Abstract:
The system utilizes a bag containing hydrophilic dry material such as powered polymer. The bag is initially light in weight. When the hydrophilic material is exposed to water it absorbs water and expands to inflate the bag. By taking on the weight of the absorbed, the bag of the invention can replace the function of a conventional sand bag. Unlike a conventional sand bag, the bag of the invention has provision for causing the bags before and after inflation to interlock which strengthens the resulting protective wall. Part of the interlocking effect is created by the incorporation of ballast modules at least two corners of the bag which interlock with pockets on diagonal corners of adjacent bags. In addition to ballast modules, the bag may contain seed modules or pockets which release seeds to vegetate and hold soil on slopes.

Description:
RELATED APPLICATION 
       [0001]    The present application is related to and claims the priority benefit of co-pending U.S. Provisional Application No. 61/350,755, entitled Self Inflating Modularized Interlocking Surface Water Barrier and Erosion Mitigation System, filed Jun. 2, 2010 by the present inventors. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    For centuries, sand and rock-filled jute, burlap, coir or poly-propylene bags measuring approximately 12″×26″ and weighing up to 50#&#39;s when filled have been used individually and in large numbers to create artificial and typically temporary barriers to divert unwelcome surface water (e.g. rain runoff and mud) from entering areas and structures containing life, real property and infrastructure that would otherwise be damaged or destroyed by atypical and unexpected surface water or mud incursion. 
         [0003]    The present invention relates generally to products, methods and systems in which various quantities of ‘modularized’ bags, tubes or flexible containers filled with sand, gravel, rock or other bulk particulate (including man-made bio-degradable matter) are used to prevent the anticipated incursion of surface water or mitigate damage to life and real property from existing or ongoing unwanted surface water, soil or silt incursion. 
         [0004]    The most common form of existing water diversion barriers have been and are simple sand bags and millions are produced and used each year around the world. Such sandbags are most commonly filled one-at-a-time using shovels, scoops, buckets or other simple manual devices. Once filled with sand, gravel or other selected particulate matter, the individual bags are typically closed off with a drawstring, metal or plastic twist tie or other mechanical or chemical based sealing mechanism or by simply folding the open end of the bag to keep the filler material contained within the bag until the bag is placed among other sandbags to form a wall or barrier. 
         [0005]    Within the last several decades, a number of manual filling assist devices have been invented and disclosed. U.S. Pat. Nos. 5,687,781; 5,802,807 and 5,845,685 are examples of such devices. As with filling bags or other containers by hand (e.g. with a shovel), the manual filling assist devices are very slow and typically inefficient. 
         [0006]    In flood emergencies (as opposed to erosion control and mitigation), the need to construct a multi-layer wall or barrier constructed using many sandbags deployed quickly poses huge problems to those residents or property owners and other persons responsible for real property. Without large numbers of workers (often volunteers), and thousands upon thousands of sandbags, as well as substantial supplies of readily available sand, gravel or rock, the flood waters cannot be held back or diverted. 
         [0007]    Over the years, the problem of filling large quantities of sandbags quickly has led to the invention and disclosure of semi-automated devices capable of filling multiple bags simultaneously and filling them utilizing gravity rather than shovels. U.S. Pat. Nos. 4,044,921; 4,184,522; 5,873,396; 5,806,576 and 5,893,260 are such examples. 
         [0008]    While typically faster than all-manual solutions, the semi-automated systems are still unable to produce the quantity of filled bags required in a true flood emergency. 
         [0009]    As filler devices, methods and systems evolved, so too did the realization that the output or throughput from such bagging devices and systems was directly dependant on the constant and increasing availability and supply of filler materials (sand, gravel, etc) itself as well as empty bags or other filler containment vessels. 
         [0010]    Beginning with U.S. Pat. Nos. 5,771,605; 6,863,094B1 and 6,978,812, fully automated mechanical bag filling devices have been disclosed. These devices are capable of automatically filling and sealing off up to 40,000 bags per day (operating around the clock) with a one or more person crew. 
         [0011]    At a high filling (production) rate of 40,000 bags per 24 hour period, approximately 800 tons (1,600,000 pounds) of filler (sand, gravel, etc) material is needed at the production site(s) together with the 40,000 empty bags and tie-off or bag sealing components. Providing such logistics can be problematic, especially on short notice. 
         [0012]    Of equal or even greater challenge is the task of physically moving and individually placing each traditional sized 35-50 LB. bag. It is exhausting and backbreaking work and currently results in considerable worker fatigue, injury incidents and damage claims. 
         [0013]    A number of Applications have been filed that deal only with the sandbag itself. These include US202/0081153 A-1; US 2003/0017288 A-1; and US 2007/0099327 A-1. 
         [0014]    The present invention overcomes the deficiencies in the prior art, by focusing on the bag design and engineering itself (modular &amp; interlocking), the filler materials, as well as the deployment and use processes. 
       SUMMARY OF THE INVENTION 
       [0015]    The present invention relates to a unique integration of both natural and man-made, non-toxic, bio &amp; photo-degradable materials engineered and manufactured in modules within a single or multi-layered, uniquely sized &amp; shaped containment bag, tube, envelope or mat (as used herein the term bag should be understood encompassing a bag, tube, envelope or mat) containing highly water absorbent dry (typically cross linked) polymers or compressed all-natural materials and/or nano particles which collectively and functionally hydrate and expand(when directly exposed to water) creating a self-inflating, lighter-weight and (typically) inter-locking surface water and soil erosion diversion and/or barrier system. Such bags, tubes or mats interlock not only in the horizontal (end-to-end) configuration but also in a vertical (stacked to create a higher barrier for the water, mud or silt to broach) configuration. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0016]    The invention is composed of a single or multi-layer bag or tube made of one or more permeable or semi-permeable photo and biodegradable geo-textile materials (such as woven jute/burlap, bamboo, coconut husk fibers (coir), and/or as manmade biodegradable and photodegradable polypropylene, or other dissolvable or non-dissolvable man-made or natural fabric, paper or other membrane measuring up to 1,400 mm in circumference and up to a hundred (100) meters in length. Sewn, glued, thermally sealed, or stapled selected layers, internally integrated or externally affixed to or into the tube/bag at regular or irregular intervals are pockets or pouches (modules) of various sizes and shapes containing one or more of the following: A) naturally occurring dense particulate matter such as sand, gravel or rock weighing up to 5,000 grams per module (pocket) and typically contained in a bio-degradable hard-shell box or similar container with a flat top and flat bottom to enhance the ‘interlocking’ capabilities described herein and hereinafter referred to as Ballast modules. The concentration of weight in each such pocket or pouch acts as ‘ballast’ to hold the tube/bag in place (from wind and/or water or topographic challenges such as steep hillsides) while B) the main and typically largest modules (expansion modules) containing measured quantities and proprietary blends of lightweight, super absorbent, (typically cross-linked) polymer powder or other natural or man-made hygroscopic (water molecule absorbing or storing) particles which absorb the ground surface water, rain or hosed-on water into or through some or all layers of the multi-layer bag, tube or mat. Nano tubes or similar micro molecular structures may be substituted or combined with the polymer to function or enhance the water absorption and encapsulation process. C) the third category of modules called seed modules are also pouches or pockets created by stitching or sealing select layers of the bag, tube or mat. The optional seed modules are for use in soil erosion mitigation applications where the system comes in direct contact with earth, not rock, concrete asphalt or other surfaces unable to sustain or encourage root and plant growth. These seed modules can be additional internal pockets or external pockets or pouches sewn or sealed or otherwise incorporated into or onto the bags, tubes or mats at fixed or variable distances. The pockets or pouches (referred to collectively as pouches) themselves are typically composed of a single outer or external layer of bio-degradable, open-weave fabric or other membrane material through which plant roots and supporting natural growth structure can penetrate. 
         [0017]    These pockets or pouches can be stitched or sealed on two (2), three (3), or all four (4) sides so that pre-formed solid or semi-solid bricks, tube-like sticks or ‘wafers’ as further described below can be placed or inserted. Such solid or semi-solid bio-mass ‘brick’, ‘stick’ or ‘wafer’ can be composed of a proprietary mix of fast or slow growing flower or ground cover seeds, super-absorbent polymers for water absorption and retention, fertilizers and/or plant food blended together with high cotton content recycled paper pulp, mulch, straw or other natural materials which well serve as a germination and incubation medium cross section illustration of ‘brick’). Following the introduction to the composite bio-mass brick or other form factor of sufficient water, the embedded seeds (which may be coated to slow germination) germinate and exit the pouch or pocket through the open or loose weave exterior fabric or membrane or as the bag or tube naturally or physically degrades and deteriorates due to ultraviolet light and exposure to the elements in their natural course or by design (such as caused by a chemical treatment or additive involving the entire bag or tube or selected portions). 
         [0018]    The above described Modules can be made from single or multilayer geo-materials. In the case of a multilayer bag, tube or mat, the outer-layer is typically a loosely woven or more open weave geo-fabric made of bio-degradable materials while the inner layer or lining is typically a much tighter or finer weave of non-woven (typically manmade) fabric required to keep the small particles of filler material (such as sand or polymers) contained within the inner liner during shipping and handling and prior to the introduction of water or other liquids which then cause the expansion module particles to grow or expand in physical size within their own containment bag or envelope. 
         [0019]    Such inner module containment layer or membrane (referred to collectively as a membrane) may, in some embodiments, be treated with starch or other non-toxic, water soluble solutions in order to further seal the inner bag to contain the very small particles of filler material. Such fabric sealers must dissolve quickly in the presence of water to allow water to quickly permeate the described inner bag or liner and reach the polymers or other materials designed to swell and expand when in contact with water. All layers or membranes of the bag or tube are liquid (water) permeable. 
         [0020]    In one embodiment, the stitched or sealed ballast pouch or pocket is left empty but still isolated (typically with through and through stitching, heat or adhesive sealing, etc) from the rest of the bag or tube with such pocket or pouch serving as an area externally marked or designated through which fastening pins or stakes can be driven or inserted through such designated layer or layers directly into the ground or other selected surface to secure the bag or tube into place while the bag/tube itself expands and increases in weight due to the water or liquid absorptive action and water retention nature of the super absorbent polymers or other naturally occurring filler materials that effectively absorb (or attach to and hold) water molecules. The empty pocket creates a recess in the inflated bag to cooperate with filled pockets on an adjacent (stacked) bag to interlock the bags and thereby stabilize stacks of bags. 
         [0021]    Immediately upon penetration of water molecules through the one or more layers of water permeable fabric(s) or dissolvable paper etc, the super absorbent polymers or nano tubes or other hygroscopic materials begin to attach to and/or encapsulate the water molecules and swell in size, filling the interior space or void of the bag, tube or mat with a gel-like material primarily composed of the external water absorbed through the layers or membranes of the bag or tube itself plus the previously referenced and described ‘ballast’ pockets and/or pouches. As the super absorbent polymers or other highly absorptive natural or man-made materials reach their maximum capacity, the weight and volume of the bag/tube or vessel increases by the exact liquid weight absorbed. Therefore the ‘plumpness’ (expanded volume) of the bag/tube and its fully saturated weight is directly dependant on the selected weight/volume and absorptive capabilities of the absorbent material itself. 
         [0022]    Because of the density variable between sand, rock and water, a specified cubic volume of sand, rock or other inert ballast will weigh more than the corresponding cubic volume of water saturated polymers or similar absorptive material but will have sufficient weight and mass to perform the same water diversion and blocking functions of traditional sandbags weighing considerably more. 
         [0023]    Typically within 5-6 minutes of contact with water, the super absorbent polymers or alternative absorptive materials herein described, swell up to hundreds of times their weight and volume and entirely occupy and fill all or most of the available and formerly vacant space (voids) in the expansion module of the tube/bag (i.e. spaces not otherwise occupied by the previously described ballast modules, pockets or compartments sealed or separated from the main bag or tube space. The polymers and other absorptive materials are typically capable of holding between 200 and 1,000 times their own weight in liquid weight and mass. 
         [0024]    The previously described ballast module pockets, pouches or compartments can be in any shape though the preferred embodiment is a rectangular or circular shape of approximately 150 mm×150 mm (approximately 9,000 square mm), scaled up or down as required, and placed along the edges adjacent to the main side seam that stitches the tube/bag together in an alternating pattern so that the ends of two individual sandbags are equally divided between ballast filled and absorptive material filled spaces therefore at each end of a bag, regardless of its length, the water infused filler material(s) (turned gel in the case of the polymers) nests on top of the adjacent bag/tubes lower and more compressed ballast section. This nesting effectively ‘locks’ the bag/tubes together in a single line AND provides additional nesting pockets along the entire length if additional bag/tubes are being stacked to form a taller, multi-layer wall or barrier. 
         [0025]    An alternative embodiment used with bags or tubes ranging in length up to 100 meters provides ballast module pockets, pouches or compartments (as previously described) stretching across the entire width of the tube or bag, rather than occupying only 50% of the width and placed at consistent intervals. 
         [0026]    In yet a different embodiment of the invention, the previously described tube or bag is fabricated or assembled to become a ‘mat’ whose width and length would be a function of the end-use application as well as limitations potentially imposed by the size of the raw materials that compose the one or more layers or membranes as previously described for the bag or tube embodiment. The typical mat embodiment would measure 1,200 mm-1,400 mm or more in width and up to one hundred meters in length. The pre-deployed mat would be constructed and distributed in ‘sheets’ or in rolls. 
         [0027]    In the mat embodiment (whose applications would include soil erosion prevention on hillsides and riverbanks), the inclusion of ballast pockets or pouches would be distributed across the entire surface area of the mat in a pattern. 
         [0028]    An alternative embodiment of the mat would also include empty ballast modules (pouches or pockets) in order to provide ‘safe’ or designated locations on the mat surface where stakes or pins or other similar fasteners or anchor points can be driven through the mate membrane(s) or fabric layers directly or indirectly into the underlying soil or other natural surfaces subject to water or wind erosion. 
         [0029]    In another embodiment the single or multilayer bag or tube does not have any dedicated ballast module or ballast pockets or pouches. Rather the tube or bag itself is divided or compartmentalized through stitching or other sealing methods to create dividers across the entire width of the bag or tube intervals (ranging from 300 mm to 1,400 mm) apart. In this particular embodiment, the water absorbing filler material as herein elsewhere described is combined or mixed with various amounts of dense natural or man-made inert ballast such as gravel, rock concrete, bricks, etc. allowing for use in a variety of weight-critical applications. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0030]    FIG. # 1 —top view (looking down onto the main, modular bag, tube, envelope or mat) depicting the various modules described elsewhere herein. The over-all length can vary with application but in the preferred embodiment, ‘x’ is up to 3 meters (3,000 mm) and the overall width (‘y’) is up to 350 mm. This embodiment depicts all the Seed Modules as internal ‘pockets’ within the bag, tube, envelope or mat. 
           [0031]    FIG. # 1 A—top view (looking down onto the main, modular bag, tube, envelope or mat as otherwise described in FIG. # 1 ). 
           [0032]    FIG. # 1 B—side view depicting un-inflated view of internal seed module ‘pocket’ embodiment. 
           [0033]    FIG. # 1 C—side view depicting internal ‘pocket’ embodiment with Inflation Modules inflated (dotted line # 120  representing approximate hydrated position of Inflation Module). 
           [0034]    FIG.  2 —intentionally omitted. 
           [0035]    FIG. # 3 A—top view (looking down onto the main, modular bag, tube, envelope or mat) of ‘pouch’ embodiment featuring external center seed module ( 140   a  and  140   b ). 
           [0036]    FIG. # 3 B—side view depicting un-inflated embodiment of the center seed module constructed as an external pouch rather than an internal pocket. 
           [0037]    FIG. # 3 C—side view depicting inflated embodiment of the center seed module constructed as an external pouch rather than an internal pocket. 
           [0038]    FIG. # 4 —end view of two (2) bags, tubes, envelopes or mats depicting locking or nesting mechanism of one to the other. The inflated portion of one bag, tube, envelope or mat nests with the flatter ballast module of the other bag, tube, envelope or mat and vice versa. 
           [0039]    FIG. # 5 —top and ‘open’ corner view of bag, tube, envelope or mat depicting the typical ‘multi-layer’ construction of the Inflation Module itself. 
       
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS  
       [0040]    # 110 —represents heavy industrial-style stitching, heat-sealing, spot-welding, adhesive bonding or other means of joining two or more layers of the geo-textiles (natural or man-made) that comprise the outer and (when applicable) the inner layers of the bag, tube, envelope or mat as well as the method for separating the various ‘modules’ described elsewhere herein. 
         [0041]    # 120 —is the outermost layer of the bag, tube or mat&#39;s geo-textile construction. This layer (natural materials such as jute, burlap, coir or bamboo or photo degradable man-made materials such as poly propylene) will, in all embodiments, be a loose or more open weave that create tiny openings between each cross-woven strand that will allow light and water to enter and plant materials and roots to exit or grow through towards sunlight or sources of nourishment. 
         [0042]    # 130 —is the overall expansion module&#39; containing blends of cross-linked potassium co-polymer of acryl amide, with acrylic acid super absorbent polymers, compressed and dried natural organic materials, nano tubes and/or other nano structures all of which absorb and hold significant multiples of their own weight and mass in water molecules. The Expansion module typically requires use of an inner bag, pouch or envelope made of a tightly woven or low porosity non-woven natural or mad-made materials, water permeable, bio-degradable geo-fabric or membrane capable of containing the very fine powder-like granules of the polymers. The fabric or membrane of this module can also be treated with starch or other water soluble but non-toxic solutions or materials to further seal the tiny polymers into this inner bag or envelope during transit and handling. The heavy stitching or other sealing material depicted in # 110  would typically penetrate this inner ‘Expansion Module’ bag or envelope to secure it from bunching or wadding up inside the main bag, tube, envelope or mat. 
         [0043]    # 130   a  is the side view of the expansion module, with the post-hydration configuration illustrated by the dotted line. 
         [0044]    # 140   a —is the single layer pocket, pouch or envelope created in the stitching or sealing process called the seed module that provides a place to insert or position a bio-mass ‘brick’, ‘stick’ ‘tube’ or ‘wafer’ containing high-cotton content re-cycled paper pulp, un-germinated plant or grass seeds, super absorbent polymers, fertilizer and/or plant food. 
         [0045]    # 140   b —is the actual seed module which can be comprised of all or some of the above referenced plant growth elements made into a solid, water dissolvable mass (brick or wafer) or loosely contained in a water dissolvable membrane bag, envelope or pouch that is placed or inserted into a designated ‘Seed Module’ pouch or pocket. This designated module area may, in some embodiments, be empty and the space used to drive a stake through the bag into the surface on which the bag, tube, envelope or mat is placed. The stake would provide additional holding stability for the entire bag, tube, envelope or mat when placed on steep hillsides or where water currents are such that the Ballast modules would be inadequate to hold the bag, tube, envelope or mat in place during its hydration process. 
         [0046]    # 150 —depicts a section of the outer bag, tube, envelope or mat that is NOT stitched as described in # 110  above. 
         [0047]    # 160   a —describes the ballast module which is a designated portion of the overall main bag, tube or envelope (which in turn contains a hard-shell box-like container with a flat top and bottom and can be of different sizes and shapes that contains dense, naturally occurring bio materials such as sand, gravel, rocks or a combination thereof with a high ratio of weight to size. This portion or module of the overall main bag, tube or mat will, by virtue of the limited amount of heavy material placed in it, not only have a tendency to remain stationary when placed on the ground (or on top of another outer bag), but the bio-degradable hard walled container also will be flatter than the adjacent expansion module space which then allows the next outer bag to ‘nest’ or ‘lock’ into the original or first bag placed. 
         [0048]    # 160   b —depicts the inner ballast module containment bag, envelope or pouch itself. Always made from bio or photo-degradable natural or man-made materials, it will be approximately 150mm×150 mm (9,000 square mm in the preferred embodiment) and placed on and in the outer bag during the manufacturing process. 
         [0049]      160   c —depicts the inner expansion module containment bag, envelope or pouch which will always be made from bio or photo-degradable natural or man-made materials (typically tightly woven or low porosity un-woven fabrics) to contain the small particles of cross linked super absorbent polymers, nano structures or other man-made or natural, highly expansive hydroscopic materials. Though of low porosity the fabric must also be highly water permeable. 
         [0050]      160   d —depicts the natural or man-made hydroscopic material formulated to inflate or expand the overall bag, tube, envelope or mat upon contact with water of any kind. The preferred embodiment utilizes cross-linked potassium co-polymer of acryl amide, with acrylic acid. Other embodiments utilize dried and compressed naturally occurring materials made from coir or similar plant products or by-products that physically expand almost immediately upon hydration. 
         [0051]    # 200   a —illustrates the ‘top view’ (looking down) similar to # 100   a  except the center seed module is constructed as an internal rather than external pouch or sleeve. 
         [0052]    # 200   b —shows the side view of the un-inflated (un-hydrated) main bag, tube or mat showing the individual ballast, seed, and expansion modules. 
         [0053]    # 200   c —illustrates a side view of an inflated (hydrated) main bag (depicted by dotted line showing actual hydrated module or chamber within the main bag, tube or mat). 
         [0054]    # 400  shows end-view of typical outer bag, tube, envelope or mat with the ballast module on left side of the diagram. 
         [0055]    # 410  also depicts the end view of a typical outer bag, tube, envelope or mat with Ballast modules alternating on the right side of the diagram. Together with # 400 , these drawings illustrate the ‘interlocking’ mechanism, design and capability of the invention. 
         [0056]    # 500  depicts a typical bag but with the corners shown unattached so that the layered construction of the bag is apparent. The outer layer of the bag  501  is stitched by stitching  502 . The stitching extends through the outer layer  501 , and the material  504  of the chamber that retains the hydroscopic material  506 .