Abstract:
This invention relates to a novel environmentally compatible culvert system. More particularly, this invention relates to a novel multi-component modular environmental culvert system which is constructed of reaction injection molded components, comprising modular interconnecting bases, modular interconnecting corrugated arch systems, and modular joining binders. A modular culvert system comprising: (a) at least one base grid module; (b) at least one corrugated arch module resting on the grid; and (c) an arch shaped binder module adjacent the arch module.

Description:
FIELD OF THE INVENTION 
       [0001]    This invention relates to a novel environmentally compatible culvert system. More particularly, this invention relates to a novel multi-component modular environmental culvert system which is constructed of reaction injection molded components, comprising modular interconnecting bases, modular interconnecting corrugated arches, and modular intermediate joining binders. 
       BACKGROUND OF THE INVENTION 
       [0002]    With increasing emphasis by regulatory authorities on minimizing damage to the environment, many jurisdictions have passed laws and regulations which prohibit the installation of materials which are regarded as being potentially harmful to the environment. Once such area is metal culvert replacement in road and bridge systems. In many jurisdictions, it is prohibited to replace existing corroded metal culverts with new metal culverts, even galvanized steel culverts. There is a need for an inexpensive, readily installable environmentally compatible culvert system that can be used for construction of new culverts and replacement of old culverts. 
         [0003]    The foregoing examples of the related art and limitations related thereto are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings. 
       SUMMARY OF THE INVENTION 
       [0004]    The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other improvements. 
         [0005]    The invention is directed to a culvert system comprising: (a) at least one base grid module; (b) at least one corrugated arch module resting on the grid module; and (c) an arched binder module located adjacent the corrugated arch module. 
         [0006]    The base grid module can comprise a plurality of interconnecting ribs with spaces therebetween and corrugated arch module receiving rails on each side thereof. The base grid module can include spatial openings therein for receiving the ends of the corrugated arch module. 
         [0007]    The depths of the grooves of the corrugations in the corrugated arch module can deepen as the arch extends from the top center to each side at the base of the arch module. The lower edges of the arch module can have a series of protrusions thereon which can be adapted to fit into spatial openings in the base grid module. 
         [0008]    There can be at least two adjacent arch modules and the arched binder can be adapted to fit between the adjacent arch modules, the binder having at the lower base thereof protrusions which fit into corresponding openings in the base grid module. 
         [0009]    The arched binder can have a T-shaped cross-section. The corrugated arch receiving rails can have a hollow semi-cylindrical configuration. The corrugated arches can be formed in the shape of a hollow half cylinder. 
         [0010]    There can be at least three base grid modules adjacent one another, at least two corrugated arch modules adjacent one another and offset  50  percent from the three base grid modules, and the arched binder fits between the two adjacent arch modules and releasably connects them together. 
         [0011]    In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following detailed descriptions. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0012]    Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive. 
           [0013]      FIG. 1  illustrates an isometric view of the environmentally compatible modular culvert system according to the invention. 
           [0014]      FIG. 2  illustrates an exploded isometric view of the environmentally compatible modular culvert system. 
           [0015]      FIG. 3  illustrates an underside isometric view of the environmentally compatible modular culvert system. 
           [0016]      FIG. 4  illustrates a bottom view of the environmentally compatible modular culvert system. 
           [0017]      FIG. 5  illustrates an isometric view of a corrugated arch module. 
           [0018]      FIG. 6  illustrates an isometric view of a binder module. 
           [0019]      FIG. 7  illustrates a cross-section exploded view of a binder module positioned between adjoining edges of two corrugated arch modules. 
           [0020]      FIG. 8  illustrates a cross-section view of a binder module fitted between the edges of two corrugated arch modules. 
           [0021]      FIG. 9  illustrates an isometric view of three adjoining base modules. 
           [0022]      FIG. 10  illustrates an underside isometric view of three adjoining base modules. 
           [0023]      FIG. 11  illustrates a plan view of a wedge-shaped arch module. 
           [0024]      FIG. 12  illustrates an isometric view of a wedge-shaped arch module. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0025]    Throughout the following description specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well known elements may not have been shown or described in detail to avoid unnecessarily obscuring the disclosure. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense. 
         [0026]    Referring to  FIG. 1 , which illustrates an isometric view of the modular culvert system  2 , the modular culvert system as seen in  FIG. 1  comprises two adjoining corrugated arch modules  4 , which by means of respective cylindrical base grips  6  on each side, rest on three adjoining base modules  8 . The three adjoining base modules  8  have on each side thereof adjoining cylindrical rails  10 , which together support the cylindrical base grips  6  of the two adjoining overhead corrugated arch modules  4 . The interior body of the base modules  8  have openings  12  which are arranged in a grid-like pattern. The two adjoining corrugated arch modules  4  are connected together by an arched binder  14 . 
         [0027]    It will be understood that the construction shown in  FIG. 1  and subsequent figures is illustrative and that any number of arch modules, base modules and binders can be connected together to construct a culvert that is required in the field. In practice, the culverts can be short, medium or long in length, and in certain cases, can be linear or curved. 
         [0028]    Referring to  FIG. 2 , which illustrates an exploded isometric view of the environmentally compatible modular culvert system, the two arch modules  4 , the interconnecting binder  14  and the three base modules  8  are readily visible. 
         [0029]    Referring to  FIG. 3 , which shows an underside isometric view of the modular culvert system  2 , the modular system comprises two adjoining corrugated arch modules  4 , with cylindrical base grips  6  on each side, which rest on three adjoining base modules  8 . The three base modules  8  have on each side thereof connecting base cylindrical rails  10 , which together support the cylindrical base grips  6  of the overhead corrugated arch modules  4 . The arch modules  4  are offset from the base modules  8  by 50 percent. 
         [0030]    Referring to  FIG. 4 , which illustrates a bottom view of the environmentally compatible modular culvert system, the modular system comprises two adjoining corrugated arch modules  4  (partially visible), which by means of cylindrical base grips  6  (not visible), rest on three adjoining base modules  8 . The three base modules  8  have on each side thereof a connecting base cylindrical rails  10 , which together support the cylindrical base grip portions  6  of the overhead corrugated arch modules  4 . Plainly visible in  FIG. 4  are the series of corrugated arch prong openings  28  and intermediate binder openings  30 . 
         [0031]    Referring to  FIG. 5 , which illustrates a detailed isometric view of a corrugated arch module  4 , the module  4  has a pair of hollow cylindrical base grips  6  on each side of the base region of the corrugated body portion of the arch module  4 . It will be noted that the lower portions of the edge flanges  16  of the corrugated arch  4  have proportionally greater depth than the depth of the corrugations at the top of the arch module. This design provides greater strength to each side of the base regions of the arch module  4 . Also, the interiors of the hollow cylindrical grips  6  have a series of prongs  18 . These spatially arranged series of prongs  18  engage with corresponding openings  28  (see  FIG. 4 ) in the base module  8 , which will be discussed later. The corrugations above the grips  6  on each side act as baffles to reduce water flow velocity thereby enhancing the passage of fish, such as salmon, through the culvert. 
         [0032]      FIG. 6  illustrates an isometric view of an arched binder module  14 , with T-shaped cross-section  20 . The arched binder  14  has the same degree of curvature as the corrugated arch module  4 . 
         [0033]      FIG. 7  illustrates a detailed exploded section view of a binder module  14  between two corrugated arch modules  4 .  FIG. 7  illustrates in particular the T-shaped cross-section of the arched binder  14 , specifically the horizontal top bar portion  22 , the main vertical stem  24  and the pair of arch engaging flanges  26  at each end of the top bar  22 . 
         [0034]      FIG. 8  illustrates a cross-section view of a binder module  14  fitted between two corrugated arch modules  4 .  FIG. 8  illustrates in particular how the T-shaped cross-section of the arched binder  14 , specifically the horizontal top bar portion  22 , the main vertical stem  24  and the pair of arch engaging flanges  26  at each end of the top bar  22 , engage the adjoining flanges  16  of the adjacent arch modules  4 . As can be seen, the long stem  24  and the spaces between the stem  24  and the flanges  26  provide a significant amount of tolerance with the adjoining flanges to accommodate uneven and off-level terrain. The joining system also has the advantage that no bolts or other connecting fixtures are required to enable arch modules to be movably connected together. 
         [0035]      FIG. 9  illustrates an isometric view of a trio of adjoining base modules  8 . This view illustrates in particular the series of prong openings  28  which are located at the interior sides of the two side rails  10 . These series of openings  28  are adapted to receive and hold the series of prongs  18  of the corrugated arch modules  4  (see  FIG. 5 ). The sides of the bars making up the grid-like openings  12  in the base module  8  are upwardly tapered so that when freezing conditions exist, and ice forms in the openings  12 , the ice force will not break the ribs of the base module  8  but will expand upwardly similar to a conventional ice cube tray. Located on each side in the mid-area of each base module  8 , on the interior sides of the two rails  10 , is a binder opening  30 , which is wider than the neighboring prong openings  28 . These openings  30  are adapted to receive the T-shaped ends of the binder module  14  as seen in  FIGS. 1 ,  3  and  4 . When assembled, the corrugated arch modules  4  will be deployed on the trio of base grid modules but offset by  50  percent as seen in  FIG. 1 . In this way, there are no joints between adjacent arch and base modules that extend in a location around the circumference of the modular culvert system  2 . This arrangement provides strength for the overall culvert system  2 . 
         [0036]      FIG. 10  illustrates an underside isometric view of a trio of base modules  8 . This view illustrates in particular the series of prong openings  28  which are adapted to receive the series of prongs  18  of the corrugated arch modules  4 .  FIG. 10  also illustrates the intermediate binder openings  30  which are adapted to receive the ends of the binder module  14 . 
         [0037]      FIG. 11  illustrates a plan view of a wedge-shaped corrugated arch module  32 , with a wide cylindrical base grip  34  at one end and a narrow base grip  36 . This module  32  can be used to connect adjoining corrugated arch modules  4  when it is necessary to deploy the modular culvert system in a curved relationship rather than a linear relationship. 
         [0038]      FIG. 12  illustrates an isometric view of a wedge-shaped arch module  32 . The wide base grip  34  and the narrow base grip  36  are plainly visible. The shape of the wedge module can be varied to accommodate different angles. 
         [0039]    The corrugated arch modules, base modules and binders can be formed from appropriate polymers using reaction injection molded technology. The polymerizing reaction is exothermic so no mold heating is required. The inventors have found that Metton™ Resin, which is available from Metton American Inc. of La Porte, Tex., is very strong, readily reaction injection-molded and is environmentally compatible. Metton LMR provides part design freedom with integrated functionality and part consolidation opportunities similar to injection molding for replacement of traditional materials such as wood and metal. The molded Metton™ resin is stronger than fibreglass, thereby permitting thinner sections, and modules can be produced from the mold at 400° F. every three to four minutes. This is a much faster production rate than fibreglass, which is labor intensive and produces two to three modules per day. The Metton™ resin is environmentally friendly and does not leach harmful ingredients into the ground water. On incineration, about one third fewer pollutants are generated than for conventional incinerated polymers. 
         [0040]    While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true spirit and scope.