Apparatus for aerating and draining

An aeration and drainage system includes an aeration & drain pipe which contains slots on its upper surface, a stand which holds said aeration & drain pipe above a bottom surface, an air and liquid transfer element attached to the aeration & drain pipe and positioned over said slots. Additionally the air and liquid transfer element extends upward from the slots, and the air and liquid transfer element contains openings on its top to allow fluids to flow into the air and liquid transfer element and through the slots in the aeration & drain pipe.

This application is a non-provisional application claiming benefit of provisional application 61/306,651 filed on Feb. 22, 2010.

BACKGROUND OF THE DISCLOSURE

The present disclosure relates to an aeration and drainage system used for example in composting and dairy farms. Prior to this disclosure, the following techniques were employed in an attempt to aerate and/or drain a floor surface.

A first example, U.S. Pat. No. 3,714,786 to Evans et al. teaches an open slot culvert for positioning in a drainage area with the open slot at the top so that any surface drainage water will flow through the slot and directly into the culvert, including a method and apparatus for its manufacture. The improved open slot culvert comprises a metallic, pipe section, split longitudinally along its upper side to form a narrow slot, and grate means, including two spaced, vertical bearing members joined by spacer means, secured in the slot. The method of making the improved open slot culvert includes the steps of providing two elongated, parallel, vertical members in spaced relation having a plurality of spacer means therebetween, longitudinally splitting the upper side of a metallic pipe section to form a narrow slot, and properly positioning the grate means within the narrow slot. The apparatus for making the improved open slot culvert generally comprises an entry pipe station, a pipe clamp, saw and tack welding station, and a finish welding and exit station.

A second, U.S. Pat. No. 3,898,778 to Erickson et al. teaches an improved method for cast-in-place construction of a concrete drainage conduit immediately below an integral concrete floor surface, including floor surface, including a longitudinal slot for discharge of surface fluids into said conduit. A water-inflated, fabric-reinforced plastic tubular form and longitudinal slot-forming inserts, used during the concrete pouring operations, are later retrieved at one end of the conduit for reuse following deflation of the tubular form. Conduits of non-circular cross section may be formed if desired. This improved method is useful for construction of drainage facilities for flushable slotted floors for cattle confinement feedlots and for other paved surface such as auto parking areas, roadway and airports.

A third example, U.S. Pat. No. 4,374,078 to Richardson teaches a method of floor drainage trough installation to prevent gaps between the upper edge portions of the side walls of the floor drainage trough and the body of concrete in which the trough is set, such gaps resulting from shrinkage of the concrete as the body of concrete is cured, strips of woven glass fiber material are provided in the upper edge portions of the side walls of the trough during the molding thereof, with closely spaced loops of the glass fiber material of which the strips are formed being coated with the plastics material of which the trough is formed during the molding of the trough and outwardly projecting under the influence of the inherent resiliency thereof by removing the trough from the mold prior to the plastics material becoming fully set. The loops are securely embedded in the body of concrete, so that during the curing of the body of concrete the shrinkage thereof causes slight splaying apart of the upper edge portions of the side walls of the trough, thereby preventing formation of the above-mentioned gaps.

A fourth example, U.S. Pat. No. 4,838,727 to Capuano teaches a one-piece slotted conduit having a thin inner body section and an encompassing frame structure. The encompassing frame structure having specially designed recesses formed in it to ensure maximum conduit strength and an economic use of material. The slotted conduit also including male/female interconnecting ends which ensure easy and accurate alignment of a plurality of conduits in an interconnected system.

A fifth example, U.S. Pat. No. 5,316,410 to Blume teaches this invention relates to the draining of foundations by using an elongate subterranean drainage structure located approximately horizontally and parallel to the foundation in combination with a plurality of elongate upwardly extending hollow drain structures extending from the structure toward the surface of the earth. Hydrostatic pressure of water in the soil forces water through holes in the upwardly extending drain structures. The water then passes rapidly to the bottom of the upwardly extending drain structures by the force of gravity and thereupon into the horizontal drain structure wherein it is carried away from the foundation.

SUMMARY OF THE DISCLOSURE

In each of the above discussed patents, none provided an effective way to drain leachate or other fluids from compost piles while also aerating the compost pile, nor a practical and efficient way to install and construct such drainage and aeration systems. The inventors of the present disclosure sought a way to effectively drain leachate and aerate while providing a rugged and durable system which could withstand heavy loads, including heavy machinery positioned over the drainage and aerating system, and would allow an efficient installation procedure

An embodiment of the aeration and drainage system of the present disclosure includes a aeration & drain pipe which contains slots on its upper surface, a stand which holds said aeration & drain pipe above a bottom surface, an air and liquid transfer element attached to said aeration & drain pipe and positioned over said slots, wherein said air and liquid transfer element extends upward from said slots, wherein said air and liquid transfer element contains openings on its top to allow fluids to flow into the air and liquid transfer element and through the slots in the aeration & drain pipe.

The aeration and drainage system is typically located in a reinforced concrete floor which may bear the weight of heavy machinery and heavy loads. Once the aeration and drainage system is assembled and positioned, concrete is poured and spread over the aeration and drainage system. Thus, the aeration and drainage system becomes a permanent fixture in the floor. This presents a challenge when the air and aeration & drain pipes become clogged.

To achieve an efficient and cost effective cleaning method, a clean-water delivery system can be incorporated into the aeration and drainage system. The aeration and drainage system can be connected to the clean-water delivery system which can pump clean water through the aeration & drain pipes, thereby removing any unwanted debris located within the aeration & drain pipes.

Further, a method of draining fluids from a floor and aerating a floor surface has also been developed. This method includes placing a frame down on a surface, placing an air and aeration & drain pipe with slots located on its top, on said frame, attaching an air and liquid transfer element to said air and aeration & drain pipe, wherein said air and liquid transfer element contains openings to allow fluids to pass through and into said aeration & drain pipe, wherein said openings are even or slightly recessed from a surface of the floor.

This aeration and drainage system has many applications including use in composting, dairy farms, or other industrial facilities.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1shows an exploded view of a first embodiment of a drainage and aeration system90. As shown inFIG. 1, an aeration & drain pipe106is positioned on frames118. Aeration & drain pipe106is made from polyvinyl chloride (PVC) or any other suitable material which is durable and capable of draining leachate and other harmful organic compounds, and capable of transporting air into the compost.

Frames118contain a curved depression109which accommodates the aeration & drain pipe106. A clamp123can then be placed over the aeration & drain pipe106and secured to the frame118. Frame118can be placed within a liner126which can be made of plastic or any other suitable material, and which frame is placed on top of a temporary form board98. Frame118holds the aeration & drain pipe at a specified distance from the finished floor surface120(shown inFIG. 5) preventing the aeration & drain pipe106from resting on the ground; and for supporting the concrete rebar that is placed parallel to the aeration and drain pipe The liner126serves as a concrete containment form, and also prevents fluids that are not captured in the aeration & drain pipe106to be captured by the liner, thereby preventing harmful fluids from seeping into the soil.

Aeration & drain pipe106also contains slots107. Slots107allow fluids to enter into the aeration & drain pipe106from a floor surface above the aeration & drain pipe106. The fluids can then be carried from the aeration & drain pipe106into an appropriate holding vessel, leaching pond, etc. (not shown).

Slots107do not extend continuously over the entire length of the aeration & drain pipe106because this could cause the aeration & drain pipe to lose some of its rigidity and become deformed. Bridges117are located in-between slots106to further sustain rigidity and structural integrity to the aeration & drain pipe106. Further, the slots107may not extend to the edge of the aeration & drain pipe106. This provides additional structural support as well as allows transverse reinforcing bars to be placed across the aeration & drain pipe106to enhance the structural integrity of the concrete slab.

Located on top of the aeration & drain pipe106and above slots117is the air and liquid transfer element103. The air and liquid transfer element103is the interface between the aeration & drain pipe106and the top of the floor120(shown inFIG. 5). The air and liquid transfer element allows fluids to flow from the surface of floor120, through holes located on the top of the air and liquid transfer element, through the slots107and into the aeration & drain pipe106, and conversely permits air transported by the aeration and drain pipe106to flow upward through slots107, through the holes located in top of the air & liquid transfer element, and thus into the compost material placed on the floor slab120. The air and liquid transfer element will be discussed in further detail below.

A removable cap strip112is located on top of the air and liquid transfer element103and prevents debris/wet concrete from clogging holes on the top of the air and liquid transfer element during construction and concrete placement. Cap strip112is designed to be removable. Plugs116are shown at each edge of air and liquid transfer element103. Plugs116prevent fluids wet concrete from migrating into the end of the air and liquid transfer element103. Located on an end of the aeration & drain pipe106may be an air and water delivery system140. In a composting environment, it is desirable to be able to deliver oxygen to the microbes breaking down the organic material, and to remove leachates and free water from the surface of the floor slab120. A primary pipe144can be supported by a pipe stand145and attached to the aeration & drain pipe106via fitting142. Air can then be fed through the primary pipe144into aeration & drain pipe106. Air is then forced up through the slots107and through air and liquid transfer element103and onto the surface of the floor. Once on the floor surface, the air can permeate the compost pile and provide the correct amount of oxygen to the microbes.

Optionally, one or more sensors can be placed in the compost pile. When the oxygen or temperature level in the compost gets below a certain value an air pump connected to the primary pipe144can be turned on, pumping air into the compost, and keeping the microbes breaking down organic material at the optimum level.

Additionally, a clean-water pipe128can be used in the system to periodically flush out the aeration & drain pipe. As discussed above, the system can be used in a composting environment. While the aeration & drain pipe is designed to remove fluids and tiny particles, it may become necessary to clean out the pipe due to a blockage in the aeration & drain pipe106. In such event, a clean-water pipe128can be used to supply clean water to the aeration & drain pipe106. The clean water supplied to the aeration & drain pipe106can then flush out any debris that is located in the aeration & drain pipe106.

FIG. 2shows a perspective view of frame118. Frame118can be made from plastic or any other suitable material. Frame118is generally rectangular in form and has a depression109which is designed to accommodate the aeration & drain pipe106. With an aeration & drain pipe106positioned inside of depression109, clamp123is then positioned over the aeration & drain pipe106. The clamp123is secured to the frame118by a locking mechanism, and serves to keep the aeration and drainage pipe106securely in place, and accurately positioned, during concrete placement, the latter being particularly important as hydraulic pressure applied by the wet concrete tends to cause flotation of the aeration and drainage pipe106.

The locking mechanism can be implemented for example by using a male locking part124and inserting it into a female locking part125. For example, a serrated tongue and groove system can be used to secure the clamp123to the frame118, as shown inFIG. 2a.

Frame118can be secured to temporary form board105via a tab108, with a screw, nail, or other fastening device to affix the frame118to the temporary form board105.

Frame118also may contain slots122which are designed to accommodate reinforcing bars, such as rebar. Rebar can then be inserted into slots122such that the rebar is parallel with the aeration & drain pipe106. The reinforced floor ensures that heavy loads can be superimposed on the floor without causing damage to the floor.

FIG. 3shows an end view of the air and liquid transfer element103attached to the aeration & drain pipe106. As shown inFIG. 3, the air and liquid transfer element103has a generally inverted U shape. The bottom of air and liquid transfer element103opens up into the slot107of the aeration & drain pipe106. This allows fluid captured in the air and liquid transfer element103to fall into the aeration & drain pipe106. Further, this helps to prevent the air and liquid transfer element103and aeration & drain pipe106from getting clogged. Further it channels the upward flowing air from the aeration & drain pipe into, and through the holes113(FIG. 4) into the compost placed on the floor120.

Air and liquid transfer element103includes flexible sidewalls102a/102b. The flexible sidewalls allow the air and liquid transfer element to fit various size aeration & drain pipes106. Further, the top of the inverted U-shaped air and liquid transfer element99acts like a spring, allowing the sidewalls102a/102bto flex inward and outward for the purpose of connecting the air and liquid transfer element99to engage the slots107in the aeration and drain pipe106, without necessitating the use of glue, screws, or any mechanical, chemical bonding or other connection method.

As shown inFIG. 3the air and liquid transfer element103is adjustable to fit a large diameter aeration & drain pipe106bor a small diameter aeration & drain pipe106a. Top flange105goes on the top of the aeration & drain pipe106and bottom flange100goes on the bottom of the aeration & drain pipe106. Together, top flange105and bottom flange100secure the air and liquid transfer element to the aeration & drain pipe106. Flanges105and100can have a radius to make it easier to fit the flanges on the aeration & drain pipe. Bottom flange100has a downward curving radius while top flange105has an upward curving radius. The curved flanges allow the edge of the aeration & drain pipe106to be quickly and easily guided into the proper position.

In order to fit the air and liquid transfer element103to the aeration & drain pipe106, the sidewalls102are pressed in and the flanges105and100of the air and liquid transfer element103are aligned with the outer circumference of the aeration & drain pipe. The depressed sidewalls102bare then released, allowing the sidewalls to extend and causing the flanges105and100to fit, respectively above and below the outer and inner circumference of the aeration & drain pipe103.

A depression115is also shown inFIG. 3, below the top edge114of the air and liquid transfer element103. The depression115is to allow concrete to more securely fasten and bind the air and liquid transfer element103. Further, the depression helps to ensure a tighter fit such that fluids do not go in between the air and liquid transfer element103and the concrete.

Removable cap strip112is shown on the top of the air and liquid transfer element103. Protrusion111is located on the bottom of the cap strip112. This protrusion can then align with a receiving slot110of the air and liquid transfer element103. Thus, the cap strip112can be held in place by the protrusion111and receiving slot110until the cap strip112is ready to be removed from the air and liquid transfer element103.

The air and liquid transfer element103can also include plugs116, as best shown inFIG. 4, which attach to the end of the air and liquid transfer element103and prevent air from escaping out of the side of the air and liquid transfer element, and to prevent wet concrete—during concrete placement—from migrating into the air and liquid transfer element103. Plugs116can be attached by gluing, ultrasonic welding, fusing, chemical bonding, screwing, or any other suitable means.

As shown inFIG. 4, the top edge114of the air and liquid transfer element103includes a series of holes113which allow fluid to enter the air and liquid transfer element, and keep out larger sized debris. The holes113also allow air to be pumped onto the floor surface and oxygenate the compost or other material. Holes113can be pre-drilled during the manufacture of the air and liquid transfer element103, or can be made after the device has been installed. If many holes are desired, then the holes113will typically be pre-drilled at the factory. Holes113are not limited to circles, but can also be elongated slots, ovals, etc. For compost aeration the holes113can be round and small, while for a biofilter, holes113can be round with close spacing in between holes, for maximum transporting of air. For animal excretions, holes113can be large and/or closer together and elongated.

FIG. 5shows an assembled view of an aeration and drainage system90in a concrete slab. The cover strip112of the air and liquid transfer element103is removed and the holes113are slightly recessed within the top of the concrete slab120. The top edge114of the air and liquid transfer element103is recessed in the concrete slab for several reasons. By recessing the top edge114, fluids will naturally collect at this low point in the floor. Recessing also extends the life of the aeration and drainage system90. When trucks and other heavy vehicles, animals, loads, etc. are on the floor, they will not contact the top edge114of the air and liquid transfer element103as it is recessed, but will instead simply come in contact with the concrete floor.

As the aeration and drainage system90is permanently fixed within the concrete floor, cleaning the aeration & drain pipes106, which eventually are clogged, becomes critical. A water delivery system may be incorporated with the aeration and drainage system90in order to facilitate easy cleaning of the system. Clean-water pipes128provide water to aeration & drain pipes106, thereby flushing out any unwanted debris in the aeration & drain pipes106. Further, an air pump may be connected to primary pipe144to supply air to the aeration and drainage system90.

As best shown inFIG. 6, there are several stages to installing an aeration and drainage system90. Once an appropriate location is chosen for the aeration and drainage system90, the system must be properly laid out. This includes calculating the spacing between aeration & drain pipes106based on the amount of air that is required for the composting or biofilter operation, or for fluids the system is designed to remove. The appropriate size aeration & drain pipes106must also be chosen. The air and water delivery system140may also be laid out, if desired in the system, depending on the size of the aeration and drainage system90to be served.

Once the layout of the aeration and drain system along with the air and water delivery system is complete, installation may begin. A liner126is laid out, within a temporary form board98, and frames118are placed in the liner, between the temporary form boards98, and attached thereto. Reinforcing bars such as steel rebar121can then be inserted into slots122in order to provide for structural reinforcing for the concrete. Aeration & drain pipe106can then be placed on the frames118and secured thereto using clamps123. Air and liquid transfer element103will already be attached to the aeration & drain pipe106when it is placed in the frames. At this stage of assembly the first concrete will be poured into the liner126, and encasing the bottom rebar121, the frames118, and the lower half of the aeration and drain pipe106. After the concrete is sufficiently set, the temporary wood form boards98can be removed, and the slab sub-grade prepared for placement of the concrete slab during the 2ndand final pour.

118. An additional layer of rebar121acan then be placed transversely with the aeration & drain pipe106. The transverse rebar121arests upon a rebar chair which allows the rebar to be fully encased in concrete in accordance with standard concrete practice. Additional layers of rebar121may then be placed parallel with the aeration & drain pipes106, as shown inFIG. 6.

Once the aeration and drainage system90, along with the air and water delivery system are in place, the concrete floor slab can be poured. Because the cap strip112covers holes113, concrete can be poured over and on the aeration and drainage system90, with no worry about clogging the holes113. This greatly increases the efficiency of installing the system. For the first pour, concrete is poured, for example up to the top of the liner126. The bottom surface119of the first pour is shown for example inFIG. 5. The bottom of the concrete floor is shown at the interface of the first pour and second pour. Once the concrete for the second pour is approximately the height of the top edge114of the air and liquid transfer element103, the concrete can then be floated and trowelled to provide a flat surface.

At this point, the concrete will cover the top edge114of the air and liquid transfer element103. However, as the cap strip112remains on top of the air and liquid transfer element103, concrete will not clog up the holes113. Before the concrete is fully set, the cap strip112can then be removed, as best shown inFIG. 7. The concrete around the cap strip112can be removed with a trowel or screw driver for example, and then the cap strip112can be pulled off of the air and liquid transfer element103. This leaves a perfectly clean opening in the top edge114of the air and liquid transfer element103. Holes113are thus perfectly clean and free of debris. This also provides for a slightly recessed top edge114, as discussed earlier.

In certain cases it will be desired to raise the concrete floor higher above the top edge114, and to create a custom drainage slot or reveal 97 in order to create a more effective drainage channel for compost leachate or for liquids on the floor.

A second embodiment of the disclosure, and more applicable to smaller composting system installations, is shown inFIGS. 8-11.FIG. 8shows an aeration system in a slab of concrete. Air pipe131is supported by stands132Stand132can rest upon sand, gravel, or any other suitable compact surface. Stands132help prevent displacement of the air pipe131when concrete is poured over the aeration system. Intermediate holders135, serve to transport air from air pipe131, similarly to132, but without being supported on the surface133(FIG. 9).

Concrete is poured up to the top of stand132and holder135. These points provide a screed level at which the concrete should be leveled at.FIG. 9shows a view taken along line9-9shown inFIG. 8. As shown inFIG. 9, a hole138is shown at the top of stand132and137. This hole is supplied pre-drilled, and serves to transport air from the air pipe131into the compost placed on top of the slab120. During construction a screw may be placed into these holes, and self-drilled into the air pipe131to maintain accuracy of spacing, and integrity of the assembly of all components, discussed in more detail below.

Further, stand132can rest in a liner, or simply on gravel, sand, or any other relatively flat surface133.

FIG. 10shows a view taken along the line10-10as shown inFIG. 8.FIG. 10shows an end view of a holder135. A screw137is shown in the upper part of the holder135. Upon installing the aeration and drainage system, the screw137can be removed, and a slightly larger diameter hole re-drilled in the same location, thereby creating a clean hole which allows air to be transported from the air pipe131into the compost,

FIG. 11shows a top view of holder135and support132, and a round aeration hole136.

An air pump may also be attached to the air pipe(s)131in order to pump air onto the floor surface and aerate a compost pile or other substance.