Portable containment systems for hazardous or other materials

A method includes placing at least one mold along outer edges of one or more first pieces of fabric. The method also includes forming free-standing flexible walls and a floor of a containment structure by depositing liquid-impervious material onto the at least one mold and the one or more first pieces of fabric. The floor is formed seamlessly with the walls. The method further includes forming flexible supports by depositing liquid-impervious material onto multiple second pieces of fabric connecting the floor and the flexible walls.

TECHNICAL FIELD

This disclosure is generally directed to containment systems. More specifically, this disclosure is directed to portable containment systems for hazardous or other materials.

BACKGROUND

Often times, it is necessary or desirable to prevent material from being released or absorbed into the ground. For example, the release of hazardous or other materials into the ground could contaminate ground water or cause other problems. As a particular example, hazardous or other materials are often stored in tanks. Any spills or leaks of materials from the tanks could lead to contamination as well as civil or regulatory fines.

SUMMARY

This disclosure provides portable containment systems for hazardous or other materials.

In a first embodiment, a method includes placing at least one mold along outer edges of one or more first pieces of fabric. The method also includes forming free-standing flexible walls and a floor of a containment structure by depositing liquid-impervious material onto the at least one mold and the one or more first pieces of fabric. The floor is formed seamlessly with the walls. The method further includes forming flexible supports by depositing liquid-impervious material onto multiple second pieces of fabric connecting the floor and the flexible walls.

In a second embodiment, an apparatus includes a containment structure having free-standing flexible walls and a floor. The walls and the floor include liquid-impervious material, and the floor further includes one or more first pieces of fabric. The floor is seamless with the walls. The apparatus also includes flexible supports having liquid-impervious material on multiple second pieces of fabric connecting the floor and the flexible walls.

In a third embodiment, a method includes placing at least one piece of shape memory material along outer edges of one or more pieces of fabric. The method also includes forming free-standing flexible walls and a floor of a containment structure by depositing liquid-impervious material onto the at least one piece of shape memory material and the one or more pieces of fabric. The floor is formed seamlessly with the walls. The method further includes depositing liquid-impervious material onto a second side of the one or more pieces of fabric to protect an underside of the containment structure.

In a fourth embodiment, a method includes placing at least one mold along outer edges of one or more first pieces of fabric. The method also includes placing multiple pieces of shape memory material along the outer edges, where the pieces of shape memory material are non-continuous around the outer edges. The method further includes forming free-standing flexible walls of a containment structure by depositing liquid-impervious material onto the at least one mold. The method also includes forming supports for the flexible walls of the containment structure by depositing liquid-impervious material onto the pieces of shape memory material. In addition, the method includes forming a floor of the containment structure by depositing liquid-impervious material onto the one or more pieces of fabric, where the floor is formed seamlessly with the walls and the supports.

DETAILED DESCRIPTION

FIGS. 1 through 6illustrate a first example portable containment system100in accordance with this disclosure.FIG. 1illustrates multiple instances of the portable containment system100. The containment system100includes a bottom portion or floor102and free-standing walls104. The containment system100operates to contain and hold material between the walls104and over the floor102, thereby helping to prevent the material from being absorbed into the ground. In some embodiments, the containment system100is a seamless structure formed from polyurea and felt. However, the containment system100could be formed from any other suitable materials. Also, the containment system100can be used to hold and prevent release of any hazardous and nonhazardous material(s).

An example containment system100is shown in greater detail inFIGS. 2 through 6. For example, inFIGS. 2 and 3, the containment system100is shown with its floor102and free-standing walls104. Multiple supports202attached to the walls104and floor102help to support the walls104of the containment system100. For example, if liquid or other material leaks into the containment system100, the supports202can help retain the walls104in an upright position to hold the material within the containment system100. The supports202include any suitable structures for supporting the walls104, such as flexible supports.

One or more molds204are used to help form the containment system100. As described in more detail below, the molds204can be used to help form the walls104of the containment system100. Each mold204includes any suitable structure for helping to form at least part of the containment system100. For example, each mold204could represent an L-shaped wooden mold that is six inches tall and four inches wide. Other types of molds could also be used, such as carbon fiber molds. Moreover, molds having other sizes and shapes, such as rounded corners, could be used.

As shown inFIGS. 4 and 5, once the containment system100is formed, the molds204can be removed, and material can be placed within the containment system100. In this case, water is being placed into the containment system100for testing purposes. The supports202help to keep the walls104upright as the containment system100is being filled with water.

The containment system100here is flexible and can be rolled or otherwise placed into a suitable form for transport. An example of this is shown inFIG. 6, where the containment system100has been rolled for transport. Once at its intended destination, the containment system100can be placed on the ground and unrolled or otherwise placed into a suitable form for use, and equipment (such as one or more storage tanks) can be placed on the containment system100. When the equipment is being placed onto the containment system100, people or machinery can be used to drag or carry the equipment onto the containment system100. The walls104of the containment system100can flex or be pressed down during this time, and the walls104may return substantially to their pre-flexed shape (although some deformation of a wall104is permissible). This helps to facilitate easier placement of the equipment on the containment system100.

Note that the containment system100here does not require the use of metallic or other solid supports to hold the walls104of the containment system100upright. Among other things, this can enable simpler transport and use of the containment system100. For instance, the containment system100could be easily rolled into the form shown inFIG. 6without requiring metallic or other solid supports to first be removed from the containment system100. Also, the containment system100could be easily unrolled into the form shown inFIG. 1for use without requiring metallic or other solid supports to first be inserted into the containment system100.

AlthoughFIGS. 1 through 6illustrate a first example of a portable containment system100, various changes may be made toFIGS. 1 through 6. For example, the containment system100could have any suitable size, shape, and dimensions. As particular examples, the containment system100could be of virtually any size as long as there is enough space to create walls for containing material meant to be contained. Also, the shape could be typically square or rectangular, although circular or other shapes could also be used. Further, the walls104could have any suitable height(s), such as six inches. Note that non-uniform heights are also possible. In addition, while the use of certain materials (such as polyurea and felt) is described here, any other suitable materials can be used to form the containment system100. For instance, any suitable textiles or other fabrics could be used in the containment system100and covered with polyurea or other liquid-impervious material(s).

FIG. 7illustrates an example method700for forming the portable containment system ofFIGS. 1 through 6according to this disclosure. As shown inFIG. 7, a desired final size of the containment system is identified at step702. One or more first pieces of felt or other fabric are cut to a desired size at step704. Each first fabric piece could have any suitable size and shape, such as a rectangle four feet by twelve feet. One or multiple first pieces of fabric could be used here.

A releasing agent is applied to one or more molds at step706. The releasing agent could represent any suitable material(s) to help prevent bonding of the containment system100to the mold(s)204, such as a polyurea releasing agent. The molds are placed along outer edges of the first fabric piece(s) at step708. The molds define where the walls104are being formed and can be placed so that the walls104define a containment system100having the desired final shape. If the molds204are L-shaped, this step could include placing outer edges of the first fabric pieces on the bottom portions of the molds204.

Polyurea is applied to the mold(s) and fabric and cured to form the walls and floor of the containment system at step710. This could include, for example, spraying polyurea onto the molds204and first fabric pieces and allowing the polyurea to cure. Any suitable amount of polyurea can be applied to the walls104and floor102of the containment system100.

To form supports for the walls, second felt or other fabric pieces are placed inside the walls of the containment system at step712. This could include, for example, cutting pieces of fabric and placing the fabric pieces spaced apart along the inner walls104of the containment structure. In particular embodiments, the second fabric pieces can be about two inches by eight inches, and the second fabric pieces can be placed about 3.5 feet apart. Note that any other suitable uniform or non-uniform sizes and spacings can be used. Polyurea is applied to the second fabric pieces to form the supports at step714.

The containment structure is turned over at step716, and polyurea is applied to the bottom of the structure at step718. The polyurea used here could represent a light application of polyurea meant to protect the underside of the structure. Once completed, the containment system can be used in any suitable manner.

AlthoughFIG. 7illustrates one example of a method700for forming the portable containment system100ofFIGS. 1 through 6, various changes may be made toFIG. 7. For example, while shown as a series of steps, various steps inFIG. 7could overlap, occur in parallel, or occur in a different order. Also, while the use of certain materials (such as polyurea and felt) is described here, any other suitable materials can be used to form the containment system. In addition, note that spraying represents one way of depositing a liquid-impervious material onto a structure and that other deposition techniques could be used.

FIGS. 8 through 10illustrate a second example portable containment system800in accordance with this disclosure.FIG. 8illustrates multiple instances of the portable containment system800. The containment system800includes a bottom portion or floor802and free-standing walls804. The containment system800operates to contain and hold material between the walls804and over the floor802, thereby helping to prevent the material from being absorbed into the ground. In some embodiments, the containment system800is a seamless structure formed from polyurea, felt, and memory foam. However, the containment system800could be formed from any other suitable materials. Also, the containment system800can be used to hold and prevent release of any hazardous and nonhazardous material(s).

A portion of the containment system800is shown in greater detail inFIG. 9and in cross-section inFIG. 10. InFIG. 9, the containment system800is shown with its floor802and a free-standing wall804. The wall804here is generally triangular in shape, although the wall804could have any other desired shape(s). If liquid or other material leaks into the containment system800, the walls804remain in an upright position to hold the material within the containment system800. The walls804can be formed using memory foam material or other type of shape memory material(s), which allows the walls804to be deformed during use.

As shown inFIG. 10, the wall804of the containment system800could be formed using felt1002and memory foam material1004. The felt1002and memory foam material1004can be covered by layers1006-1008of polyurea to create a liquid-impervious structure. Once again, note that the memory foam material1004could have any other desired shape, and any other material(s) could be used in place of the felt1002.

The containment system800here is flexible and can be rolled or otherwise placed into a suitable form for transport (similar to that shown inFIG. 6). Once at its intended destination, the containment system800can be placed on the ground and unrolled or otherwise placed into a suitable form for use, and equipment (such as one or more storage tanks) can be placed on the containment system800. When the equipment is being placed onto the containment system800, people or machinery can be used to drag or carry the equipment onto the containment system800. The walls804of the containment system800can be depressed, and the walls804may return substantially to their pre-depressed shape (although some deformation of a wall804is permissible). This helps to facilitate easier placement of the equipment on the containment system800.

Note that the containment system800here does not require the use of metallic or other solid supports to hold the walls804of the containment system800upright. Among other things, this can enable simpler transport and use of the containment system800. For instance, the containment system800could be easily rolled into a form similar to that shown inFIG. 6without requiring metallic or other solid supports to first be removed from the containment system800. Also, the containment system800could be easily unrolled into the form shown inFIG. 8for use without requiring metallic or other solid supports to first be inserted into the containment system800.

AlthoughFIGS. 8 through 10illustrate a second example of a portable containment system800, various changes may be made toFIGS. 8 through 10. For example, the containment system800could have any suitable size, shape, and dimensions. As particular examples, the containment system800could be of virtually any size as long as there is enough space to create walls for containing material meant to be contained. Also, the shape could be typically square or rectangular, although circular or other shapes could also be used. Further, the walls804could have any suitable height(s), and non-uniform heights are also possible. In addition, while the use of certain materials (such as polyurea, felt, and memory foam) is described here, any other suitable materials can be used to form the containment system800. For instance, any suitable textiles or other fabrics could be used in the containment system800and covered with polyurea or other liquid-impervious material(s). Moreover, any suitable shape-memory material(s) could be used in the walls804of the containment system800.

FIG. 11illustrates an example method1100for forming the portable containment system ofFIGS. 8 through 10according to this disclosure. As shown inFIG. 11, a desired final size of the containment system is identified at step1102. One or more pieces of felt or other fabric are cut to a desired size at step1104. Each fabric piece could have any suitable size and shape, such as a rectangle four feet by twelve feet. One or multiple pieces of fabric could be used here.

One or more pieces of memory foam are cut to fit the desired size at step1106. The memory foam could be cut so that one or more pieces fit along the outer edges of the fabric piece(s). The memory foam pieces define where the walls804are being formed.

Polyurea is applied to the outer edges of the fabric at step1108, and the memory foam pieces are attached to the outer edges of the fabric at step1110. The memory foam pieces are therefore attached to the outer edges of the fabric when the polyurea cures.

Polyurea is applied onto the fabric and memory foam pieces at step1112. The containment structure is turned over at step1114, and polyurea is applied to the bottom of the structure at step1116. Any suitable amount of polyurea can be applied to the walls804and floor802of the containment system800. Once completed, the containment system can be used in any suitable manner.

AlthoughFIG. 11illustrates one example of a method1100for forming the portable containment system ofFIGS. 8 through 10, various changes may be made toFIG. 11. For example, while shown as a series of steps, various steps inFIG. 11could overlap, occur in parallel, or occur in a different order. Also, while the use of certain materials (such as polyurea, felt, and memory foam) is described here, any other suitable materials can be used to form the containment system. In addition, note that spraying represents one way of depositing a liquid-impervious material onto a structure and that other deposition techniques could be used.

FIG. 12illustrates a third example portable containment system1200in accordance with this disclosure. As shown inFIG. 12, the containment system1200includes a floor1202and walls1204. The floor1202can be formed using felt or other fabric(s), and the floor1202and the walls1204can be formed using polyurea or other liquid-impervious material(s). These structures could be formed in the same or similar manner as in the containment system100described above.

The containment system1200also includes multiple supports1206attached to the walls1204and floor1202. The supports1206can be formed using memory foam material or other type of shape memory material(s). These structures could be formed in the same or similar manner as in the containment system800described above, except the shape memory material in the supports1206is not continuous around the entire containment system1200. The walls1204and supports1206here can be deformed during use and may return substantially to their pre-flexed shape (although some deformation of a wall1204or support1206is permissible).

AlthoughFIG. 12illustrates a third example of a portable containment system1200, various changes may be made toFIG. 12. For example, the containment system1200could have any suitable size, shape, and dimensions. As particular examples, the containment system1200could be of virtually any size as long as there is enough space to create walls for containing material meant to be contained. Also, the shape could be typically square or rectangular, although circular or other shapes could also be used. Further, the walls1204could have any suitable height(s), and non-uniform heights are also possible. Moreover, the supports1206could have any suitable size and shape, and any number of supports1206could be used. In addition, while the use of certain materials (such as polyurea, felt, and memory foam) is described here, any other suitable materials can be used to form the containment system1200. For instance, any suitable textiles or other fabrics could be used in the containment system1200and covered with polyurea or other liquid-impervious material(s). Beyond that, any suitable shape-memory material(s) could be used in the supports1206of the containment system1200.

FIG. 13illustrates an example method1300for forming the portable containment system ofFIG. 12according to this disclosure. As shown inFIG. 13, a desired final size of the containment system is identified at step1302. One or more pieces of felt or other fabric are cut to a desired size at step1304. Each fabric piece could have any suitable size and shape, such as a rectangle four feet by twelve feet. One or multiple pieces of fabric could be used here. Multiple pieces of memory foam are cut at step1306. The memory foam could be cut so that the supports1206have any suitable size and shape, such as triangular wedges.

A releasing agent is applied to one or more molds at step1308. The releasing agent could represent any suitable material(s) to help prevent bonding of the containment system1200to the mold(s), such as a polyurea releasing agent. The molds are placed along outer edges of the fabric piece(s) at step1310. If the molds are L-shaped, this step could include placing outer edges of the fabric pieces on the bottom portions of the molds.

Polyurea is applied to the outer edges of the fabric at step1312, and the memory foam pieces are attached to the outer edges of the fabric at step1314. The memory foam pieces are therefore attached to the outer edges of the fabric when the polyurea cures.

Polyurea is applied to the mold(s), fabric, and memory foam pieces and cured to form the floor, walls, and supports of the containment system at step1316. This could include, for example, spraying polyurea onto the molds, fabric pieces, and memory foam pieces and allowing the polyurea to cure. Any suitable amount of polyurea can be applied to the floor1202, walls1204, and supports1206of the containment system1200.

The containment structure is turned over at step1318, and polyurea is applied to the bottom of the structure at step1320. The polyurea used here could represent a light application of polyurea meant to protect the underside of the structure. Once completed, the containment system can be used in any suitable manner.

AlthoughFIG. 13illustrates one example of a method1300for forming the portable containment system1200ofFIG. 12, various changes may be made toFIG. 13. For example, while shown as a series of steps, various steps inFIG. 13could overlap, occur in parallel, or occur in a different order. Also, while the use of certain materials (such as polyurea, felt, and memory foam) is described here, any other suitable materials can be used to form the containment system. In addition, note that spraying represents one way of depositing a liquid-impervious material onto a structure and that other deposition techniques could be used.

Note that the containment systems100,800,1200could include any other suitable features as desired depending on the implementation. For example, at one end of the containment system100,800,1200, multiple tabs can be formed with holes or openings. As a particular example, multiple tabs formed by felt covered in polyurea can be placed at one end of the containment system100,800,1200, such as tabs formed using one foot by two foot pieces of felt. The tabs could include oblong openings, such as openings of around one inch by five inches in size. A forklift operator can place the forklift's fingers into the openings of the tabs, allowing the forklift operator to raise and lower the containment system100,800,1200without requiring the forklift to physically touch the floor and walls of the containment system100,800,1200. As another example, handles can be formed along the walls or floor of the containment system100,800,1200, such as by using a “cut and weave” design to attach the handles to the felt pieces and then spraying the structure with polyurea to seal the handles to the structure. As yet another example, serial number tags, company logos, or other components can be attached to a containment system100,800,1200before, during, or after fabrication of the containment system100,800,1200. Any other or additional features could be used in the containment system100,800,1200.

While this disclosure has described certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this invention. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this invention as defined by the following claims.