Abstract:
Methods for protecting a ground surface from exposure to material that may be spilled from or leak from one or more containers, which includes setting up a portable spill containment system that includes at least one grate for supporting the one or more containers. The grate includes a plurality of drain holes. The portable spill containment system includes a flexible bag configured to contain spills or leakage from the one or more containers that pass through the drain holes of the grate. In one embodiment, the portable spill containment system includes a plurality of pedestals that support the at least one grate. In another embodiment, the portable spill containment system includes an interconnected grid structure formed of separate and distinct spaced apart beams.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 14/380,357, filed Aug. 21, 2014, now U.S. Pat. No. 9,150,350 B2, which is a U.S. National Stage of PCT/US2013/027026, filed Feb. 21, 2013, and claims priority to U.S. Provisional App. Ser. No. 61/601,246, filed Feb. 21, 2012. 
    
    
     BACKGROUND OF THE INVENTION 
     Field of Invention 
     The present invention relates to portable spill containment systems. 
     Description of Related Art 
     Drums or containers are commonly used to store solids or fluids. These drums or containers can sometimes leak or spill their contents during storage or use. It is desirable to contain such spilled or leaked contents to reduce the risk of damage or injury that such contents could cause. 
     Spill containment assemblies such as disclosed in U.S. Pat. Nos. 7,234,608 and 7,621,422, both of which are owned by the assignee of the present application, can be used to support drums or containers on grates above a flexible containment bag. Such filled containment assemblies more than adequately meet the requirements for basic spill containment. However, additional improvements and features are disclosed herein. 
     BRIEF SUMMARY OF THE INVENTION 
     According to one aspect, a portable spill containment system according to the invention includes at least one grate that supports a container. The grate defines a plurality of drain holes. The spill containment system also includes a flexible bag that contains leakage from the container that passes through the drain holes of the grate. The portable spill containment system also includes a plurality of pedestals that support the at least one grate. The pedestals each include a top wall with a primarily planer face that faces the grate. The pedestals each include a plurality of primary projections that extend from the planer face of the top wall toward the grate. 
     According to another aspect, a portable spill containment system includes at least one grate that supports a container. The grate defines a plurality of drain holes. The portable spill containment system also includes a flexible bag that defines an interior to contain leakage from the container that passes through the drain holes of the grate. The flexible bag includes a bag bottom and a bag sidewall. The bag bottom and the bag sidewall each include an interior surface that faces the grate and an exterior surface that is opposite the respective interior surface. The portable spill containment system also includes a plurality of first beams that are spaced from and oriented parallel to one another. The first beams each include a first beam top surfaces that faces the grate and a first beam bottom surface that is opposite the first beam top surface. The portable spill containment system also includes a plurality of second beams being spaced from one another and crossing the plurality of first beams. The second beams each include a second beam top surface that faces the grate and a second beam bottom surface that is opposite the second beam top surface. The first beams and the second beams are disposed within the flexible bag so that at least one of the first beam top surfaces and the second beam top surfaces contacts the grate and at least of the first beam surfaces and the second beam bottom surfaces contacts the interior surface of the bag bottom of the flexible bag. 
     According to another aspect, a portable spill containment system includes at least one grate that supports a container. The grate defines a plurality of drain holes. The portable spill containment system also includes a plurality of pedestals that support the at least one grate. The pedestals each include a top wall with a primarily planer face that faces the grate. The pedestals each include a plurality of primary projections that extend from the planer face of the top wall toward the grate. The portable spill containment system also includes a flexible bag that receives the plurality of pedestals and contains leakage from the container that passes through the drain holes of the grate. The flexible bag includes an interior surface that faces the plurality of pedestals and an exterior surface that is opposite the interior surface. The portable spill containment system also includes a carry handle that is attached to the exterior surface of the flexible bag at a plurality of locations so as to define a loop. 
     According to another aspect, a portable spill containment system includes at least one grate that supports a container. The grate defines a plurality of drain holes. The portable spill containment system also includes a flexible bag that contains leakage from the container that passes through the drain holes of the grate. The portable spill containment system also includes a plurality of pedestals that support the at least one grate. The pedestals each include a top wall with a primarily planar face that faces the grate. The planar face includes at least one indentation. The grate includes at least one projection that downwardly extends toward the plurality of pedestals so as to be received by the at least one indentation. 
     The foregoing and other features of the invention are hereinafter more fully described and particularly pointed out in the claims, the following description setting forth in detail certain illustrative embodiments of the invention, these being indicative, however, of but a few of the various ways in which the principles of the present invention may be employed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a portable spill containment system. 
         FIG. 2  is a partial perspective view of  FIG. 1  with a portion of a grate removed. 
         FIG. 3  is a partial perspective view of  FIG. 1  with a portion of a flexible bag removed. 
         FIG. 4  is a partial perspective view of an alternative portable spill containment system. 
         FIG. 5  is a partial perspective view of composite pedestals shown in  FIG. 4 . 
         FIG. 6  is a partial perspective view of an alternative portable spill containment system. 
         FIG. 7  is an exploded partial perspective view of an alternative portable spill containment system. 
         FIG. 8  is a partial perspective view of a post bracket. 
         FIG. 9  is a sectional view of  FIG. 8 . 
         FIG. 10  is a plan view of  FIG. 8 . 
         FIG. 11  is a partial sectional view of an alternative post bracket. 
         FIG. 12  is a plan view of  FIG. 11 . 
         FIG. 13  is an exploded partial perspective view of an alternative portable containment system. 
         FIG. 14  is a partial sectional view of  FIG. 13 . 
         FIG. 15  is an exploded partial perspective view of  FIG. 13 . 
         FIG. 16  is a partial sectional view of  FIG. 13 . 
         FIG. 17  is a perspective view of an alternative portable containment system. 
         FIG. 18  is a perspective view of an alternative portable containment system. 
         FIG. 19  is a perspective view of an alternative portable spill containment system. 
     
    
    
     It should be understood that the descriptions and drawings herein are merely illustrative and that various modifications and changes can be made in the structures disclosed without departing from the present disclosure. In general, the figures are not to scale. It will be appreciated that the various identified components of the exemplary portable spill containment system disclosed herein are merely terms of art that may vary from one manufacturer to another and should not be deemed to limit the present disclosure. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings, wherein like numerals refer to like parts throughout the several views,  FIG. 1  illustrates a portable containment system  30 . The portable containment system  30  includes a flexible bag  32 , a plurality of pedestals  34 , and at least one grate  36 . As illustrated, the grate  36  supports a container  38 . Further, a railing  42  can be attached to the pedestals  34 . 
     With reference to  FIGS. 1-3 and 7 , the flexible bag  32  is formed of a flexible fabric or sheet that defines an integral fluid-tight or leak-proof structure. Initially, it is noted that the term ‘leakage’ could include solids or liquids. The flexible bag  32  includes a bag interior  44  that is defined by the bag sidewall  46 . The bag sidewall  46  includes a bag sidewall interior surface  48  and a bag sidewall exterior surface  52 , which is opposite the interior surface  48 . The flexible bag  32  contains any leakage that may occur from the container  38  that has passed through the grate  36 . 
     As illustrated, the flexible bag  32  also includes a bag bottom  54  that is opposite the grate  36 . For reference, the bag sidewall  46  defines an opening that receives the grate  36 . The bag bottom  54  includes a bag bottom interior surface  56  and bag bottom exterior surface  58 , with the bag bottom exterior surface  58  being opposite the bag bottom interior surface  56 . As illustrated, the bag  32  receives the plurality of pedestals  34  and contains leakage from the container  38 . The interior surfaces  48 ,  56  of the flexible bag  32  face the plurality of pedestals  34 . 
     With the continued reference to  FIGS. 1-3 , the grate  36 , which could also be referred to as a support deck, includes an upper grate surface  62  and a lower grate surface  64  and is of a generally rectangular shape. The grate  36  can be made from injection-molded or rotationally molded plastic or structured foam. The lower grate surface  64  is opposite the upper grate surface  62 . The grate  36  also includes a side grate surface  66  that faces the bag sidewall  46 . The grate  36  also defines a plurality of drain holes  68  that allow leakage from the container  38  to pass therethrough for collection in the bag  32 . Further, the grate  36  serves to support the container  38 . While illustrated as being a plurality of grates, it will be appreciated that the grate  36  could be a single grate or a plurality of grates. 
     With particular attention to  FIGS. 2-3 and 7 , the pedestal  34  is shown. The pedestal  34  includes a pedestal top wall  72  that has a generally planar face that faces toward the grate  36 . The planar face allows for a stable interface between the pedestals  34  and the grate  36 . The pedestals  34  are hollow, which allows them to be stacked on atop the other in nested fashion, much like disposable drinking cups (open end down). This allows for the pedestals  34  to be shipped and stored in a compact condition. The pedestal wall  74  can define a plurality of grooves  76  that extend in a generally vertical direction. The grooves  76  increase the strength of the pedestals  34  and also allow air to enter between the pedestals  34  when they are being separated from each other (i.e., un-nested), making separation easier 
     As shown in  FIGS. 2-3 , the pedestals  34  are single-piece, unitary construction, which can be made from injection-molded or rotationally molded plastic or structured foam. The pedestals  34  may reduce in cross-sectional size as they extend from the bag bottom  54  toward the grate  36  so as to have a tapered shape. This tapered shape allows a wide base to increase stability with a smaller top to reduce the number of drain holes  68  that are obstructed by the pedestal  34 . It will be appreciated that additional pedestals could be used to support the grate  36  at positions other than the perimeter (i.e., under the center of the grate). The pedestals  34  illustrated in  FIGS. 1-3 and 7  are single-piece, unitary pedestals. 
     The pedestals  34  include a plurality of primary projections  78  that extend from the planer face of the top wall  72  toward the grate  36  so as to be received alongside the grate  36 . As illustrated, the primary projections  78  have a circular cross-section. However, it will be appreciated that other shapes are contemplated. The pedestals  34  can also include a plurality of secondary projections  82  that extend from the planer face of the top wall  72  toward the grate  36 . Although the secondary projections  82  are shown as having a circular cross-section, it will be appreciated that other shapes are possible. Specifically, any shape that allows the secondary projections  82  to be received in the drain hole  68  of the grate  36  is possible. As illustrated, the primary projections  78  are disposed around a perimeter of the top wall  72  so as to at least partially surround the secondary projections  82 . This arrangement helps to keep the grate  36  secured to the pedestal  34 . 
     Further, the secondary projections  82  define a secondary projection length as they extend from the top wall  72  toward the grate  36  just as the primary projections  78  define a primary projection length as they extend from the top wall  72  toward the grate  36 . As illustrated, the primary projection length is greater than the secondary projection length. This difference in projection length between the primary projections  78  and the secondary projections  82  allows for the grate  36  to be indexed to the pedestal  34  with the primary projections  78  while still providing positive engagement between the grate  34  and the secondary projections  82 . 
     It will be appreciated that the primary and secondary projections  78 ,  82  described hereinabove could be part of the grate  36  instead of the pedestals  34 . Specifically, alternate projections could downwardly extend from the grate  36  toward the pedestals  34  so as to provide similar engagement between the grate  36  and the pedestals  36  as previously described. It will also be appreciated that if alternate projections extending from the grate were utilized, that the pedestals could include at least one bore or indentation provided in the top wall to receive the respective projections. Further, it will be understood that a combination of projections extending from the grate and projections extending from the pedestal could simultaneously be employed without departing from the scope of the invention. 
     With reference to  FIGS. 1-2 , a plurality of posts  84  are shown. The posts  84  each include a first end  86  and a second end  88 , with the second end  88  being opposite the first end  86 . The plurality of posts  84  are joined to one another by a connecting rail  92  that attaches near the first end  86  of each of the posts  84 . Further, the posts  84  can be attached to the pedestals  34  at the second end  88  of the respective posts  84 . As such, the second end  88  of the respective post  84  can receive at least a portion of the primary projection  78  of the pedestal  34 . Therefore, the posts  84  can be mounted to the pedestal  34  without the use of additional hardware, thereby minimizing cost and simplifying assembly of the system. 
     With reference to  FIGS. 4-5 , an alternative containment system  90  with a a composite pedestal  94  is shown. The composite pedestal  94  can be made of the same materials as the pedestal  34 . Further, the composite pedestal  94  can also be hollow. The composite pedestal  94  can include an upper pedestal member  96  with a sidewall  98  and a top wall  102 . The composite pedestal  94  can also include a lower pedestal member  104  with a sidewall  106  and a top wall  108 . 
     The lower pedestal member  104  can include a raised rim  112 . This raised rim  112  can be used to prevent lateral disengagement between the upper pedestal member  96  and the lower pedestal member  104 . The lower pedestal member  104  can also include a base ring  114 . This base ring increases a general footprint of the pedestal  94  to increase stability while being received with the bag  32 . 
     As illustrated, the lower pedestal member  104  can also include a bead  116  and the upper pedestal member  96  can include a column  118 . The bead  116  and the column  118  cooperate to assist when the respective pedestal members  96 ,  104  are respectively nested, similar in function to the groove  76 . As shown, a block  122  may be used as an interface between the grate  36  and the composite pedestal  94 . The block  122  may optionally be used to adjust an overall height of the grate  36 . As shown in  FIG. 5 , the composite pedestal  94  includes primary projections  78  and secondary projections  82  as like the pedestal  34 . 
     The composite pedestal  94  allows for customization. Specifically, depending upon the particular needs, the end user could use only upper pedestal member  96  or the lower pedestal member  104  to support the grate  36 . Alternatively, the end user could use both the upper pedestal member  96  and the lower pedestal member  104  to form taller pedestal structures. Thus, for small volume containment needs or in instances when the grate  36  is going to be used to store a drum or container in a workstation configuration, a shorter single pedestal member could be used. However, in instances when a pallet of drums was going to be stored and the volume of potentially leakable materials is greater, taller multi-component pedestals could be used. 
     As illustrated in  FIG. 5 , the bag  32  can include a pocket  124  that receives the primary projection  78  so as to attach the bag  32  to the pedestal  34 ,  94 . Specifically, at least one of the primary projections  78  can at least be partially inserted through the pocket  124 . The pocket  124  may be made of the same or similar materials as the bag  32 . Alternatively, the pocket  124  may be made of other materials that provide sufficient strength to connect the bag  32  to the pedestal  34 . Further, the pocket  124  may be integral to the bag  32  or a separate component. 
     With reference to  FIG. 6 , an alternate containment system  120  is shown. The bag  32  can include a sidewall flap  126 . The sidewall flap  126  at least partially extends onto the upper grate surface  62  of the grate  36 . The sidewall flap  126  may be of the same material and construction as the bag sidewall  46 . The sidewall flap  126  may be affixed to the grate  36  with adhesive tape  128 . This tape  128  may be used solely to attach the bag  32  to the pedestal  34 ,  94  or in addition to other attachment methods. 
     With reference to  FIG. 7 , an alternate containment system  129  is shown. The alternate containment system  129  utilizes the bag  32  and pedestal  34  to contain any leakage that has passed through the drain holes  68  of the grate  36 . However, the alternate containment system  129  also includes a mounting member  130 . The mounting member  130  is disposed between the pedestal  34  and the grate  36  to ensure that the bag sidewall  46  of the bag  32  remains sufficiently vertical so as provide an adequate volume for capturing the leakage. As illustrated, the mounting member  130  includes mounting holes  131  that receive the primary projections  78 . The mounting member  130  may be integral to the bag  32  or may be a separate component that is connected to the bag  32 . As such, the mounting member  130  may be made of any material that provides sufficient strength to retain the bag sidewall  46  in a generally upright position. Because the mounting member  130  is disposed between the pedestal  34  and the grate  36 , the mounting member  130  is exposed to downward force due to the weight of the container  38  (i.e., a compressive force between the pedestal  34  and the grate  36 ). As such, the connection strength between the bag  32  and the pedestal  34  improves as the weight of the container  38  on the grate  36  is increased. 
     With reference to  FIGS. 8-12 , post brackets are shown. The post brackets can be used to mount the post  84  to the grate  36 . The post brackets can be used in addition to or in place of mounting the post  84  to the primary projections  78 . Further, the post brackets can be made of any number of materials that provide sufficient strength and rigidity to support the post  84  as will be described in more detail hereinafter. 
     With reference to  FIGS. 8-10 , a clamp  132  is used as a post bracket. The clamp  132  includes an upper wall  134 , a lower wall  136 , and a connecting wall  138 . The upper wall  134  defines a posthole  142 . The grate  36  is disposed between the upper wall  134  and the lower wall  136 . Because of the shape of the clamp  132 , the clamp  132  can be securely connected to the grate  36 , while still permitting removal of the clamp  132  from the grate  36  when desired. 
     In particular, the posthole  142  receives the post  84  to allow for easy attachment of the post  84  to the grate  36 . Specifically, the first end  86  of the post  84  is vertically spaced from the grate  36  a distance that is greater than a vertical distance between the second end  88  of the post  84  and the grate  36 . The bracket can further include a retention member  144  that extends from the upper wall  134  toward the lower wall  136  so as to be received at least one of the drain holes  68 . The retention member  144  can have a square cross-sectional shape. This shape complements the shape of the drain hole  68  for sufficient engagement. The connecting wall  138  joins the upper wall  134  and the lower wall  136  so that the post  84  is disposed between the connecting wall  138  and the grate  36 , thereby ensuring a sturdy connection. 
     With reference to  FIGS. 11-12 , an alternate bracket is shown as a clip  146 . The clip  146  can include an upper wall  148  and a lower wall  152 . A partition wall  154  joins the upper wall  148  and the lower wall  152  together so that the partition wall  154  is disposed between the post  84  and the grate  36 . The upper wall  148  can also include a post aperture  156  for receipt of the post  84 . Further still, a post boss  158  can extend from the lower wall  152  toward the upper wall  148  so as to be in registry with the post aperture  156  for engagement with the second end of the post  84 . The post boss  158  provides additional stability to the connection between the post  84  and the clip  146 . The clip  146  can also include a retention projection  162  with an X-shaped cross-section. The retention projection  162  extends from the upper wall  148  toward the lower wall  152  and is received in the drain holes  68  of the grate  36 . The X-shaped cross-section of the retention projection  162  helps to minimize weight and material cost for the clip  146  while still providing sufficient engagement between the clip  146  and the grate  36 . 
     With reference to  FIGS. 13-16 , an alternate containment system  164  is shown. The containment system  164  can include a first beam  166  and a second beam  168 . The beams  166 ,  168  can have a generally rectangular shape and be made of any number of materials. It is envisioned that the beams  166 ,  168  be constructed of materials that are chemically inert and lightweight. However, other materials are possible and contemplated. The first beams  166  are spaced from and oriented parallel to one another. Further, the first beams  166  each include a first beam top surface  172  that faces the grate  36  and a first beam bottom surface  174  that is opposite the first beam top surface  172 . 
     The second beams  168  are spaced from one another. As illustrated, the second beams  168  are oriented perpendicular to the plurality of first beams  166 . However, it will be understood that the second beams  168  could be oriented to the plurality of first beams  168  in alternative layouts. The second beams  168  can each include a second beam top surface  176  that faces the grate  36  and a second beam bottom surface  178  that is opposite the second beam top surface  176 . The first beams  166  and the second beams  168  are disposed within the flexible bag  32  so that at least one of the first beam top surfaces  172  and the second beam top surfaces  176  contacts the grate  36  and at least one of the first beam bottom surfaces  174  and the second beam bottom surfaces  178  contacts the interior surface of the bag bottom  54  of the bag  32 . The first beams  166  and the second beams  168  can include beam fingers  182 ,  184 , respectively. It will be appreciated that the first and second beams  166 ,  168  could be spaced from one another greater than is illustrated so as to create a large void in a center of the assembly so as to create a picture frame type support. As the number of beams  166 ,  168  is reduced, the storage capacity of the bag  32  is increased. 
     As shown in  FIG. 14 , the flexible bag  34  may include a plurality of yokes  186  that extend toward the interior of the flexible bag  32 . The yokes  186  may be made of the same or similar material as the bag  32 . Alternatively, the yokes  186  may be made of any other material while provides sufficient strength to hold the bag  32  to the beams  166 ,  168  when the bag  32  is full of leaked material. The fingers  182 ,  184  can removably engage the yokes  186  of the bag  32  to attach the bag  32  to the beams  166 ,  168 . 
     With reference to  FIG. 15 , the first beam  166  and the second beam  168  are shown in an exploded view. The first beam  166  can include a joining channel  188  and the second beam  168  can include a joining channel  192 . The joining channels  188 ,  192  cooperate with one another to allow assembly of the first beams  166  and second beams  168  together in a structurally rigid configuration as illustrated. 
     With reference to  FIG. 16 , the first beam  166  is shown. As illustrated, the first beam  166  can include a tab  194  and slot  196 . The tab  194  and the slot  196  complement one another to allow shorter lengths of the first beam  166  to be combined to increase the overall length. It will be appreciated that a similar type of tab/slot layout could be used with the second beam  168 . 
     With reference to  FIG. 17 , an alternative spill containment system  198  with an enclosure is shown. This system  198  includes a canopy  200 . The canopy includes a frame  202  that supports a covering  204 . The frame  202  includes a plurality of upright members  206 , linear connection members  208 , and curved connection members  210 . These members  206 ,  208 ,  210  are held together with a variety of connectors  212 . The frame  202  cooperates with the covering  204  to define a shell wall  216  and a shell top  218 . Further, a shell door  222  is affixed to the shell wall  216  with a zipper  224  to allow access within the canopy  200 . Further, a document window  226  can be used to retain various documents associated with the materials located within the container  38 . Further still, a tie down  228  may be used to affix the shell wall  216  to the flexible bag  32 . Finally, a mounting strap  232  can be used in conjunction with a stake  234  to affix the containment system  198  to the ground or otherwise. 
     With reference to  FIG. 18 , an alternate containment system  236  with an enclosure is shown. This system  236  includes a rigid structure  238  with panels  240  and a roof  242 . Further, a tambour door  244  is attached to the panels  240  with a rail arrangement to allow access to the container  38  disposed within. Although not illustrated, it will be understood that the system  236  could also include a document window  226  for holding documents. 
     As is considered apparent, the enclosures of  FIGS. 17-18  allow the container  38  to be located between the grate  36  and the enclosure (i.e., canopy  200 , rigid structure  238 ). The enclosure allows the containment assembly to be used in outdoor applications. Further, rain and other precipitation does not enter into the flexible bag  32 , but rather passes off the enclosure and onto the ground. However, materials that have leaked from the drums or contains stored on the grate  36  would be collected in the flexible bag  32 . This ensures that the bag  32  does not become prematurely filled with material that does not need to be contained. 
     With reference to  FIG. 19 , an alternate portable containment system  246  is shown. The system  246  can include a carrying handle  248  that is attached to the exterior surface  52  of the bag  32  at a plurality of locations so as to define a loop. The loop is adapted to be of sufficient size to allow for receipt of a human hand to aid in carrying the system  246 . Additionally, a plurality of packing straps  252  may encircle the flexible bag  32 . These packing straps  252  can be disposed so as to be spaced from and on opposite sides of the carrying handle  248 . The straps  252  ensure that all of the components remain within the bag  32  until deployment of the system  246  is needed. 
     Thus, the portable containment system  246  can be shipped or stored in a compact arrangement, not unlike a suitcase, which can be transported to an assembly location and assembled to form the containment system as illustrated in the other embodiments of the present application. Notably, the pedestals  34  and/or composite pedestals  94  could be disposed within the bag  32  during shipment or storage or could be separately located. Further still, the grate(s)  36  could be received within the bag  32  illustrated in  FIG. 19  during shipment or storage. Thus, the bag  32  serves to contain the various components during shipment/storage and also capture leakage from the container placed on the grate during usage. 
     Additionally, advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and illustrative examples shown and described herein. Accordingly, various modifications may be made without departing from the scope or spirit of the general inventive concept as defined by the appended claims and their equivalence.