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BACKGROUND OF THE INVENTION  
       [0001]     1. Technical Field  
         [0002]     The present invention relates generally to erosion control devices, and more particularly to a sediment control wattle including a durable synthetic sheath containing a polymeric fill material.  
         [0003]     2. Background  
         [0004]     The prior art includes a variety of assemblies directed towards reducing the effects of soil erosion. Straw and excelsior wattles, logs and rolls, in common use, are configured as elongated tubes of compacted straw or excelsior encased in flexible netting material. See www.earth-savers.com for general descriptions and specifications of wattles. Wattles are installed along contours or at the base of slopes to reduce soil erosion and retain sediment. Straw and excelsior wattles, logs and rolls have been state-of-the-art in erosion and sediment control for many years, and are considered best management practice or BMP in current Clean Water Act regulations and guidelines. Yet, the rice straw wattle testing and properties table claims only 58% minimum soil loss effectiveness for a 9-inch wattle.  
         [0005]     Additionally, the prior art includes U.S. Pat. No. 6,855,650 to Bohannon, Jr., entitled Synthetic Fiber Filled Erosion Control Blanket, discloses a resilient erosion control blanket including a recycled filler including polyethyleneterephthalate in the form of recycled soda bottles which has been converted into a crimped, highly resilient fibrous filler contained within an open-meshed material of natural or synthetic fibers.  
         [0006]     U.S. Pat. Nos. 6,641,335 and 6,527,477 to Allard, entitled Erosion Control Rolls, discloses an erosion control device including a walled elongated core member is disclosed having a first open end, a second end, an interior space and one or more openings in the wall communicating the interior space with the exterior of the core member. An outer filter member surrounds the core member. One or both the first and second ends of the core member can be open. One or both of the open ends can comprise couplers or connectors for connecting one core member to one or two complimentary core members. The core member may comprise a flexible plastic pipe, such as high-density polyethylene pipe having a plurality of perforations.  
         [0007]     U.S. Pat. No. 5,786,281 to Prunty, et al., entitled Erosion Control Blanket and Method of Manufacture, discloses an environmentally sound vegetation growth-enhancing erosion control blanket formed from an elongated rectangular excelsior/wood wool mat. The mat is held together with adhesive and a surface pattern is embossed therein. As ground vegetation grows, it ultimately replaces the blanket which decomposes providing nutritive mulch.  
         [0008]     U.S. Pat. No. 5,678,954 to Bestmann, entitled Ecological Coir Roll Element and Shoreline Protected Thereby, discloses a generally cylindrical fiber roll consisting essentially of coir material with a netting material about the exterior surface of the roll.  
         [0009]     U.S. Pat. No. 5,651,641 to Stephens, et al., entitled Geosynthetics, discloses a mat formed of scrim which is tufted with a number of tufted ends in order to provide high tensile strength, greatly porous and flexible mats contain a number of interstices for capturing root systems, retaining soil, and controlling the flow of water.  
         [0010]     U.S. Pat. No. 5,519,985 to Dyck et al., entitled Machine for Producing Straw-Filled Tubes of Flexible Netting Material discloses an apparatus and method of filling tubes of flexible, large mesh, netting material with compacted rice straw, or the like. The finished straw tubes are on the order of nine inches in diameter, twenty five feet in length and thirty pounds in weight; and lend themselves to use in controlling or mitigating the effects of erosion and to promoting revegetation.  
         [0011]     U.S. Pat. No. 5,405,217 to Dias, et al., entitled Device for Erosion Control, discloses an elongated tubular assembly including a plurality of tubular units disposed in end-to-end relationship, each unit including a lower section composed of a variably rigid impermeable contact base and an upper section with a variably rigid protruding hull. The lower and upper parts are connected to each other to provide an internal space into which ballast can be admitted.  
         [0012]     U.S. Pat. Nos. 5,330,828 and 5,484,501 to Jacobsen, Jr., et al., entitled Wood Fiber Mat for Soil Applications, discloses a wood fiber mat comprised of a mixture of thermo-mechanically processed wood and synthetic fibers.  
         [0013]     U.S. Pat. Nos. 5,249,893 and 5,358,356 to Romanek et al., entitled Erosion Control Mat, discloses an erosion control mat formed as a composite fabric including a scrim formed of polypropylene, polyester, nylon, rayon, polyethylene, cotton, or combinations thereof, and uniform lightweight web secured to the scrim.  
         [0014]     U.S. Pat. No. 5,207,020 to Aslam, Jr., et al., entitled Biodegradable Slit and Expanded Erosion Control Cover, discloses an erosion control blanket made of recycled, biodegradable slit and expanded sheets of paper.  
         [0015]     U.S. Pat. No. 4,635,576 to Bowers, entitled Stitched Woodwool Mat, discloses a soil erosion control blanket formed from a mat of interlocking woodwool fibers, the mat of woodwool being retained as a coherent structure by means of longitudinal rows of stitching.  
         [0016]     U.S. Pat. No. 4,592,675 to Scales, et al., entitled Revetment Panel with Staggered Compartments discloses a revetment panel including a fabric web having a plurality of compartments that are staggered in relation to each other and separated by selvage. The web is formed of two fabric layers, which are woven separately to form the compartments and fastened together to form selvage separating them. The web is transported to its installation site and placed. The compartments in the web are then inflated with the filler material, which may be cementitous slurry or mortar.  
         [0017]     U.S. Pat. No. 4,342,807 to Rasen, et al., entitled Low Density Matting and Process, discloses a matting consisting essentially of melt-spun thermoplastic macrofilaments which are self-bonded or fused at random points of intersection without using any bonding agent or reinforcing inserts.  
         [0018]     U.S. Pat. No. 4,353,946 to Bowers, entitled Erosion Control Means, discloses an erosion control blanket formed from wood wool fibers retained in a coherent structure with a biodegradable mesh.  
         [0019]     U.S. Pat. No. 3,517,514 to Visser, entitled Soil Protection Mats discloses mats of non-woven fabric having randomly oriented polypropylene fibers.  
         [0020]     While the prior art provides any of a number of devices aimed at controlling or reducing the effects of soil erosion, it appears that few if any of the disclosed devices or systems provide a very effective means for reducing flow beneath the device or a means for joining two or more wattles, or other erosion control devices together to reduce flow or migration of sediment between the individual devices. Additionally, many of the previously disclosed devices are constructed of materials that are relatively absorbent and therefore are not prone to removal and reinstallation. Additionally, increased weight and volume contribute to increased cost of transportation and handling.  
         [0021]     Therefore, advantage may be found in providing a relatively lightweight sediment control wattle, constructed of a durable fabric having a lightweight fill that is relatively non-absorbent. Additionally, advantage may be found in providing a sediment control wattle that is constructed in such a manner that permits adjacent wattles to be joined to form an erosion and sediment control system in a manner that reduces migration and flow of fluid and sediment between wattles. Additionally, advantage may be found in providing a sediment control wattle that is constructed in such a manner that provides a means for securing the sediment control wattles to a hillside or slope in a manner that reduces migration and flow of fluid and sediment underneath the wattles. Further advantage may be found in reduced excavation required for installation and reduced labor and cost for transportation, handling and installation of a small lightweight sediment control wattle. Additionally, advantage and savings may be found in the ability to re-use the sediment control wattle from project to project over a period of several years.  
         [0022]     Therefore, an objective of the present invention is providing a relatively lightweight sediment control wattle, constructed of a durable fabric having a lightweight fill that is relatively non-absorbent. An additional objective of the present invention is providing a sediment control wattle that is constructed in such a manner that provides a means for securing the sediment control wattle to a hillside or slope in a manner that reduces migration and flow of fluid and sediment underneath the wattles. Additionally, an objective of the present invention is providing a sediment control wattle that is constructed in such a manner that permits adjacent wattles to be joined to form a sediment control system in a manner that reduces migration and flow of fluid and sediment between wattles. A further objective of the present invention is providing small lightweight sediment control wattles that allow reduced excavation for installation and reduced labor and cost for transportation, handling and installation of the wattles. Additionally, an objective of the present invention is providing a durable sediment control wattle capable of being re-used from project to project over a period of several years.  
       SUMMARY OF THE INVENTION  
       [0023]     The present invention is directed to an sediment control wattle comprising a sheath formed of a geotextile, the sheath containing a filler media. The sheath includes an apron constructed along a length of the sheath, extending from the sheath. The apron provides an element that may be pinned or otherwise attached to a terrain in a manner that reduces migration and flow of fluid and sediment underneath the wattles. In a preferred embodiment, the sediment control wattle also includes a joint wrap, which permits adjacent wattles to be joined, in an end to end configuration, to form a sediment control system in a manner that reduces migration and flow of fluid and sediment between wattles.  
         [0024]     The present invention is also directed to a relatively lightweight sediment control wattle, constructed of a geotextile fabric having a lightweight fill that is relatively non-absorbent. In addition, the invention is directed to a sediment control system including a plurality of sediment control wattles constructed according to the teaching of the present invention, the plurality of sediment control wattles being connected at adjacent ends.  
         [0025]     Additional advantages and novel features of the invention will be set forth in part in the description that follows, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention. Additionally, the advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims. 
     
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0026]      FIG. 1  is a representative perspective view of a sediment control wattle according to the present invention;  
         [0027]      FIG. 2  is a representative perspective view of a sediment control system including a plurality of joined sediment control wattles according to the present invention;  
         [0028]      FIG. 3  is a representative top view of a sediment control wattle according to the present invention;  
         [0029]      FIG. 4  is a representative cross sectional view of a sediment control wattle wrap according to the present invention;  
         [0030]      FIG. 5  is a representative cross sectional view of a sediment control wattle mid-section according to the present invention;  
         [0031]      FIG. 6  is a representative cross sectional view of a sediment control wattle end stitching according to the present invention;  
         [0032]      FIG. 7  is a representative cross sectional view of a sediment control wattle end tie according to the present invention;  
         [0033]      FIG. 8  is a representative top view of a sediment control wattle system according to the present invention;  
         [0034]      FIG. 9  is a representative cross sectional view of the two joined sediment wattles at the joint wrap in an installed condition, according to the present invention;  
         [0035]      FIG. 10  is a representative top view of a sediment control wattle according to an alternate embodiment of the of the present invention;  
         [0036]      FIG. 11  is a representative cross sectional view of a sediment control wattle according to an alternate embodiment of the present invention; and  
         [0037]      FIG. 12  is a representative cross sectional view of a sediment control wattle according to an alternate embodiment of the present invention.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0038]     Referring to  FIGS. 1 and 3 , sediment control wattle  10  is shown including sheath  11  formed of a geotextile fabric. Sediment control wattle  10  also includes apron  12  and joint wrap  14 . In the preferred embodiment, sheath  11  is configured as a tubular sheath formed by rolling first edge  18  back towards second edge  19  and sewing longitudinal seam  15  along a length of the geotextile fabric. Longitudinal seam  15  is positioned along line L located between first edge  18  and second edge  19  resulting in the formation of tubular sheath  11  and apron  12 . In the preferred embodiment, end stitching  16 , located at first end  21 , and a self-locking cable tie  17 , located at second end  22 , are used to contain a filler media inside sheath  11 . Generally speaking, a geotextile is a fabric or textile that is designed to work in conjunction with a geological environment to enhance a particular environmental or geological objective, for instance soil erosion control or containment of soils. A geotextile may be woven or non-woven, formulated of natural or synthetic materials. A geotextile may be constructed of a rot-proof and/or ultra violet resistant material or, in the alternative the geotextile may be constructed of a material that is biodegradable. A geotextile may be impermeable or permeable to water and often the rate of permeability is a controlled feature of the construction of a geotextile. A geotextile may be made from staple or continuous filaments. Synthetic materials, including for instance, polypropylene, nylon and polyester and natural fibers including hemp, ramie, and jute provide satisfactory materials from which geotextiles may be fabricated. A permeable geotextile appropriate for the present invention may range in weight from 65 g/m 2 , (or approximately 2 ounces per square yard), to 700 g/m 2 , (or approximately 21 ounces per square yard). Permeable woven and non-woven geotextiles are characterized by relatively uniform, distinct and measurable percentages of open area. This assures that both water and soil particles up to a maximum size will have passage through the geotextile. Permeable woven and non-woven fabrics having relatively little open area, often trap soil particles within the fabric, clogging the geotextile.  
         [0039]     Referring to  FIG. 2 , a sediment control system  50  is shown including a plurality of sediment control wattles  10 A and  10 B, including sheath  11 A and  11 B, apron  12 A and  12 B and joint wrap  14 A and  14 B respectively. Sheath  11 A and sheath  11 B are each configured as tubular segments formed by sewing longitudinal seam  15 A and longitudinal seam  15   b  respectively. As shown, sediment control wattles  10 A and  10 B include sheath  11 A and  11 B, apron  12 A and  12 B and joint wrap  14 A and  14 B respectively. Aprons  12 A and  12 B are construed to extend laterally from sheath  11 A and  11 B respectively. Sheath  11 A includes first and second ends  21 A and  22 A formed by end stitching  16 A and self-locking cable tie  17 A respectively. Similarly, sheath  11 B includes first and second ends  21 B and  22 B formed by end stitching  16 B and self-locking cable tie  17 B respectively. As shown, second end  22 A of sediment control wattle  10 A is placed adjacent to first end  21 B of sediment control wattle  10 B and inside joint wrap  14 B with an axis A of sediment control wattle  10 A and  10 B lying substantially in line. Apron  12 A is laid directly over apron  12 B at the joint wrap when installing  10 A and  10 B end to end.  
         [0040]      FIG. 4  is a section taken through joint wrap  14  of sediment control wattle  10  shown in  FIG. 3 , wherein sheath  11  and apron  12  are left un-sewn to form joint wrap  14 . End stitching  16  can be seen at the inside of joint wrap  14 .  
         [0041]      FIG. 5  is a section taken through a mid-section of sediment control wattle  10  shown in  FIG. 3 . Sediment control wattle  10  includes sheath  11  configured as a tubular segment formed by rolling first edge  18  back towards second edge  19  of apron  12  and sewing longitudinal seam  15 . Sheath  11  is shown filled with filler media  20 . In a preferred embodiment, filler media  20  includes a plurality of irregular globules formed of foam polystyrene, for instance Styrofoam® “peanuts”. Alternately, filler media  20  may comprise any of a variety of shapes including substantially spherical shapes, solid polygons or irregular solids. Preferably, erosion control baffle  10  may include any natural or synthetic fill having an absorption capacity under 2.0% by volume. Additionally, the preferred filler media exhibits a dimensional stability with under 10% linear change. Additionally, the preferred filler media exhibits a minimum compressive strength of 138 g/cm 2  or approximately 5 lb/in 2 .  
         [0042]     Referring to  FIG. 6 , sediment control wattle  10  including apron  12 , constructed according to the preferred embodiment of the present invention, is shown in cross section at end stitching  16 , which forms a closure at first end  21  of sheath  11 , as seen in  FIGS. 1 and 3 . Preferably, end stitching  16  is oriented vertically to provide a vertical section having a height H that is at least equal to a diameter D of wattle  10 . As seen in  FIG. 6 , longitudinal seam  15  is located with respect to end stitching  16  such that leg  25  is formed. Leg  25  assists in maintaining a generally vertical orientation of end stitching  16  when wattle  10  is in use. This construction results in a configuration that tends to eliminate slump between wattles  10 A and  10 B of sediment control system  50  at joint wrap  14 B, as shown in  FIG. 2 .  
         [0043]     Referring to  FIG. 7 , sediment control wattle  10 , constructed according to the preferred embodiment of the present invention, is shown in cross section at the self-locking cable tie  17 , which is used to contain filler media  20  after the sheath  11  is filled with filler media  20  as shown in  FIG. 5 . To attach self-locking cable tie  17 , a pointed end of the plastic cable tie is pushed through the apron  12  and wrapped around the gathered sheath  11 . The pointed end of the cable tie is then threaded through the cable tie self locking mechanism and pulled tight. It will be noted that self-locking cable tie  17  may be removed and replaced as desired to either add or remove filler media as desired.  
         [0044]     Referring to  FIG. 8 , sediment control wattles  10 A and  10 B are shown laid out end to end for installation along their respective axes represented by the reference character A As shown, sediment control wattles  10 A and  10 B include sheath  11 A and  11 B, apron  12 A and  12 B and joint wrap  14 A and  14 B respectively. Aprons  12 A and  12 B are construed to extend laterally from sheath  11 A and  11 B respectively. Sheath  11 A includes first and second ends formed by end stitching  16 A and self-locking cable tie  17 A. Similarly, sheath  11 B includes first and second ends formed by end stitching  16 B and self-locking cable tie  17 B. As shown, second end of sediment control wattle  10 A is placed adjacent to first end of sediment control wattle  10 B and inside joint wrap  14 B with an axis A of sediment control wattle  10 A and  10 B lying substantially in line. Apron  12 A is laid directly over apron  12 B at the joint wrap when installing  10 A and  10 B end to end.  
         [0045]     Referring to  FIG. 9 , installation of sediment control wattle  10 A inside, and  10 B, outside, are shown in cross section installed on terrain T. Sediment control wattles  10 A and  10 B are positioned in a cut C made substantially perpendicular to a slope, shown generally by vector SL, of terrain T. Aprons  12 A and  12 B are pinned to terrain T employing a plurality of pins shown generally as pin P 1 . Joint wrap  14 B is shown wrapped about a circumference of sheath  11 A of sediment control wattle  10 A and pinned to terrain T by pin P 2 . Fill F is then placed over aprons  12 A and  12 B.  
         [0046]     Sediment control system  50  provides a sediment control device which minimizes migration of soils from an upper side of joined sediment control wattles  10 A and  10 B to a lower or downhill side of sediment control system  50  as aprons  12 A and  12 B are pinned and fill F is placed over aprons  12 A and  12 B thereby providing that a flow along slope SL of water and sediment would be against rather than underneath sediment control wattles  10 A and  10 B. Additionally, sediment control system  50 , as shown in  FIGS. 2 and 8 , provides a means for combining a plurality of adjacent sediment control wattles in an end-to-end arrangement that eliminates migration of soils between adjacent sediment control wattles, as each pair of adjacent sediment control wattles  10 A and  10 B in  FIGS. 2 and 10 A and  10 B in  FIG. 8 , are coupled by a joint wrap, in this case  14 B.  
         [0047]     Referring to  FIG. 10 , an alternate configuration for a sediment control wattle  100  including apron  112  and joint wrap  114  is shown. Sheath  111  is shown closed at first end  121  by stitching  116  and self-locking cable tie  117  located at second end  122 . In this alternate embodiment, joint wrap  114  is configured as a panel that extends to sheath  111  and apron  112  of sediment control wattle  100 . Joint wrap  114  may be wrapped around the ends of sediment control wattle  100  and an adjacent sediment control wattle and secured to the ground with pins, similar to that described for  FIG. 8  and  FIG. 9  above.  
         [0048]      FIG. 11  shows an alternate apron configuration in cross section for sediment control wattle  200 . Apron  212  formed by first and second layers  213  and  214  of geotextile sewn together at longitudinal seam  215  and at apron stitching  221  near an outside edge of apron  212  forming pocket  225  and filled with an anchoring media  222  such as pea gravel. Anchoring media  222  may be bound to apron  212  with an adhesive to assure consistent distribution. The sheath  211 , longitudinal seam  215  and sheath filler media  220  are similar to that described for  FIG. 5 . The purpose of this embodiment is for use on hard surfaces such as asphalt and concrete without the use of pins to fasten the sediment control wattle in place.  
         [0049]      FIG. 12  shows an alternate apron and sheath configuration in cross section for sediment control wattle  300 , having an apron  312  formed by two layers  313  and  314  of geotextile extending to both sides of the sheath  311 , and sewn together at apron stitching  321 A and  321 B located at the outside edges of layers  313  and  314  forming pocket  325  which may be filled with an anchoring media  322  such as pea gravel. Anchoring media  322  may be bound to apron  312  with an adhesive to assure consistent anchoring media  322  distribution. An alternate sheath configuration is shown in  FIG. 12 , wherein sheath  311  is formed from a rectangular piece of geotextile separate from the apron  312 . As shown, sheath  311  is sewn to the top of apron  312  along both sides of the sheath  311  at longitudinal seams  315 A and  315 B. Sheath filler media  320  is similar to that described for  FIG. 5 . The purpose of this embodiment is for use on hard surfaces such as asphalt and concrete without the use of pins to fasten the sediment control wattle in place.  
         [0050]     In an alternate embodiment, an apron includes a plurality of discreet or separate pocket compartments similar to those shown in  FIGS. 11 and 12  to reduce migration of the anchoring media. In yet another alternate embodiment, pockets of the type shown in  FIGS. 11 and 12  may be configured as re-closable so that anchoring media may be added or removed as desired.  
         [0051]     It is to be understood that the invention is not limited to the embodiment shown and described above. Various other embodiments of the invention may be made and practiced without departing from the scope of the invention, as defined in the following claims.

Summary:
A sediment control wattle including a sheath formed of a geotextile, the sheath containing a filler media. An apron extends from the sheath providing an element that may be pinned or otherwise attached to a terrain in a manner that reduces migration and flow of fluid and sediment underneath the wattles. The sediment control wattle may also include a joint wrap which permits adjacent wattles to be joined to form a sediment control system in a manner that reduces migration and flow of fluid and sediment between wattles.