Methods and apparatus for containing hazardous material

Methods and apparatus for containing a hazardous material according to various aspects of the present invention operate in conjunction with a container having two compartments. The first compartment is configured to contain the hazardous material within a non-rigid bladder and the second compartment contains a hazard control material within a two-piece container configured to enclose the first compartment. The container may further comprise a wall separating the first compartment from the second compartment that is configured to open upon occurrence of a trigger event to release the hazard control material.

BACKGROUND OF THE INVENTION

Flammable and otherwise hazardous materials play an important role in the everyday lives of most people. Most people encounter flammable materials, such as gasoline, engine oil, diesel fuel, and natural gas, without danger. Because the flammable materials are contained, they typically present no problem for those that are nearby.

Occasionally, the vessels used to contain hazardous material rupture and the hazardous material escapes. For instance, the fuel tank in a military vehicle may rupture when struck by a projectile, causing the fuel or associated vapor to leak out. The uncontained fuel and vapor may pose a host of dangers including combustion of the fuel, toxic fumes, adverse chemical reaction with other substances outside the container.

A variety of systems have been developed to ameliorate the problems associated with uncontained hazardous material. These systems generally include a container of hazard control material such as fire extinguishant positioned in the vicinity of the hazardous material container. The hazard control material is then applied manually or automatically to reduce the danger of the hazardous material. These hazard control systems are generally stand-alone units and/or after-market systems applied to preexisting hazardous material containers.

SUMMARY OF THE INVENTION

Methods and apparatus for containing a hazardous material according to various aspects of the present in operate in conjunction with a container having two compartments. The first compartment is configured to contain the hazardous material within a non-rigid bladder and the second compartment contains a hazard control material within a two-piece container configured to enclose the first compartment. The container may further comprise a wall separating the first compartment from the second compartment that is configured to open upon occurrence of a trigger event to release the hazard control material.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The present invention may be described in terms of functional block components and various processing steps. Such functional blocks may be realized by any number of components configured to perform the specified functions and achieve the various results. For example, the present invention may employ various hazardous materials, hazard control materials, container materials, pressurizations, dimensions, and geometries, which may carry out a variety of operations suited to a specified hazard condition, application, or environment. In addition, the present invention may be practiced in conjunction with any number of systems configured for operation with the hazardous material and/or hazard control material, and the system described, is merely one exemplary application for the invention. Further, the present invention ma employ any number of conventional techniques for hazard control, hazard prevention, risk reduction, and the like.

Referring toFIGS. 1A-1B, methods and apparatus for containing a hazardous material according to various aspects of the present invention operate in conjunction with a container100to reduce the danger of a contained hazardous material105. For example, referring toFIG. 1, the container100may contain the hazardous material105within a first compartment115and a hazard control material107within a second compartment125configured to at least substantially enclose the first compartment115within an interior portion of the second compartment125. The container100may be configured to release the hazard control material107in response to a hazard condition such that the hazardous material105is less hazardous or rendered substantially harmless.

The container100may be configured in any manner to release the hazard control material107in response to the relevant hazard condition. For example, in one embodiment, the container100may comprise a first surface110defining at least an interior portion of the second compartment125, a second surface120defining at least an exterior portion of the second compartment125, and a wall150configured to lose integrity in response to a trigger event corresponding to the hazard condition. The second compartment125may at least partially enclose the first compartment115. In an alternative embodiment, the wall150may comprise the first surface110of the second compartment125and be adapted to substantially maintain its structural integrity in response to a trigger event corresponding to the hazard condition. The container100may be implemented in a variety of environments, including stand-alone storage systems or fuel tanks for motor vehicles.

The container100may comprise a fuel tank, such that the first compartment115is configured to store fuel and its associated vapors, and the second compartment125may be configured to contain the hazard control material107which may comprise a fire extinguishant or fire suppressant material. The container100may release the extinguishant to mix with vapors or fuel in the first compartment115to interfere with the combustion of the vapors. If the container100experiences a hazard condition, such as penetration by a projectile, the wall150may at least partially open or otherwise allow for the release of the extinguishant to reduce the flammability of the fuel. In this way, the probability of creating a fireball in the fuel tank is reduced and the risks associated with operation of the vehicle are decreased.

The first compartment115may contain the hazardous material105, which may comprise any material that may need to be neutralized or otherwise rendered less dangerous. For example, the hazardous material105may comprise fuel for a combustion engine, battery chemicals, solvents, brake fluid, transmission fluid, jet fuel, waste products such as radioactive and/or biological waste, and/or the like. In addition, the hazardous material105may be in any form, such as a liquid, vapor, solid, powder, granular, and/or other form. The hazardous material105may exhibit properties to be controlled, such as inflammability, chemical reactivity, toxicity, radioactivity, acidity, contagiousness, and/or the like.

In one embodiment for a vehicle fuel tank, the first compartment115may be configured to provide adequate volume to accommodate the fuel needs of the vehicle. Furthermore, the first compartment115may be shaped to fit into the fuel compartment area of the vehicle or comprise a fuel tank positioned on the exterior of the vehicle. For example, referring now toFIG. 7, in one embodiment, the first compartment115may comprise a bladder702having a substantially cylindrical shape with an interior volume for storing the hazardous material105. In addition, the first compartment115may comprise any appropriate materials to accommodate the hazardous material105such as polymers, elastomers, and/or multi-layer composites. For example, in one embodiment, the bladder702may comprise a fiberglass cloth covered in a semi-rigid polyurethane material. In a second embodiment, the bladder702may comprise a self-sealing rubber based elastomer adapted to automatically seal punctures under a predetermined size. Further, the first compartment115may be lined with materials that do not react to the hazardous material105, provide a shield around the hazardous material105, or provide thermal and/or electrical insulation.

The first compartment115may also be adapted to the application and/or environment. In various embodiments, the first compartment115may include baffles or one or more subcompartments, which may be interconnected or isolated from each other. For example, in one embodiment a reticulated polyurethane open-cell foam906may be positioned within the interior volume of the bladder702and may act as a baffle to reduce sloshing of fuel within the bladder702and/or help maintain the shape of the bladder702when empty. For example, the bladder702may comprise a semi-rigid body such that it might substantially conform to the shape of the second compartment125when full but lack structural elements necessary to fully maintain that shape when empty. Referring toFIGS. 1B and 7, the first compartment115may include an inlet108and an outlet109, for example to permit fuel to be added to and removed from the fuel tank. The first compartment115may be otherwise adapted according to the application and environment of the container100.

The second compartment125contains the hazard control material107. The second compartment125may be configured in any manner to contain the hazard control material107, for example according to the environment, application, hazard control material107, hazardous material105, and/or other relevant factors. For example, the second compartment125may provide adequate volume to accommodate sufficient hazard control material107according to the anticipated hazard. Furthermore, the second compartment125may be shaped to fit into the fuel compartment area of the vehicle and to engage the outer contours of the first compartment115. In addition, the second compartment125may comprise any appropriate materials to accommodate the hazard control material107. For example, the second surface120at least partially defining, the second compartment125may comprise or be lined with materials that do not react to the hazard control material107, provide a shield around the hazard control material107, or provide thermal and/or electrical insulation. The first surface110and/or the second surface120may further be configured to open upon impact or other force from an external body, such as a bullet or shrapnel, or an internal body, such as a clapper, explosive, or other actuator. The puncture, opening, or other decomposition of the second surface120may facilitate the release of the hazard control material107into the surrounding environment.

In the present embodiment, the second compartment125is positioned adjacent the first compartment115and separated from the first compartment115by one or more surfaces, such as the wall150and/or the second surface110. The second compartment125may comprise one or more separate subcompartments, or interconnected semi-separate subcompartments. For example, referring now toFIGS. 8 and 9, in one embodiment, the second compartment125may comprise a two-piece structure having, a first half802configured to couple to a second half804. The first half802may comprise a first subcompartment902and the second half804may comprise a second subcompartment904. In addition, the second compartment125and/or each subcompartment may include at least one horizontal or vertical partition111or other mechanism for maintaining the distribution of the hazard control material107within the second compartment125and/or each subcompartment and/or providing structural support. The second compartment125may include other elements, such as at least one inlet, at least one outlet, at least one point of constriction, and/or the like.

The second compartment125may comprise various structures and/or mechanisms configured to deploy the hazard control material107in response to the relevant hazard condition. For example, the partitions111maintain the distribution of the hazard control material107within the second compartment125. In addition, referring now toFIG. 2, the second compartment125may comprise interconnections270between subcompartments, for example to facilitate transfer of the hazard control material107between the subcompartments, such as to initially fill the second compartment125with the hazard control material107. The second compartment125may also include an actuator, such as electronic, pneumatic, and/or hydraulic systems, to facilitate flow of the hazard control material107between the subcompartments and/or deploy the hazard control material107in response to the relevant hazard condition. The second compartment125may also be pressurized to enhance dispersal of the hazard control material107.

Alternatively, referring, again toFIGS. 8 and 9, the first subcompartment902and the second subcompartment904may be configured to maintain a volume of the hazard control material107independently from each other. For example, the first half802and the second half804may be configured in a clamshell arrangement such that the two halves802,804couple together to form the interior portion of the second compartment125that is configured to but the first compartment115. The two halves802,804may be permanently or selectively coupled together by any suitable method such as mechanically or adhesively.

The hazard control material107comprises a material for neutralizing or otherwise reducing the hazard presented by the hazardous material105in the event of the hazard condition. The hazard control material107may comprise any appropriate material to control or reduce the effects of the hazardous material105, such as a fire extinguishant, an acid neutralizer, or other hazard control material107selected according to the hazardous material105. For example, the hazard control material107may comprise a fire extinguishant if the hazardous material105is flammable. In the present embodiment, the hazard control material107comprises the Black Widow® fire extinguishant available from Firetrace Aerospace, LLC. As another example, if the hazardous material105is chemically reactive, the hazard control material107may reduce or dilute the chemical reactivity of the hazardous material105. As yet another example, if the hazardous material105is radioactive, the hazard control material107may inhibit transmission of radiation. Alternatively, if the hazardous material105presents a biological hazard or a toxic material, the hazard control material107may neutralize, reduce the threat of, create a visual marker of, or counter the biological hazard or toxicity. The properties of the hazard control material107may be selected according to the hazardous material105.

The hazard control material107may comprise a substantially solid material such as granular material or a powder, as well as a substantially fluid material such as liquids, gases, and vapors. The hazard control material107may comprise a material in various phases simultaneously. In addition, the hazard control material107may include multiple materials to counter multiple hazardous materials105.

The container100may release the hazard control material107in response to a particular hazard condition. The hazard condition may be represented by any appropriate trigger event, such as a change in the status of the contained hazard material105. For example, the trigger event may include a change in temperature or pressure of the hazardous material105or the first compartment115, impact by another object, sudden acceleration or deceleration, or release, leakage, or contamination of the hazardous material105. The container100may detect and/or respond to the hazard condition in any appropriate manner. For example, the container100may include a hazard detector, such as a pressure sensor, temperature sensor, radiation sensor, chemical sensor, or the like and an actuator configured to deploy the hazard control material107from the second compartment125in response to the hazard detector. For example, the actuator may compromise the integrity of the second compartment125or the wall150, open a valve on the second compartment125, or otherwise release the hazard control material107from the second compartment125.

In the present embodiment, the container100releases the hazard control material107in response to a mechanical disruption of the container100such that the second compartment125releases the hazard control material107when the disruption is likely to cause a release of the hazardous material105or otherwise cause a dangerous condition. For example, one or more surfaces defining the second compartment125may be configured to rip, tear, be punctured crack decompose, dissolve, or otherwise lose integrity to facilitate release of the hazard control material107.

In one embodiment, the container100includes at least one wall150separating the first compartment115from the second compartment125. The wall150may comprise any partition between the first compartment115and the second compartment125that loses its integrity in response to the hazard condition. In this embodiment, a portion of the wall150may open upon impact or other force from an external body, such as a bullet or shrapnel, or an internal body, such as a clapper, explosive, or other actuator. The opening or other decomposition of the wall150facilitates release of the hazard control material107, for example into the environment surrounding the container100, into the first compartment, or an area adjacent to the hazardous material105. The wall150may open by any suitable amount such as local to the disruption or impact and create a relatively small hole in the wall150, or may open more substantially, such as substantially completely, to release a maximum amount of hazard control material107.

The wall150may be disposed in any position relative to the first compartment115and the second compartment125to facilitate deployment of the hazard control material107. Referring again toFIG. 9, in one embodiment, the wall150is disposed concentrically within the second surface120, thus defining the second compartment125as the space between the wall150and the second surface120. The wall150may be contiguous so that the first compartment115is completely enclosed within the second compartment125. Thus, any exterior object penetrating the first compartment115must first penetrate the second compartment125and the wall150, causing the wall150to open and deploy the hazard control material107.

Alternatively, referring now toFIGS. 1A and 1B, the wall150may at least partially define the first compartment115and one or more other surfaces, such as the first surface110, may define the remaining portion of the first compartment115. The wall150may define an unenclosed region.160that is not enclosed by the second compartment125. The unenclosed region160may be situated in a portion of the container100that is unlikely to be susceptible to hazard conditions. For example, it the container100is stacked with other systems, it may be acceptable to leave portions of the first compartment115unenclosed by the second compartment125. The first surface110and the wall150may be configured to define multiple unenclosed regions160. For example, referring toFIG. 2, the unenclosed region160may comprise an indentation of the second compartment125configured to fit the container100within certain other systems, such as within a vehicle. As yet another example, referring toFIG. 3, the unenclosed region160may be a continuous portion of the exterior of the container100and extend to more than one surface of the wall150.

The wall150may deploy the hazard control material107in any appropriate manner. In one embodiment, the wall150may open in response to the hazard condition, such as opening relative to the size of a puncture or impact caused by a projectile. For example, the wall150may comprise a material, such as polyethylene, polyvinyl chloride, composite, metal, or other sufficiently rigid or semi-rigid material. The wall150may be configured to open such that at least a portion of the hazard control material107within the second compartment125is released in response to the hazard condition.

In a second embodiment in the wall150may be configured to open in manner that is larger than the size of a puncture or impact caused by a projectile. For example, the wall150may comprise a breakable material, such as glass, ceramic, acrylic, plastic, metal, or other sufficiently non-impervious material. The wall150may be configured to open such that substantially all of the contents of the second compartment125are released in response to the hazard condition. For example, the wall150may comprise stress points, such as thinner sections of the wall150in the form of grooves or hatching, to facilitate opening for full deployment, and/or directional deployment of the hazard control material107. Likewise, the material of the wall150may exhibit a grain such that the wall150tends to open or separate across or along the grain.

The wall150may release the hazardous control material107in any suitable manner. In one embodiment, the wall150is compromised upon impact by an object, such as a bullet, shrapnel, or missile. The wall150may be configured to release the hazardous control material107, however, in response to any appropriate trigger event signifying a hazard condition, such as a specified stress, pressure, or temperature in or upon the wall150, or incidence of a particular material, such as a particular material corresponding to the hazard condition, with a portion of the wall150. Further, the container100may include additional systems to facilitate breaching the wall150. For example, the container100may include a control system to control the integrity of the wall150. The control system may include any appropriate components, such as one or more sensors to detect the hazard condition, and one or more actuators, such as hydraulic actuators, pneumatic actuators, and/or solenoid valves, to compromise the integrity of or otherwise breach the wall150or otherwise deploy the hazard control material107in response to a signal from the sensor.

In another embodiment, the container100may further comprise a membrane positioned between the first compartment115and the second compartment125. Alternatively, the membrane may be disposed solely along, an outer surface of the second compartment125. The membrane seals small holes or punctures that might result in a small leak of the hazardous material105not resulting in an immediately hazardous situation. The membrane may comprise any suitable self-sealing system such as a single-piece system configured to fit between the first compartment115and the second compartment125or a coating applied to the first compartment115and/or the second compartment125. The membrane may comprise any suitable material such as gel, polyurethane, rubberized asphalt, elastomeric coatings, foam and the like. For example, the membrane may comprise a self-sealing coating suitably configured to seal holes caused by small arms fire that is applied to the first compartment115before the second compartment125is position around the first compartment115.

The container100may include multiple first and second compartments115,125. For example, referring toFIGS. 2-5, the container100may include one or more additional compartments135. The compartments115,125,135may be isolated (FIG. 3) or interconnected by one or more interconnections270(FIGS. 2 and 4). The wall150may separate the additional compartments135from the first compartment115. The second compartment125and the additional compartments135may fully enclose the first compartment115, or partially enclose the first compartment115to form the unenclosed region160. The additional compartments135may include any relevant additional features, such as inlets, outlets, subcompartments, channels, valves, points of constriction, or the like.

The additional compartments135may contain any appropriate material. In one embodiment, the additional compartments135contain the hazard control material107. Alternatively, the additional compartments135may contain different hazard control materials107to address different hazards. In addition, the additional compartments135may be configured to contain more or less hazard control material107, deploy the hazard control material107in a selected direction or manner, or react to a selected hazard condition, for example according to anticipated angles of attack. Further, the additional compartments135may deploy the hazard control material107in response to different hazard conditions, for example by changing the thickness or materials of the wall150associated with the different compartments135.

The compartments115,125,135may be arranged in any configuration, for example to deploy multiple hazard control materials107or to deploy the hazard control material107in response to hazard conditions arriving from different incident angles. For example, referring toFIG. 5, the additional compartment135may be sandwiched between the first compartment115and the second compartment125, such that both compartments125,135are disposed between the first compartment115and the external environment. Alternatively, the additional compartment135may at least partially enclose the second compartment125.

Referring toFIG. 6A-B, in operation, the container100is initially formed and the second compartment125is filled with the hazard control material107. The container100may be installed in the appropriate environment or application, such as in a vehicle or as a stand-alone storage facility and used for its ordinary applications. In the present embodiment, the container100is installed as a fuel tank in a vehicle. The fuel may comprise a flammable fuel, such as conventional gasoline or jet fuel.

The container100responds to the trigger event corresponding to the hazard condition. The container100may detect and respond to the hazard event in any manner. In the present embodiment, a projectile122pierces the second surface120and passes through hazard control material107(FIG. 6B). The projectile122then strikes the wall150, causing the wall150to fail, such as by puncturing. In the present embodiment, a large portion of the wall150breaks open, releasing the hazard control material107from multiple subcompartments of the second compartment125(FIG. 6C) both into the first compartment115and into the surrounding environment. The failure of the wall150reduces or eliminates the separation of the hazard control material107from the hazardous material105.

As the projectile122proceeds into the first compartment115, the projectile122may tend to release and/or ignite the hazardous material105or otherwise generate the hazard condition. The failure of the wall150, however, releases the hazard control material107, which may follow the projectile122into the first compartment115and mix with the hazardous material105. In addition, if the hazardous material105leaves the first compartment, the hazard control material107may accompany the hazardous material105. Thus, the hazard control material107tends to mitigate the hazard presented by the hazardous material105following the trigger event.

The particular implementations shown and described are illustrative of the invention and its best mode and are not intended to otherwise limit the scope of the present invention in any way. Indeed, for the sake of brevity, conventional manufacturing, connection, preparation, and other functional aspects of the system may not be described in detail. Furthermore, the connecting lines that may be shown in the various figures are intended to represent exemplary functional relationships and/or physical couplings between the various elements. Many alternative or additional functional relationships or physical connections may be present in a practical system. Benefits, other advantages and solutions to problems that have been described above with regard to particular embodiments are not to be construed as critical, required or essential features or components. Changes and modifications may be made to the exemplary embodiments embodiment without departing from the scope of the present invention. These and other changes or modifications are intended to be included within the scope of the present invention, as expressed in the following claims.

In the foregoing description, the invention has been described with reference to specific exemplary embodiments; however, various modifications and changes may be made without departing from the scope of the present invention. The description and figures are to be regarded in an illustrative manner rather than a restrictive one, and all such modifications are intended to be included within the scope of the present invention. Accordingly, the scope of the invention should be determined by the generic embodiments described and their legal equivalents rather than by merely the specific examples described above. For example, the steps recited in any method or process embodiment may be executed in any order and are not limited to the explicit order presented in the specific examples. Additionally, the components and/or elements recited in any apparatus embodiment may be assembled or otherwise operationally configured in a variety of permutations to produce substantially the same result as the present invention and are accordingly not limited to the specific configuration recited in the specific examples.