Abstract:
The present invention is an apparatus for filling a tubular bag with a granular material in order to construct a levee. The apparatus includes a hopper for funneling material into a loading box. A ram drive system then forces the granular material from the loading box into a tubular bag. The force of the ram also serves to propel the apparatus away from the filled bag so that the apparatus does not require a drive unit. The tubular bag is a pleated design installed around the opening of the loading box so as to extend as loaded. The apparatus can be scaled to accept different size bags to create levees of different heights and lengths.

Description:
RELATED APPLICATIONS  
       [0001]    This application claims the benefit of U.S. Provisional Application No. 60/467,386, filed on May 2, 2003, hereby incorporated herein in its entirety by reference. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The subject of this invention relates to the construction of barricades and in particular, this invention relates to an apparatus and a method for quickly filling a resilient tubular structure with a granular material to create a temporary levee.  
         BACKGROUND OF THE INVENTION  
         [0003]    Unexpected weather situations, environmental spills and erosion control frequently require the rapid deployment of a barricade system. Unexpected increases in water levels due to spring snow melts, hurricanes, heavy rains and flash floods create a need for the rapid deployment of a material barrier to prevent property loss due to rising water. Likewise, environmental spills of oil and other chemicals as well as construction projects, which might induce hazardous run-off from a building site, require the creation of barriers to prevent the further spread of harmful agents in the environment. There is a need then for a device capable of creating a quick temporary barrier in order to prevent property damage.  
           [0004]    Typically such barriers are built by hand using sandbags. Do to time constraints, these barriers are frequently filled by teams of volunteers and placed by hand in a line. In flood situation the barriers typically extend for hundreds of yards. For large barriers, filling the enormous number of sand bags required is a time consuming and backbreaking endeavor. A barricade of any length requires scores of workers and many hours to complete. There is a need for a simpler way to create barriers or levees, which requires relatively few personnel, and by which a substantial wall can be completed in less time than it takes for a crew of manual labor volunteers to arrive at the scene and begin filling sand bags.  
           [0005]    For larger spills or flooding, earth-moving machines are frequently used to build an earthen barrier. While less people are needed to perform this work, the granular fill used to form the barriers is unprotected and subject to erosion from the very substances the barriers are intended to contain. Therefore, there is a need to create a larger size barrier that is protected from water or liquid so as to survive the contact with the floodwaters or the spill material. Ideally, the protective covering should provide some structure to the wall, which is lacking in an earthen dam created by typical construction machinery.  
           [0006]    There is a need then for a device which can rapidly create a barricade. The device should require minimal amounts of manpower to operate. The device should create a barricade that is resistant to the affects of the environment. Moreover, it is desirable to have this device be reliable, efficient and less cost than the comparable manpower required to fill sandbags or run multiple pieces of heavy machinery.  
         SUMMARY OF THE INVENTION  
         [0007]    The levee builder system of the present invention substantially meets the needs as outlined above. The present invention is an apparatus for filling a tubular bag with a granular material in order to construct a levee. The apparatus includes a hopper for funneling material into a loading box. A ram drive system then forces the granular material from the loading box into a tubular bag. The force of the ram also serves to propel the apparatus away from the filled bag so that the apparatus does not require a drive unit. The tubular bag is a pleated design installed around the opening of the loading box so as to extend as loaded. It is understood that the tubular bag is only partially filled across its diameter, as ideally the filled tubular bag has a wider base then top as it extends from the apparatus. The apparatus can be scaled to accept different size bags to create levees of different heights.  
           [0008]    In a first embodiment, the portable levee builder apparatus includes a loading box disposed to receive a granular material, the loading box having a center retaining area, an upper portal, a first open side and a second open side; wherein said first open side and second open side define a passage through the loading box. The center retaining area of the loading box can have a rectangular shape or a cylindrical shape.  
           [0009]    A hopper is disposed above the loading box for receiving and funneling a granular material through the upper portal into the center retaining area. The hopper is preferably sized to accommodate a standard bucket load from a skid steer sized loader although the hopper can be sized to accommodate other loaders or conveyors. The hopper may include an auger disposed to assist the granular material into the center retaining area  
           [0010]    A ram drive system engages the granular material in the center retaining area. The ram drive system has a retracted position proximate the first open side and an extended position achieved after activation of a ram drive beyond the second open side. The ram drive system includes a ram support structure, the ram drive, and a ram plate box attached to the ram drive. The ram support structure is a tubular frame structure that supports the ram drive assembly and provides structure around the loading box. The ram drive may be a hydraulic unit or an auger unit. The ram plate box has an area slightly smaller than the passage defined by the first open side and the second open side of the loading box. The ram plate box includes an upper face or hopper plate disposed relative the upper portal so that granular material cannot fall behind the ram plate box when the ram plate is in the extended position. It is envisioned that the apparatus will include a control unit for activating the ram drive system when the center retaining area is sufficiently filled with granular material. The control unit may further include a sensor for automatically activating the ram drive system when the center retaining area is filled with granular material.  
           [0011]    A levee bag mount is also disposed about the second open side, said levee bag mount having a horseshoe shape over which a folded levee bag is placed. The levee bag mount of portable levee builder may include retaining clips to hold the levee bag in place.  
           [0012]    The portable levee builder apparatus may further include a hitch system for positioning the portable levee builder proximate a beginning point for the retaining structure. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]    [0013]FIG. 1 is a side perspective view of a levee builder in accordance with the present invention.  
         [0014]    [0014]FIG. 2 is a top phantom view of the levee builder of the present invention.  
         [0015]    [0015]FIG. 3 is a rear perspective view of a discharge end of the levee builder of the present invention.  
         [0016]    [0016]FIG. 4 is a front perspective view of the levee builder and a bag of the present invention.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0017]    The levee builder  10  is depicted in the FIGS. 1-4 The levee builder  10  generally includes hopper  12 , loading box  14 , ram drive system  16 , bag feeder  18  and levee bag  20 . Hopper  12  is of a conventional inverted hollow frustum shape having a rectangular shaped upper opening  22  and a smaller rectangular shaped lower opening  24  connected by four angled sides. The upper opening  22  of hopper  12  is sized appropriately to accept the introduction of sand or other granular fill material from the bucket of a front-end loader or conveyor (not shown). Hopper  12  is sturdily constructed of, for example, aluminum or plate steel. It is further envisioned that hopper  12  may have a support structures, such as angle irons or rectangular tubing, disposed about the upper opening  22 , lower opening  24  and at intermediate locations. Referring to FIG. 1, hopper  12  is located generally above loading box  14 .  
         [0018]    Loading box  14  is in communication with hopper  12  so that granular material placed into hopper  12  will funnel, preferably via gravity, into loading box  14 . Loading box  14  is depicted herein as a quadrilateral structure, however, loading box  14  may be cylindrical or any other desired shape and still remain within the spirit and scope of the invention. Loading box  14  includes an upper loading box section  26  and a ram section  28 . Upper loading box section  26  is vertically disposed above ram section  28  so as to allow for the unimpeded operation of expansion of bag  20  during filling operations. Ram section  28  is sized to accommodate the operation of ram drive system  16 . Ram section  28  is preferably surrounded by ram support structure  30 .  
         [0019]    Ram drive system  16  generally includes ram plate box  32 , hydraulic cylinder  34  and ram support structure  30 . Hydraulic cylinder  34  is affixed to ram plate box  32  at plate mount  36  and to ram support structure  30  at loading box mount  38 . Ram support structure  30  is preferably an open tubular metal frame construction formed in a shape to support ram section  28  at a first end and support the hydraulic cylinder  34  at a second end. The height and width of ram support structure  30  is larger than the height and width of ram plate box  32  and the length of ram support structure is slightly longer than the combined length of the hydraulic cylinder  34  and loading box  14 .  
         [0020]    Hydraulic cylinder  34  is preferably of a double acting design, actuated by a hydraulic pump system that can be incorporated into the levee builder  10  or can be supplied from an outside source such as a tractor. Preferably, the tractor or other source of hydraulics support is capable of supplying 2,000 lbs per square inch of hydraulic pressure and sufficient hydraulic fluid flow to cycle the ram plate box  32  at a desired rate.  
         [0021]    Ram plate box  32  is constructed of metal of sufficient thickness and rigidity to withstand the hydraulic pressure needed to force the granular material into levee bag  20 . The outer dimensions of ram plate box  32  may be covered completely or in part by an ultra high molecular weight polyethylene (UHMWPE) or like material to provide for easy sliding within loading box  14 . UHMWPE also will prevent fouling of ram plate box  32  with wet or muddy fill. It is envisioned that an upper wall or hopper plate of ram plate box  32  will extend far enough so that when ram drive system is fully extended granular material will not be able to fall behind the ram plate box  32 . It is further envisioned that ram plate box  32  is internally supported by cross beams  33  as shown in FIG. 3.  
         [0022]    Bag feeder  18  generally includes bag ring  42  and bag storage area  44 . Bag ring  42  is operably connected to the open end of ram section  28  of loading box  14 . The open end of ram section  28  is at the opposite end of loading box  14  from ram drive system  16 . Bag ring  42  is preferably located adjacent to bag storage area  44 . Bag storage area  44  provides a place for levee bag  20  to be stored and feed from during the operational process.  
         [0023]    Bag storage area  44  preferably includes bag retainers  52 . Bag retainers  52  may include spring-loaded arms  53  which apply tension to a folded levee bag  20  attached to the bag ring  42 . Preferably, bag retainers  52  retain levee bag  20  at three points around the circumference of bag ring  42  but other variations can be used. Bag retainers  52  apply spring tension to the bag  20  to support it in place and allow it to unfold as needed. Other bag retainers  52  can readily be imagined by those skilled in the art.  
         [0024]    Levee builder  10  is supported on a movable carriage  48 . Carriage  48  preferably includes skids  50 . Carriage  48  preferably provides a wide, stable platform for support of levee builder  10 . Preferably, carriage  48  includes three skids to allow the levee builder  10  to be slid over the ground even in poor or irregular ground conditions, for example, mud. The levee builder  10  can be hauled and directed though application by hitch assembly  54  which is attached to ram support structure  30 . A tractor or other mover can attach to hitch assembly  54  by a pin hitch  56  or other comparable means of attachment.  
         [0025]    Levee bag  20  may be of any desired dimensions and is formed from a durable material of sufficient tensile strength to withstand the weight of the enclosed granular fill. Levee big  20  may be essentially an elongate tube that can be readily closed at either end. It is envisioned that a commercially available silage bag with an eight-foot diameter would be used in a first embodiment. Alternative embodiments may use thicker bags to increase the life of the levee.  
         [0026]    In operation, levee builder  10  is delivered to a location at which it is desired to build a levee. A folded or gathered levee bag  20  is installed over bag ring  42  into bag storage area  44  and secured by bag retainers  52 . Since levee bag  20  is typically open at both ends, a portion of levee bag  20  is extended from bag ring  42  and the distal end of bag  20  is closed off, for example, by tying.  
         [0027]    Granular material such as sand, gravel or dirt is feed into hopper  12  by a loader. Ram drive system  16  is cycled back and forth by actuating hydraulic cylinder  34 . On the backstroke, ram plate box  32  is retracted allowing granular material to drop from hopper  12  into ram section  28  of loading box  14 . Ram plate box  32  preferably is constructed to include a horizontal top plate or hopper plate, with a perpendicular section so as to close hopper  12  when ram plate box  32  is advanced thereby holding additional material in the hopper  12  and not allowing material to fall behind ram plate box  32 .  
         [0028]    Ram plate  22  is cycled on the backstroke to allow granular material to fall from hopper  12  in the loading box  14 . When loading box  14  is filled or partially filled with granular material, sand ram drive system  16  is cycled on a forward stroke thereby forcing the granular material out through bag ring  42  and into levee bag  20 . This process both fills levee bag  20  with granular material, such as sand, and causes levee builder  10  and the prime mover, if present, to be pushed away from levee bag  20 . This causes the automatic feeding of a further length of levee bag  20  from bag feeder  18 . The cycle is repeated over and over again. In the process, levee bag  20  is rapidly filled with a large quantity of granular material and levee builder  10  is advanced away from the bag  20 , in the process, creating a large self-contained levee in a very rapid and efficient fashion. When levee bag  20  is completely filled, levee bag  20  is detached from levee builder  10  and the detached end of levee bag  20  is closed. The process is then repeated by installing a new levee bag  20  and operating the device  10  until the levee meets the required length.  
         [0029]    Alternate embodiments are envisioned in which the present invention can be powered by a hydraulic ram driven by a gas engine and a hydraulic pump instead of the tractor or prime mover. The movement of the levee builder can be adjusted based on the terrain or job requirements. The skids  48  could be substituted with wheels or rollers which may be necessary in swampy terrain. The levee builder  10  could be provided with a drive unit for self-propulsion by means of wheels or tracks operably coupled to an engine.  
         [0030]    The filling mechanism can also be designed to utilize other pieces of hardware. An auger/conveyor with a dump loading box closer to the ground could be installed to transport the granular material to the hopper on top of the levee builder. It is envisioned that such a system would require that the auger/conveyor be rigidly attached to the levee builder with skids or wheels under the dump loading box so that the entire unit advances as one.  
         [0031]    The hydraulic ram can also be replaced by an auger sized proportional to the bag diameter. The granular material is placed in the loading box and the rotating auger forces it into the bag. The auger could be powered by an attached motor or through the power take off of a prime mover. The entire machine will move in reaction to the auger force on the bagged material. Filling could also be accomplished through the use of a blower system or conveyor. However, such a device would only dump the granular material. An external drive system would be required to propel the device away from the bag as it fills.  
         [0032]    It is envisioned that all of the concept described above could be incorporated into a system sized for filling bags of smaller diameters. It is envisioned that the present invention would be invaluable for creating soil erosion walls or containing product spills which may require a barrier substantially smaller.  
         [0033]    The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof; and it is, therefore, desired that the present embodiment be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention.