ROOFTOP STORMWATER MANAGEMENT APPARATUS AND METHOD

- LOW & BONAR INC.

A stormwater management apparatus and method including a water storage component, and a drainage component. The water storage component, and protective component form a composite that allows for stormwater to be retained to an appropriate extent, and for excess stormwater to be adequately controlled. The water storage component and drainage component are provided in a single unit.

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Description
BACKGROUND

Stormwater, or water that originates during precipitation events, is a resource and its appropriate management is particularly desirable given that the world's population continues to grow, and accordingly requires an increased amount of water. A consideration in the design and construction of residential, commercial and other structures relates to the rooftop or other urban surfaces, and particularly to the management of stormwater that contacts the rooftop or other urban surfaces. While it may be desirable for stormwater to be captured and ultimately used, large volumes of untreated stormwater are known to run off rooftops or other urban surfaces, often through sewage systems, and into rivers, streams or other sources of water that may serve as drinking water or other water consumed or otherwise used by humans. Use of such water can lead to increased health risks and other undesirable hazards and environmental problems. Stormwater runoff also is a particular problem in many urban areas because of the increase in impervious area as the density of building and paved area increases. Further, flooding from stormwater runoff may lead to damages in infrastructures such as buildings, roadways and bridges.

Further, in high precipitation events, sewer systems or drainage systems in many urban areas cannot effectively handle the amount of water, which causes flooding that could lead to significant damage to urban infrastructure plus issues in sewage management, such as combined sewage overflow, and could lead to water that is ineffectively treated for user consumption or otherwise lead to contaminated water to enter a river or other waterway.

One type of roofing system provided to appropriately capture rooftop stormwater is known as a blue roof. A blue roof is a roof design that is explicitly intended to store water. Blue roofs can be created by temporarily ponding water on the roofs through devices that may actively or passively regulate the drainage of the water from the roof, such as weirs and control flow drains. Blue roofs allow for a regulated runoff of stormwater from the roof, thus preventing a downstream stormwater infrastructure from surcharging.

In blue roofs, ponding water will exert hydrostatic pressure on the roof, which could void the warranty of roofing membrane manufacturers. Waterproofing thus can be required to adequately secure the roof structure and avoid leakage. Further, blue roofs often suffer from bacteria growth, foul smells, algae and provide breeding ground for mosquitos given the necessary standing water retained by the blue roof, leading to health concerns.

In some blue roofs, ponding water may be retained on trays that are placed on the roof, and such trays can be oriented so that, once the trays are full, the excess rainwater will overflow onto the roof membrane and flow to drains. However, even in such a situation, there exists exposed standing water and the hazards of bacteria growth, foul smells, algae and mosquitos discussed above.

Non-penetrating detention trays may be used, but have a complex installation, which may damage a roof membrane and cause a leak. The trays are exposed to ultraviolet rays and can become aged and brittle over time. Stones may also be used to avoid wind uplift, but this would lead to loss in water storage capacity. Blue trays also have an open water orientation, which will also have exposed standing water and the hazards of bacteria growth, foul smells, algae and mosquitos discussed above.

Another type of roofing system provided to regulate stormwater is known as a green roof. A green roof is a roof that is covered with vegetation and a growing medium that is planted over a waterproofing membrane. Green roofs have multiple layers that can include vegetation, a growing medium, and other components, but have a higher upfront cost with a complex installation and higher maintenance costs.

The present application provides for a design of a stormwater management system that is capable of effectively at least holding back and retaining stormwater runoff from a rooftop or other urban surface, can be usable with a variety of types of roofs or other areas of a building, and allows for a lightweight stormwater management system with little maintenance, but avoids some drawbacks of conventional stormwater management apparatuses. Further, a water retention amount can be improved with respect to known solutions, and a system that allows for a controlled release rate while still having desirable water retention can be achieved. A design that includes a water permeable and reflective top that allows rainwater penetration and reduces energy use is also within the scope of this application.

SUMMARY

In embodiments, a stormwater management apparatus is described. The apparatus includes a composite having a water storage component and a drainage component provided below the water storage component, so as to allow for controlled flow of stormwater from the water storage component to the drainage component. The water storage component and drainage component are provided in a single unit.

In embodiments, a stormwater management apparatus is described. The apparatus includes a composite having a first protective component, a water storage component, and a drainage component provided below the first protective component, so as to allow for controlled flow of stormwater to the water storage component. The water storage component, first protective component and drainage component are provided in a single unit.

In embodiments, a method for managing stormwater runoff is described. The method includes assembling, as a single unit, a composite comprising a water storage component and a drainage component, the drainage component being provided at a position below the water storage component. The method further includes providing the composite on a new or previously urban surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows a diagram of a stormwater management apparatus according to an embodiment.

FIG. 1B shows a diagram of a drainage mat of the stormwater management apparatus according to an embodiment.

FIGS. 2A, 2B, 2C and 2D show diagrams of a stormwater management apparatus according to embodiments.

FIGS. 3A and 3B show diagrams of a stormwater management apparatus according to an embodiment.

FIG. 4 shows a diagram of a stormwater management apparatus according to embodiments.

FIGS. 5A, 5B and 5C shows a diagram of a stormwater management apparatus and its joining method according to embodiments.

FIG. 6 shows a diagram of a stormwater management apparatus according to an embodiment.

FIG. 7 shows a diagram of a stormwater management apparatus according to an embodiment.

FIG. 8 shows a diagram of a stormwater management apparatus according to an embodiment.

FIG. 9 shows a diagram of a stormwater management apparatus according to an embodiment.

FIG. 10 shows a diagram of a stormwater management apparatus according to an embodiment.

 DETAILED DESCRIPTION

In the following description, numerous details are set forth to provide an understanding of the present disclosure. However, it may be understood by those skilled in the art that the methods of the present disclosure may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.

At the outset, it should be noted that in the development of any such actual embodiment, numerous implementation-specific decisions may be made to achieve the developer's specific goals, such as compliance with system related and business related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. In addition, the composition used/disclosed herein can also comprise some components other than those cited. In the summary and this detailed description, each numerical value should be read once as modified by the term “about” (unless already expressly so modified), and then read again as not so modified unless otherwise indicated in context. The term about should be understood as any amount or range within 10% of the recited amount or range (for example, a range from about 1 to about 10 encompasses a range from 0.9 to 11). Also, in the summary and this detailed description, it should be understood that a range listed or described as being useful, suitable, or the like, is intended to include support for any conceivable sub-range within the range at least because every point within the range, including the end points, is to be considered as having been stated. For example, “a range of from 1 to 10” is to be read as indicating each possible number along the continuum between about 1 and about 10. Furthermore, one or more of the data points in the present examples may be combined together, or may be combined with one of the data points in the specification to create a range, and thus include each possible value or number within this range. Thus, (1) even if numerous specific data points within the range are explicitly identified, (2) even if reference is made to a few specific data points within the range, or (3) even when no data points within the range are explicitly identified, it is to be understood (i) that the inventors appreciate and understand that any conceivable data point within the range is to be considered to have been specified, and (ii) that the inventors possessed knowledge of the entire range, each conceivable sub-range within the range, and each conceivable point within the range. Furthermore, the subject matter of this application illustratively disclosed herein suitably may be practiced in the absence of any element(s) that are not specifically disclosed herein.

The term “urban surface,” as used herein, may refer to a rooftop, a roadside, a sidewalk side, or any surface that may be found in an urban setting.

FIG. 1A shows a stormwater control apparatus according to embodiments. FIG. 1A shows a composite 5 formed of water storage component 1 and a drainage component 2, which may be in the form of a drainage mat. The composite 5 is formed as a single unit, which can be thusly installed as a single entity. The components of the composite, be they the water storage component 1 and drainage component 2, or any other portions of the composite as discussed herein, may be joined together by any connecting means, including but not limited to ultrasonic connections, being loosely laid in pillow form, adhesive, heat bonding, or stitching. The use of a single unit component may allow for an improved installation, and the composite may be provided in a soft and pliable manner that does not indent or damage the roof membrane during install and in service. The composite may also be easily removed and replaced to allow, for example, for roof repairs, and the composite 5 may protect the roof membrane from UV exposure, which may increase its durability.

The water storage component 1, which may also be referred to as a fleece, may be a commercially available water retention fleece, such as XF 110 and/or XF 154 sold by Low and Bonar Inc. under the Xeroflor brand. XF 110 and XF 154 are needle-punch nonwovens having particular configurations, and include polyester and other content. Also, the water storage component may be in the form of recycled material or any material capable of providing a layer that can hold at least some amount of water for at least some amount of time above the drainage mat 2. Further, the water storage component 1 may include any high loft nonwoven material. The water storage component may be wholly or partially in the form of a mineral wool roll or mineral wool slab, as discussed with reference to other Figures, below.

The composite 5 including the water storage component 1 may have a water holding capacity of from about 20-150l/m2 (0.49-3.68 gal/sf) or from about 20-100l/m2 (0.49-2.45 gal/sf), or from about 20-75 l/m2 (0.49-1.84 gal/sf).

The water storage component 1 may have a high water retention to weight ratio. For example, the ratio of water retention to weight may be from about 70-97%, or about 80-95%, or from about 85-95%. One skilled in the art would recognize a water retention to weight ratio can be determined by a mass of water retained divided by the mass of the component (e.g., the water storage component 1) when fully saturated.

The water storage component 1 may have a thickness of about 0.2 to about 8, or about 1.25 to about 1.75, or about 1.5, inches. The thickness of the water storage component 1 may be at least 5 times more than, or at least 10 times more than, or at least 20 times more than the thickness of the drainage component 2.

Utilizing such a composite having the water storage component 1 and drainage component 2, there may be no open water to promote bacterial/algae growth, and mosquito breeding and foul smells are also avoidable.

The water storage component 1 may also act as a protective component, so as to protect the drainage component 2 from uncontrolled exposure to water. While in some embodiments, such as that in FIG. 1A, the water storage component acts as a protective component, other embodiments, described in detail below, utilize a water component and protective component separately.

In some embodiments, the drainage component 2 may be in the form of a commercially available drainage and filter mat, such as XF 108 sold by Low and Bonar Inc. under the Xeroflor brand. XF 108 and/or the drainage mat 2 may also have an entangled filament structure such as an entangled core that is comprised of thermally bonded polypropylene or any polymeric monofilaments. The filaments may be randomly entangled and formed in various patterns so as to provide a network of material forming the drainage component 2.

The drainage component may be a mat 2 may be formed of an elongate, indeterminate-length openwork mat (or web), of randomly convoluted polymeric filaments. The randomly convoluted polymeric filaments comprising mat 2 may be made of any thermoplastic material. In some embodiments, the thermoplastic material is able to withstand various temperatures. The thermoplastic material may be, for example, a polyester, polyolefin, or nylon. Exemplary materials for the thermoplastic material include polypropylene, nylon 6 (or polyamide 6), polylactic acid, polycaprolactone, polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polyethylene naphthalate, vectran, high density polyethylene, and blends or copolymers thereof.

The randomly convoluted polymeric filaments may be intersecting filaments that form a three-dimensional mat. That is, the filaments may intersect each other at one or multiple points along each respective filament and bonded to each other at intersecting points. The filaments may have a diameter of 300 to 1000 microns, or 650 to 750 microns, or 500 to 600 microns.

The weight of the filaments comprising the mat 2 may be between 8 and 30 ounces per square yard (osy), or between 15 and 25 osy.

The polymer structure of the mat 2 may be formed by extrusion of the thermoplastic material at a temperature above the melting point of the material into or onto a structure or mold having a patterned configuration. As shown in FIGS. 1A and 1B, the pattern may include a series of spaced three-dimensional structures 3.

For example, the mat 2 may have a patterned configuration of three-dimensional structures 3 including waffle, pyramids, cones, cylinders, cubes and the like. In some embodiments, the structures 3 of the mat 2 may comprise a grid-like structure comprised of truncated cones or pyramids. The structures 3 may form a grid-like pattern where each column of structures 3 is spaced from each other along a first axis when viewed top-down or bottom-up. In some embodiments, the three-dimensional structures 3 may be arranged in a plurality of columns with bottoms of the three-dimensional structures 3 spaced from each other as seen from a the bottom-up front view of the mat 2 as seen in FIG. 1B. Further, the structures 3 may have rows each spaced from each other when viewed alone a second axis perpendicular to the first axis when viewed top-down or bottom up. Thus, each structure 3 may be separated from adjacent structures 3 when viewed along both a first and second axis.

A drainage rate (e.g., a flow rate) afforded by the mat 2 may be from 2-10 gal/min/ft at a 0.05 gradient, or from 2-8 gal/min/ft, or from 2-6 gal/min/ft at the same gradient.

The mat 2 may also have an air gap provided so as to avoid hydrostatic pressure on the roof membrane or a comparable urban surface. A thickness of such an air gap may be from about 6-51 mm (0.25-2 inches), or about 6-38 mm (0.25-1.5 inches), or about 6-25 mm (0.25-1 inches).

By way of example, a contemplated process for producing the mat 2 is to utilize a method where continuous molten thermoplastic monofilaments are extruded onto a three-dimensional profiled support structure or into a mold in overlapping rows of irregular loops which are self-bonded or fused at random points of intersection without using any bonding agent or reinforcing inserts. However, bonding agents or inserts may also be used. Additionally, while the above-described configuration, shown as a configuration in FIG. 2A with a mat 2a may be used as a drainage mat 2, other embodiments utilizing, for example, a dimpled drain configuration or a reservoir drain configuration as the drainage mat 2 are within the scope of this disclosure.

FIG. 2B shows an example of a dimpled drain configuration 2b being used. The FIG. 2B configuration is otherwise consistent with that of FIG. 2A.

FIG. 2C shows an example of a reservoir drain configuration 2c being used. The FIG. 2C configuration is otherwise consistent with that of FIG. 2A.

FIG. 2D shows an example of a drain 2d that may be comprised of any one of or any combination of a mat with an entangled filament structure as described with respect to FIGS. 1A and/or 2A, a dimpled drain as in FIG. 2B, and a reservoir drain as in FIG. 2C.

The composite may be provided in roll or sheet form and installed onto a new or pre-existing roof in rows. The composite, and thus its constituent components, may have a flexibility sufficient to allow for its being provided in roll form.

Atop the uppermost component of the composite, which may be the water storage component, a filter fabric (described in further detail below), or one or more fleeces, may be a ballast layer (not shown in FIG. 1A, but shown in other Figures as described in more detail below). The ballast layer is included to provide weight on the composite so the composite is not moved or otherwise disengaged because of wind or other occurrences. The ballast layer will still allow for stormwater to reach the composite, and may regulate a flow of water to the composite. The ballast layer may be in the form of aggregates and may include particles, and can be landscape pavers (pervious or permeable) or tiles. The ballast layer may include engineered soil, and/or garden material. The ballast layer may be provided after the installation of the composite and thus may be additional to the composite, or may be integrated with the composite. Additionally or instead of a ballast layer, embodiments utilizing pavers that sit on pedestals, the pedestal provided adjacent to the composite 5, are conceived.

The composite 5 may be provided in roll form and installed onto a new or pre-existing roof in rows. The composite, and thus its constituent components, may have a flexibility sufficient to allow for its being provided in roll form.

FIGS. 3A and 3B show a stormwater control apparatus according to embodiments. FIGS. 3A and 3B show a composite 50 formed of water storage component 10, protective components 11a and 11b, and a drainage component 12 which may be in the form of a drainage mat. The feature of FIGS. 3A and 3B, except where otherwise described, may be considered to have the characteristics of the corresponding components described with reference to FIG. 1. Further, the additional features of FIGS. 3A-10 not discussed with reference to FIGS. 1 and 2, including at least the ballast component, aggregates, filter fabric, growing medium, plants and pre-vegetated mat, may also be included within the embodiments of FIGS. 1 and 2. A composite 50 is used to reference other stormwater composites shown in FIGS. 3-10 as well, and refer generally to the same type of stormwater composite, though their particular composition may be different as further described in the respective embodiments.

In one embodiment as shown in FIG. 3A, the apparatus includes a composite 50 including a second protective component in the form of top protective fleece 11a, water storage component 10, a first protective component in the form of bottom protective fleece 11b, and drainage component in the form of a drainage mat 12. The composite 50 is formed as a single unit, which can be thusly installed as a single entity. Further, in embodiments where only one of the fleeces (e.g., 11a only or 11b only) is present, the composite may still be formed as a single unit. The components of the composite, be they the water storage component 10 and drainage component 12, either or both of the fleeces 11a and 11b, or any other portions of the composite as discussed herein, may be joined together by any connecting means, including but not limited to ultrasonic connections, being loosely laid in pillow form, adhesive, heat bonding, or stitching.

FIG. 4 shows an exemplary multi-layer water storage component that also includes multiple protective components, similar to FIGS. 3A and 3B. The protective components may be in the form of protective fleeces or another larger protective layer. This component may have a water storage component 10 between two non-woven fleeces and/or filter fabrics 11a and 11b, whereby a water storage component, such as a mineral wool roll or slab, is between the two non-woven fleeces and/or filter fabrics. Below the lower fleece/filter fabric 11b is a drainage material 2, which can be any time of mat similar to those described with respect to FIGS. 1 and 2.

Referring to FIGS. 3A, 3B and 4, the top and bottom protective fleeces 11a and 11b may be commercially available retention fleeces, such as XF 110 and/or XF 154 sold by Low and Bonar Inc. under the Xeroflor brand. Also, the fleeces 11a and 11b may be in the form of recycled material or any material capable of providing a permeable barrier between the water storage component 10 and the drainage mat 12. Further, the top and bottom fleeces 11a and 11b may include any high loft nonwoven material.

In the embodiment shown in FIGS. 3A and 4, a water storage component 10 is provided between the top 11a and bottom 11b fleeces. While the inclusion of both a top 11a and bottom 11b fleece may be desirable in some embodiments, some embodiments may have only a top fleece 11a or only a bottom fleece 11b. Further, while FIGS. 3A and 4 provides for two fleeces (the top and bottom fleeces 11a and 11b), embodiments using only one fleece, or one fleece with multiple layers, or multiple fleeces each with multiple layers can be used.

In some embodiments such as that shown in FIG. 3B, the top fleece 11a may be in the form of a filter fabric, or any fabric able to provide a permeable protective layer, and the bottom fleece 11b may be in the form of recycled material or any material capable of providing a permeable barrier between the water storage component 10 and the drainage mat 12. While not shown in FIG. 1, the embodiment described in FIG. 1 may also include either or both fleeces in addition to the components described therein.

In some embodiments, the water storage component 10 may be in the form of a mineral wool roll or a mineral roll slab. The mineral wool roll or mineral wool slab may comprise a mineral wool, a recycled nonwoven pad and/or a superabsorbent polymer (SAP) in powder, pellet and/or fiber form. The SAP may be able to absorb, retain and slowly release an amount of water up to 500 times by weight. In some embodiments, the water storage component 1 or water storage component 10 mineral wool roll or mineral wool slab may be capable of holding 0.5 inches or more, or one inch or more, or two inches or more, water per 24 hours. In some embodiments, the water storage component 10 may have a density of about 40-250 kg/m3 (2.5-15.6 pcf), a thickness of about 5 mm to about 100 mm.

The drainage mat 12 may be substantially similar to the drainage mat 2 described with reference to FIG. 1A.

In some embodiments, the fleeces 11a and/or 11b and the water storage component 10 can be preassembled by sandwiching the water storage component 10 between layers of one of the fleeces, or between multiple fleeces (e.g., 11a and 11b), prior to placement on the roof. In some embodiments, the water storage component 10 is tightly sandwiched between the two fleeces 11a and 11b, thereby leaving substantially no space between the fleeces and the water storage component 10. In other embodiments, the water storage component 10 is more loosely provided between the fleeces 11a and 11b, or between one of the fleeces 11a and another component of the composite.

The protective fleece(s) 11a and/or 11b can be connected to the water storage component 10. The technology or medium used to connect the protective fleece(s) and water storage component may be, but is not limited to, ultrasonic connections, being loosely laid in pillow form, adhesive, heat bonding, or stitching. Configurations where the water storage component 10 is placed between two layers of fleece or between two fleeces but spacing exists between the water storage component and one or both of the layers or fleeces is also conceived. In some embodiments, ultrasonic connections or stitched side seams may be used to connect any of the components 10, 11a, 11b, 12 with or to each other.

FIGS. 5A-5C show an assembly of the stormwater composite. In FIG. 5A, the water storage component 1 is bonded to the drainage mat 2. Exemplary bonding material is shown with numeral 40. The bonding may occur using a direct thermal or adhesive, or a heat activated adhesive in between, for example, the water storage component 1 and drainage component 2.

In FIG. 5B, stitching 41 is applied to connect at least fleeces 11a, 10 and 11b together. While the stitching method is shown with respect to a multi-fleece configuration, multiple fleeces need not be necessary for stitching to be used between components of the stormwater composite.

In FIG. 5C, a loosely laid pillow configuration, represented by numeral 42, exists with respect to at least fleeces 11a, 10 and 11b. While the pillow method is shown with respect to a multi-fleece configuration, multiple fleeces need not be necessary for stitching to be used between components of the stormwater composite.

Sandwiching the water storage component 10 in some fashion between the top 11a and bottom 11b protective fleeces may advantageously allow for the integrity and handling of the mineral roll to be increased. The inclusion of the protective fleeces may particularly aid in handling and integrity when the fleeces and/or water storage component 10, which may be in the form of a mineral wool roll, are wet, as the mineral wool tends to be fragile when wet. Further, the bottom protective fleece 11b may allow for stormwater runoff that is percolated from the mineral wool roll to be slowed. The water storage component 10 may have different water holding qualities from the fleeces 11a and 11b. The water storage component 10 may have more, or less, water retention ability than one or both of the fleeces 11a and 11b.

The composite 50 as described above may be provided in roll or sheet form and installed onto a new or pre-existing roof in rows. The composite, and thus its constituent components, may have a flexibility sufficient to allow for its being provided in roll form. Each row may be sandwiched by a separate set of protective fleeces, or a single set of protective fleeces may sandwich all rows of the water storage component.

In some embodiments, the top fleece 11a may be provided with an extension, for example of 10 mm to 100 mm or more, so as to extend outward from the surface of the water storage component from which it covers. The extension may be along a plane parallel to the surface of the top fleece 11a and may extend beyond the remainder of the components of the composite 50. This extension allows for the top fleece 11a to extend over the abutting portion of an adjacent section of the composites 50 when installed in rows.

In some embodiments, a drainage component in the form of a drainage mat 12 may be placed below the water storage component 10 and/or below the bottom fleece 11b, thereby forming a composite of the protective fleeces 11a and 11b, water storage component 10 and drainage mat 12. The drainage mat 12 may be bonded or adhered to the bottom fleece 11b using heat bonding, or any adhesive process. The drainage mat 12 is provided to allow for runoff of excess stormwater, and may generally aid in water flow. The system generally may allow for a prevention of constant contact of a roof membrane or other urban surface membrane with stored water. The drainage mat 12 may be a three-dimensional, lightweight, and flexible composite material having a drainage core of looped polymeric filaments and optionally bonded to a nonwoven filter fabric.

The water storage component 10, which in some embodiments may be a mineral wool roll, slabs, cubes, or otherwise connected pieces, may, in concert with the protective fleece, retain a predetermined amount of stormwater. In some embodiments, the combination of the mineral wool roll and protective fleece can be designed to retain the first 25 mm or 1 inch of stormwater, or more, so as to comply with requirements of some municipalities.

Referring to FIG. 3A, in embodiments where the top protective fleece 11a is not already a filter fabric, the top protective fleece 11a may have on top of it a separate filter fabric 13, such as a nonwoven polypropylene landscape fabric. In such an embodiment, the top protective fleece 11a may be made of a same or similar material as the bottom protective fleece 11b. The filter fabric 13 may be provided so as to serve as a weed barrier and a filter to prevent dirt dust, or other unwanted accumulation in the composite, but still be permeable to water. This filter fabric 13 may, similar to the embodiment where the top protective fleece 11a is a filter fabric (such as a landscape fabric), be in the form of recycled material or any material capable of providing a permeable barrier between the water storage component 10 and the drainage mat 12, and/or include any high loft nonwoven material. Ultrasonic connections or stitched side seams may be used to connect any of the components 10, 11a, 11b, 12 to the filter fabric 13 as necessary, as may any other adhesive or connection process. The use of a filter fabric in the embodiment of FIG. 1, whereby the filter fabric is placed atop the water storage component 1, is also contemplated and within the scope of this disclosure. Further, embodiments using only fleeces 11a and 11b, but not a filter fabric 13 are within the scope of this disclosure.

Referring again to FIG. 2A3A in embodiments where the top protective fleece 11a is a filter fabric, the top protective fleece may have the same barrier and filter qualities as the filter fabric 13.

Referring again to FIGS. 3A and 3B, atop the filter fabric 13 or the first protective fleece 11a may be a ballast layer 14. The ballast layer 14 is included to provide weight on the composite so the composite is not moved or otherwise disengaged because of wind or other occurrences. The ballast layer will still allow for stormwater to reach the composite, and may regulate a flow of water to the composite. The ballast layer may be in the form of aggregates and may include particles, and can be landscape pervious, permeable or porous pavers or tiles. The ballast layer may include engineered soil, and/or garden material, and plant materials which may be plant plugs or pre-vegetated mats. This is described with further detail with respect to other Figures, later. The ballast layer 14 may be provided after the installation of the composite 50 and thus may be additional to the composite 50, or may be integrated with the composite 50. The use of a ballast layer in the embodiment of FIG. 1, whereby the filter fabric is placed atop the water storage component 1 or atop a fleece or filter fabric, is also contemplated and within the scope of this disclosure.

The following examples show some properties of an exemplary, nonlimiting stormwater management apparatus according to the above-described embodiments. Of note, XF 110, XF 154 and XF 108 have been previously described. RM 12/35, GRS MD, GRS 40, PP 100/40 and PP 100/100 are comprised of mineral and/or rockwool rolls or slabs, and XF 301 include a moss-sedum mat configuration.

Regarding Tables 1A and 1B. Table 1 A provides properties of a system using a combination of a top protective fleece of 300 g/m2, a mineral wool roll, a bottom protective fleece of 800 g/m2 and a drainage and filter mat. Table 1B provides properties of a system using a combination of a top protective fleece of 300 g/m2, a mineral wool roll, a bottom protective fleece of 300 g/m2 and a drainage and filter mat.

TABLE 1A SI Unit US Customary Unit System Build Up Thickness Dry Wt. Sat. Wt. Water ret. Thickness Dry Wt. Sat. Wt. Water ret. Product ID Description (mm) (kg/m2) (kg/m2) (l/m2) (inch) (lb/ft2) (lb/ft2) (inch) XF110 protective fleece 300 g/m2 2.0 0.30 3.13 2.83 0.08 0.06 0.64 0.111 RM 12/35 Grodan RM 12/25 35.0 1.50 19.50 18.00 1.38 0.31 3.99 0.709 XF154 retention fleece 800 g/m2 8.0 0.88 6.04 5.16 0.31 0.18 1.24 0.203 XF108 drainage and filter mat 15.0 0.40 0.80 0.40 0.59 0.08 0.16 0.016 Total 60.0 3.08 29.47 26.39 2.36 0.63 6.04 1.04

TABLE 1B SI Unit US Customary Unit System Build Up Thickness Dry Wt. Sat. Wt. Water ret. Thickness Dry Wt. Sat. Wt. Water ret. Product ID Description (mm) (kg/m2) (kg/m2) (l/m2) (inch) (lb/ft2) (lb/ft2) (inch) XF110 protective fleece 300 g/m2 2.0 0.30 3.13 2.83 0.08 0.06 0.64 0.111 GRS 40 Knauf Green Roll Standard 40 40.0 4.40 33.40 29.00 1.57 0.90 6.84 1.142 XF110 protective fleece 300 g/m2 2.0 0.30 3.13 2.83 0.08 0.06 0.64 0.111 XF108 drainage and filter mat 15.0 0.40 0.80 0.40 0.59 0.08 0.16 0.016 Total 59.0 5.40 40.46 35.06 2.32 1.11 8.29 1.38

Table 1A shows a water retention of 26.391/m2. Table 1B shows a water retention of 35.061/m2.

FIG. 6 shows a stormwater control composite according to another embodiment. A water storage component in the form of mineral wool slab 20 is provided between a top protective fleece 21a and bottom protective fleece 21b. These may be fabrics, or may be of a thicker material. In some embodiments, the mineral wool slab 20 is tightly sandwiched between the two fleeces similar to the embodiment described with respect to FIG. 1.

The mineral wool slab 20 may have a density and compressive strength higher as compared to the water storage component as a mineral wool roll 10 discussed above. The mineral wool slab 20 may be provided in slab form and installed onto a new or pre-existing roof in rows. Each row may be sandwiched by a separate set of protective fleeces, or a single set of protective fleeces may sandwich all rows of the mineral wool roll. The mineral wool slab 20 may have different water holding capacities from the fleeces 21a and 21b.

As shown in FIG. 6, atop the top fleece 21a may be a filter fabric 23, such as a nonwoven polypropylene landscape fabric. This fabric may be provided so as to serve as a weed barrier and a filter to prevent dirt accumulation in the composite. Additionally, similar to the embodiments relating to water storage component 10, the filter fabric 23 may be in addition to the top fleece 21a, or may instead be the top fleece 21a. Fleeces 21a and 21b may share similar characteristics to fleeces 11a and 11b as discussed previously.

Atop the filter fabric 23 and/or top fleece 21a be a ballast layer in the form of permeable or pervious pavers 24. These pavers may be permeable, can be snapped or connected together atop the filter fabric 23 and/or top fleece 21a. The density and strength of the mineral wool slab composite may allow for the pavers to be appropriately supported. During rainfall, the stormwater can go around or through the pavers and be captured in the composite below.

Tables 2A-2C show some properties of a stormwater management apparatus according to the above-described embodiment. Table 2A provides properties of a system using a combination of a top protective fleece of 300 g/m2, a mineral wool slab, a bottom protective fleece of 800 g/m2 and a drainage and filter mat. Table 2B provides properties of a system using a combination of a top protective fleece of 300 g/m2, a mineral wool slab a bottom protective fleece of 300 g/m2 and a drainage and filter mat. Table 2C provides properties of a system using a combination of a top protective fleece of 300 g/m2, a mineral wool slab, a bottom protective fleece of 300 g/m2 and a drainage and filter mat.

TABLE 2A SI Unit Imperial Unit System Build Up Thickness Dry Wt. Sat. Wt. Water ret. Thickness Dry Wt. Sat. Wt. Water ret. Product ID Description (mm) (kg/m2) (kg/m2) (l/m2) (inch) (lb/ft2) (lb/ft2) (inch) XF110 protective fleece 300 g/m2 2.0 0.30 3.13 2.83 0.08 0.06 0.64 0.111 GRS MD Knauf Green Roll Standard MD 26.0 3.30 20.30 17.00 1.02 0.68 4.16 0.669 XF154 retention fleece 800 g/m2 8.0 0.88 6.04 5.16 0.31 0.18 1.24 0.203 XF108 drainage and filter mat 15.0 0.40 0.80 0.40 0.59 0.08 0.16 0.016 Total 51.0 4.88 30.27 25.39 2.01 1.00 6.20 1.00

TABLE 2B SI Unit US Customary Unit System Build Up Thickness Dry Wt. Sat. Wt. Water ret. Thickness DryWt. Sat. Wt. Water ret. Product ID Description (mm) (kg/m2) (kg/m2) (l/m2) (inch) (lb/ft2) (lb/ft2) (inch) XF110 protective fleece 300 g/m2 2.0 0.30 3.13 2.83 0.08 0.06 0.64 0.111 PP 100/40 Grodan PP 100/40 40.0 6.80 38.80 32.00 1.57 1.39 7.95 1.260 XF110 protective fleece 300 g/m2 2.0 0.30 3.13 2.83 0.08 0.06 0.64 0.111 XF108 drainage and filter mat 15.0 0.40 0.80 0.40 0.59 0.08 0.16 0.016 Total 59.0 7.80 45.86 38.06 2.32 1.60 9.39 1.50

TABLE 2C SI Unit US Customary Unit System Build Up Thickness Dry Wt. Sat. Wt. Water ret. Thickness Dry Wt. Sat. Wt. Water ret. Product ID Description (mm) (kg/m2) (kg/m2) (l/m2) (inch) (lb/ft2) (lb/ft2) (inch) XF110 protective fleece 300 g/m2 2.0 0.30 3.13 2.83 0.08 0.06 0.64 0.111 PP100/100 Grodan PP 100/100 100.0 17.00 97.00 80.00 3.94 3.48 19.87 3.150 XF110 protective fleece 300 g/m2 2.0 0.30 3.13 2.83 0.08 0.06 0.64 0.111 XF108 drainage and filter mat 15.0 0.40 0.80 0.40 0.59 0.08 0.16 0.016 Total 119.0 18.00 104.06 86.06 4.69 3.69 21.31 3.39

Table 2A shows a water retention of 25.391/m2. Table 2B shows a water retention of 38.061/m2. Table 2C shows a water retention of 86.061/m2.

FIG. 7 shows a configuration similar to FIG. 6, whereby an additional, optionally larger retention fleece 21c is shown below the component 20. In this embodiment and in the embodiment of FIG. 6, the component 20 may be any water storage component as described with reference to FIGS. 1-3, and the use of mineral wool or slabs is merely exemplary. The ballast layer 24 may be made of aggregates including but not limited to permeable or pervious pavers.

FIG. 8 shows an embodiment similar to the embodiment shown in FIGS. 2A and 2B, but instead of a ballast layer 14, an additional mat 34 is provided. The additional mat can be a commercially available pre-vegetated mat consisting of mature, established moss-sedum plants growing on a thin layer of growing medium supported by a vegetation carrier. Such a mat used in combination with the composite of mineral wool roll 30, fleeces 31a and 31b, and drainage mat 32, may allow for increased water retention of green roof systems while keeping the weight low. Fleeces 31a and 31b may share similar characteristics to fleeces 11a and 11b, and/or 21a and 21b, as discussed previously. Tables 3A and 3B shows water retention for a composite similar to those shown in Tables 1A and 1B, respectively, but the apparatus further includes a moss-sedum mat with a fleece. Also, the embodiment of FIG. 3 does not include a filter fabric as in the embodiment of FIG. 3A or 3B, but a filter fabric can also be included in this configuration, either as a top fleece 31a or in addition to a top fleece 31a. Further, a ballast layer such as that in various other embodiments may optionally be included.

FIG. 9 shows an embodiment similar to FIG. 8, but there exists optional aggregates 34a and a pre-vegetated mat 34b. The aggregates may be provided atop the pre-vegetated mat. Both may be atop a water storage component 30 (which may be similar to water storage components 1, 10 and 20 in other embodiments) and a mat 32 (which may be similar to mats 2, 12 and 22 in other embodiments). FIG. 9 does not include any retention fleeces or fabrics as in FIG. 7 or 8, but they can be optionally included.

FIG. 10 includes a configuration similar to that of FIG. 9, but further includes vegetation 47 atop a growing medium 46. The growing medium is any medium that can allow for such vegetation to grow. The vegetation 47 may include, for example, vegetables, perennials or grasses. The growing medium 46 is placed atop the stormwater composite which will include a mat 42 (similar to the mats 2, 12, 22 and 32 described in other embodiments) and a water storage component 40 (similar to components 1, 10, 20 and 30 described in other embodiments). There may also exist one or more filter fabrics 43 within the stormwater composite system (e.g., either above the water storage component 40, as shown, and/or below the water storage component 40).

TABLE 3A SI Unit US Customary Unit System Build Up Thickness Dry Wt. Sat. Wt. Water ret. Thickness Dry Wt. Sat. Wt. Water ret. Product ID Description (mm) (kg/m2) (kg/m2) (l/m2) (inch) (lb/ft2) (lb/ft2) (inch) XF301 moss-sedum mat with fleece 30.0 19.70 37.00 17.30 1.18 4.03 7.58 0.681 XF110 protective fleece 300 g/m2 2.0 0.30 3.13 2.83 0.08 0.06 0.64 0.111 RM 12/35 Grodan RM 12/25 35.0 1.50 19.50 18.00 1.38 0.31 3.99 0.709 XF154 retention fleece 800 g/m2 8.0 0.88 6.04 5.16 0.31 0.18 1.24 0.203 XF108 drainage and filter mat 15.0 0.40 0.80 0.40 0.59 0.08 0.16 0.016 Total 90.0 22.78 66.47 43.69 3.54 4.67 13.61 1.72

TABLE 3B SI Unit US Customary Unit System Build Up Thickness Dry Wt. Sat. Wt. Water ret. Thickness Dry Wt. Sat. Wt. Water ret. Product ID Description (mm) (kg/m2) (kg/m2) (l/m2) (inch) (lb/ft2) (lb/ft2) (inch) XF301 moss-sedum mat with fleece 30.0 19.70 37.00 17.30 1.18 4.03 7.58 0.681 XF110 protective fleece 300 g/m2 2.0 0.30 3.13 2.83 0.08 0.06 0.64 0.111 GRS 40 Knauf Green Roll Standard 40 40.0 4.40 33.40 29.00 1.57 0.90 6.84 1.142 XF110 protective fleece 300 g/m2 2.0 0.30 3.13 2.83 0.08 0.06 0.64 0.111 XF108 drainage and filter mat 15.0 0.40 0.80 0.40 0.59 0.08 0.16 0.016 Total 89.0 25.10 77.46 52.36 3.50 5.14 15.87 2.06

The composite of the protective fleeces 31a and 31b and mineral wool roll 30 allow for a green roof (a roof including the pre-vegetated mat) to achieve a desirable water retention level using growing media at a fraction of the loading required by traditional green roofs.

An optional additional component to the composites described with respect to FIGS. 1-10 is a super absorbent polymer (SAP). A super absorbent polymer is a material that absorbs, retains and slowly releases water up to 500 times by weight. Hot-melt SAP adhesives can be used with respect to the composites described herein, either to bond or join composite layers of the stormwater management apparatus together, or as a low density permeable coating. The SAP may be provided within a layer of the composite, above the drainage component. The SAP can serve to chemically bond layers of the stormwater management device together, and provide its own absorbent properties. If used as a permeable coating, the SAP could act as a self-regulating valve within the apparatus, so as to regulate water flow as the SAP swells and shrinks with retained water. Further, the SAP can be used in addition to, or in place of, the water storage components described in the embodiments of FIGS. 1A-10.

Additionally or alternatively, a stormwater management structure may include a reflective top portion so as to reduce solar heat gain and reduce energy use. This reflective top portion may include any of a nonwoven portion, a water permeable coating, a perforated membrane, perforated metal, permeable cement based pavers, aggregate pavers, or loose laid ballast. The coatings or fabrics may be thermochromic to reflect heat or dry out water retention. Under the top portion would be a water retention layer, such as a mineral wool portion similar to portions 10 or 20 described above, and/or a specialty nonwoven or cuspated cup structure. An insulation layer may exist and improve upon the insulation value of the new or existing roof to which this structure is to be included upon. Under the mineral wool portion and/or any insulation layer, a drain (or drain layer) may be included so as to allow excess water to be drained once the water holding capacity has been exceeded. This may be similar to the drain 12 or 22 as described above, or any other serviceable draining device. The water retention layer may be sufficient to allow for evaporation so as to dry out between precipitation events, and nonwovens can be further included so as to further control water runoff.

The composite 50 described herein may also advantageously provide for sound dampening qualities with reference to the structure on which the composite is placed.

Although the preceding description has been described herein with reference to particular means, materials and embodiments, it is not intended to be limited to the particulars disclosed herein; rather, it extends to all functionally equivalent structures, methods and uses, such are within the scope of the appended claims.

Claims

1. A stormwater management apparatus, comprising:

a composite comprising: a water storage component; and a drainage component provided below the water storage component, so as to allow for controlled flow of stormwater from the water storage component to the drainage component,
wherein the water storage component and drainage component are provided in a single unit.

2. The stormwater management apparatus according to claim 1, wherein the water storage component has a water retention capacity of about 0.49 to about 3.68 gal/sf.

3. The stormwater management apparatus according to claim 1, wherein the drainage component has a drainage rate of about 2-10 gal/min/ft at a 0.05 gradient.

4. The stormwater management apparatus according to claim 1, wherein the drainage component has a thickness of about 0.25 to about 2 inches.

5. The stormwater management apparatus according to claim 1, wherein the water storage component is a retention fleece made of a composite material.

6. The stormwater management apparatus according to claim 1, further comprising a protective component.

7. The stormwater management apparatus according to claim 6, wherein the protective component is provided between the water storage component and the drainage component when in use, and/or above the water storage component when in use.

8. The stormwater management apparatus according to claim 6, wherein the protective component is a filter fabric.

9. The stormwater management apparatus according to claim 1, wherein the water storage component is a mineral wool roll.

10. The stormwater management apparatus according to claim 1, further comprising a ballast component provided atop the water storage component.

11. A stormwater management apparatus, comprising:

a composite comprising: a first protective component; a water storage component; and a drainage component provided below the first protective component, so as to allow for controlled flow of stormwater to the water storage component,
wherein the water storage component, first protective component and drainage component are provided in a single unit.

12. The stormwater management apparatus according to claim 11, further comprising a second protective component, the first protective component provided between the water storage component and the drainage component when in use, the second protective component provided above the water storage component when in use.

13. The stormwater management apparatus according to claim 12, wherein the water storage component is sandwiched between the first and second protective components.

14. The stormwater management apparatus according to claim 12, wherein the second protective component is a water permeable landscape fabric.

15. The stormwater management apparatus according to claim 12, wherein the water storage component is a mineral wool.

16. The stormwater management apparatus according to claim 12, further comprising an additional mat provided above the second protective component.

17. The stormwater management apparatus according to claim 11, further comprising a super absorbent polymer.

18. The stormwater management apparatus according to claim 1, wherein the drainage mat comprises an entangled core that is comprised of thermally bonded polymeric monofilaments.

19. A method for managing stormwater runoff, comprising:

assembling a composite, as a single unit comprising a water storage component and a drainage component, the drainage component being provided at a position below the water storage component; and
providing the composite in a unitary manner on a new or previously installed urban surface.

20. The method for managing stormwater runoff according to claim 20, further comprising:

providing a ballast component at a position above the water storage component and drainage component composite, the ballast component disposed so as to allow for controlled flow of stormwater to the composite.
Patent History
Publication number: 20200095770
Type: Application
Filed: Sep 17, 2019
Publication Date: Mar 26, 2020
Applicants: LOW & BONAR INC. (CANDLER, NC), BONAR XEROFLOR GMBH (ERLENBACH AM MAIN)
Inventors: Lori HASCHER (Candler, NC), Karen Ka Yan LIU (Vancouver), Allan WINGFIELD (Candler, NC)
Application Number: 16/572,667
Classifications
International Classification: E04D 13/04 (20060101); E04D 11/00 (20060101);