sealed end. An emitter or opening through which an irrigation “spaghetti” tube or other similarly sized irrigation tube may be connected and/or inserted may be utilized. The emitter may be sized such that the irrigation tube or adapter may have a friction fit, thereby sealing the opening such that evaporation from the irrigation implement is minimized.

One embodiment of an irrigation implement may include a member having a first end a second end. The first end may be open and the second end may include a pinched seal. The member may further define an opening disposed toward the second end, and be configured to enable an irrigation tube to be attached to the opening such that the opening is sealed by the irrigation tube.

One embodiment of a method of manufacturing an irrigation implement may include receiving tubing. The tubing may be conventional plastic irrigation tubing. The tubing may be cut to form a first end of an irrigation implement. The tubing may be cut to form a second end of the irrigation implement. Either the first end or the second end of the irrigation implement may be pinched, and the pinched end of the irrigation implement may be sealed.

BRIEF DESCRIPTION

A more complete understanding of the method and apparatus of the present invention may be obtained by reference to the following Detailed Description when taken in conjunction with the accompanying Drawings wherein:

FIGS. 1A-1G are illustrations are different views of an illustrative irrigation implement for irrigating plants or trees; and

FIG. 2 is a method of manufacturing the irrigation implement of FIG. 1.

DETAILED DESCRIPTION OF THE DRAWINGS

With regard to FIGS. 1A-1G, illustrations of an illustrative irrigation implement 100 are shown. FIG. 1A-1G are respectively orthogonal, front, rear, left, right, top, and bottom views of the illustrative irrigation implement 100. The irrigation implement 100 includes a member 102 including a first end 104a and a second end 104b. The first end 104a and the second end 104b are formed by cutting tubing, such as irrigation tubing mounted on a spool or otherwise, into irrigation implement sections having lengths of between 6 inches to about 12 inches. Other lengths for the irrigation implement 100 may be used, as well. The irrigation implement 100 may be ½ inch to 1 inch in diameter. Alternative diameters may be used depending on the nature of the usage, such as different aged plants or trees. The irrigation implement 100 may be composed of plastic, rubber, or any other material capable of enduring environmental and weather elements where being utilized. The irrigation implement 100 may be any color, as well. The dashed lines and curves shown are indicative of curvature of the irrigation implement 100.

The first end 104a of the irrigation implement 100 is cut and has the same diameter as the irrigation implement 100. The second end 104b may be pinched to form a seal region 106. In one embodiment, the seal region 106 may be heat sealed, where the material of the member 102 is heat sealed to itself or self-sealed by heating the seal region 106 and pressing the two sides against one another until the two sides melt together. In an alternative embodiment, a sealing material, such as glue, epoxy, or otherwise, may be used to seal the second end 104b of the implement 100 using a pinched or unpinched technique prior to or during the sealing process.

In an alternative embodiment, rather than pinching and sealing the irrigation implement 100, a cap (not shown) or stopper member (not shown) may be applied to the second end 104b of the irrigation implement 100. The cap or stopper member adds another component to form the irrigation implement, but eliminates the sealing step. In either case, the irrigation implement may be utilized in the same manner.

As shown, an emitter 108 is included toward the second end 104b of the member 102. The emitter 108 is shown to be circular, and configured to provide for a certain number of gallons per hour of water to be leaked if used as a conventional emitter. However, the irrigation implement 100 is to use the emitter 108 as an input to receive an irrigation “spaghetti” tube or other irrigation tube that is capable of fitting into the emitter to form a friction fit. Alternatively, an adapter (not shown) may be configured to fit into the emitter on one side and receive an irrigation tube on the other side so as to supply water into the irrigation implement 100. The emitter 108 is shown to be located toward the second end 104b of the implement so that an irrigation tube can be connected or inserted into the emitter 108 when in operation (e.g., when the first end 104a is inserted into soil). In one embodiment, the emitter 108 may be located within 3-inches of the first end 104a. In another embodiment, the emitter 108 may be located within 1-inch of the first end 104a.

It should be understood that the dimensions and scale of the irrigation implement 100 are illustrative, and that alternative dimensions and scaling may be utilized to provide for the functionality described herein. It should further be understood that alternative shapes for the irrigation implement 100 may be utilized, including additional decorative features, such as different shapes of the member (e.g., inclusive of a waist, profile of a person, profile of a tool, or any other geometric or non-geometric shape), different shapes of the seal region 106 (e.g., “V” shape, “U” shape, wave shape, etc.), and different shapes of the second end (e.g., wave shape, multiple “V shape, etc.).

With regard to FIG. 2, a flow diagram of a process 200 of manufacturing the irrigation implement of FIG. 1 is shown. The process 200 of manufacturing an irrigation implement may start at step 202, where irrigation tubing may be received. The tubing, and thus the implement, may be plastic, rubber, or any other material. The tubing may be irrigation tubing (i.e., tubing specifically designed for irrigation), and be received in bulk (e.g., 500 feet or more) from a spool or otherwise. In receiving the tubing from a spool, the tubing may be manually, semi-automatically, or automatically fed from the spool (or other device) for processing (e.g., pinching, cutting, and sealing). In an alternative embodiment, smaller lengths, including individual lengths (e.g., 9 inches) or multiple lengths (e.g., 18 inches) of a single irrigation implement may be received for processing to form the irrigation implement. If the tubing is semi-automatically or automatically fed from the spool, the tubing may be received from the spool in a synchronous or coordinated manner with other processing steps, such as a pinching process, for manufacturing the irrigation implement.

Although not specifically shown in FIG. 2, one or more steps may be included to form (e.g., punch) emitters or openings in the tubing if the bulk tubing does not already include the emitters. In one embodiment of the tubing, emitters or openings may be periodically spaced along the tubing. For example, the emitters may be regularly spaced every 6-inches, 9-inches, 12-inches, or otherwise. The emitters may be sized for a certain number of gallons per hour (GPH), such as 1 GPH, such that the emitter, in this case, may receive irrigation “spaghetti” tubing or other appropriately sized irrigation tubing with a friction fit. Alternatively, an adapter may be used to adapt or provide a bridge for the irrigation “spaghetti” tubing or other irrigation tubing to the irrigation implement.

The tubing may be cut to form a first end of an irrigation implement at step 204. If the tubing has regularly spaced emitters, then the first cut may be made slightly above the regularly spaced emitter, such as between 1-inch and 3-inches, or second cut may be made slightly below the emitter, depending on the configuration of the manufacturing equipment. At step 206, the tube may be cut to form a second end of the irrigation implement. Either the first end or the second end of the irrigation implement may be pinched at step 208, depending on whichever is closer to the emitter, and sealed at step 210.

In sealing the pinched end of the irrigation implement, when the tubing is being pinched or just prior to the tubing is pinched, heat may be applied to cause the material of the second end to melt and form a seal. In one embodiment, the pinching and sealing at step 208 and 210 may be performed simultaneously through use of a heated press inclusive of a cutter. In one embodiment, the sealing may be performed for two irrigation implements in a row, and a cut within the seal to separate the two irrigation implements may be made. Although shown as multiple steps, it should be understood that two or more of the steps may be combined into a single step. For example, steps 206, 208, and 210 may be combined into a single step of cutting, pinching, and sealing the tube. It should further be understood that the order of the steps in FIG. 2 may be varied. For example, the process 200 may include pinching, sealing, and cutting the hose from a spool in a single step. Alternatively, two steps to perform the functions of pinching, sealing, and cutting may be utilized.

In cutting the ends of the irrigation implement, the cutter may be a blade, saw, heated element, laser, or any other device capable of cutting the tube. As described herein, the process 200 may be performed in a fully automated, semi-automated, or manual manner. In one embodiment, a cutter machine may be performed independent of a press machine and heater machine. Alternatively the press machine and heater machine may be a single machine. Still yet, a single machine capable of cutting, pressing or pinching, and heating to seal the irrigation implement may be utilized. In one embodiment, one, two, or more irrigation implements may be produced simultaneously using a single tubing.

Depending on the number of simultaneously produced irrigation implements, the tubing may have a certain pattern of emitters such that, for example, a pair of irrigation implements may have first ends or second ends head-to-head or at opposite ends from one another. In other words, the emitters may be positioned with a regular spacing or pairs of emitters may be positioned with a regular spacing and a pinched seal may be made between the pair of emitters. In whatever configuration of equipment that is used to produce individual irrigation implements, irrigation tubing may be used in bulk with emitters as conventionally available or specially made to meet the production capabilities for producing the irrigation implements.

In the event of the tubing not having emitters that are regularly spaced, an opening may be formed in the irrigation implement toward the pinched end. The opening may be located within 3-inches of the pinched end. In another embodiment, the opening may be within 1-inch of the pinched end. The opening may be formed by a punch, drill, heated element, laser, or other device, and formed toward the pinched end or toward the end that is going to be pinched. Other techniques may be used for creating an opening in the irrigation implement. The opening may be circular or any other shape. The opening may be sized to fit a standard irrigation tube that is to be friction fit within the opening. In an alternative embodiment, the opening may be sized and shaped to fit an adapter that may engage with an irrigation tube.

In operation, the irrigation implement may be inserted into soil near a plant or tree. In one embodiment, the irrigation implement may be utilized for irrigating plants or trees in a second or later season of production. Because the irrigation implement has an opening at the bottom and one opening that is sealed toward the top, evaporation from the irrigation implement is minimal or none. Moreover, because the water that enters the irrigation implement is released from the bottom, the irrigation can be limited to a specific location in the soil, so evaporation may be reduced.

Utilizing the processes described herein, the cost of manufacturing may be significantly lower than conventional irrigation implements, such that the retail price of the irrigation implements may be less than one-quarter of conventional irrigation implements.

Although the irrigation implement has been described as being tubular, it should be understood that the irrigation implement may be formed with a variety of profile shapes, include square, rectangular, or any other geometric shape. Because tubular irrigation plastic material is currently produced in bulk, the cost of producing irrigation implements using tubular shapes may be lower than other shaped irrigation devices.

The previous description is of a preferred embodiment for implementing the invention, and the scope of the invention should not necessarily be limited by this description. The scope of the present invention is instead defined by the following claims.

Claims

1. A method of manufacturing an irrigation implement, comprising:

receiving tubing;

cutting the tubing to form a first end of an irrigation implement;

cutting the tubing to form a second end of the irrigation implement;

pinching either the first end or the second end of the tubing in forming the irrigation implement; and

sealing the pinched end of the tubing to form the irrigation implement.

2. The method according to claim 1, wherein pinching and sealing are performed simultaneously by heating the end of the tubing being pinched to cause the pinched region of the tubing to melt together.

3. The method according to claim 1, further comprising forming an opening in the tubing to be positioned toward the pinched end.

4. The method according to claim 3, wherein forming the opening includes punching a circular opening sized to receive and engage an irrigation tube such that the opening is sealed by the irrigation tube.

5. The method according to claim 3, wherein forming the opening includes forming the opening within 7.62 cm (3-inches) of the second end of the irrigation implement.

6. The method according to claim 1, wherein receiving the tubing includes receiving plastic tubing.

7. The method according to claim 1, wherein cutting the first end and cutting the second end of the tube are performed within 30.48 cm (12-inches) of one another.

8. The method according to claim 1, wherein receiving tubing includes receiving tubing having an inner diameter between 1.27 cm (½-inch) and 2.54 cm (1-inch) in diameter.

9. The method according to claim 1, wherein receiving the tubing includes receiving a plastic irrigation hose.

10. The method according to claim 1, wherein receiving a plastic irrigation hose includes receiving a plastic irrigation hose from a spool.

11. The method according to claim 1, wherein

wherein receiving tubing includes receiving tubing that defines a single opening defined along the tubing between the first end and the second end of the irrigation implement; and

wherein pinching either the first end or the second end of the tubing includes pinching either the first end or the second end at a distance sufficiently far from the single opening such that the single opening is oriented entirely along a longitudinal-oriented portion of a sidewall and closer to the pinched first end or second end than the non-pinched first end or second end.

12. The method according to claim 11, wherein pinching either the first end or the second end of the tubing includes forming a heated pinched seal at either the first end or the second end.

13. The method according to claim 11, wherein receiving tubing that defines a single opening includes receiving tubing that defines a single opening sized to receive an irrigation tube such that when the irrigation tube is inserted into the single opening that the irrigation tube seals the single opening.