Abstract:
An improved device and method for mechanically installing erosion blankets on a ground surface. The device holds a roll of an erosion blanket and provides that the blanket unwind when the device is propelled forward. Upon unwinding, the device positions the blanket on the ground and pins the blanket in position using staples, stakes or the like. Preferred embodiments of the device provide for furrowing of the ground before installation of the blanket.

Description:
FIELD OF THE INVENTION 
     This invention is related generally to prevention of erosion and promotion of seed germination in soil, and more particularly, to installation of erosion blankets to prevent erosion and promote seed germination. 
     BACKGROUND OF THE INVENTION 
     Erosion blankets are used throughout the world to stabilize soil before seed germinates and/or small plant plugs cover the ground. Erosion blankets are used for a variety of reasons, such as stabilizing large areas along highways, stabilizing areas around detention/retention ponds, establishing fine quality lawns for commercial and residential properties and restoring prairies. Erosion blankets are typically provided in rolls of 65 to 100 yard rolls, depending upon the type of blanket. The most widely used blankets are made of straw and wood fiber. Typically, erosion blankets of every type are installed by hand. 
     Erosion blankets are typically utilized to keep the soil and seed from eroding away during and after precipitation. In addition to preventing erosion, such blankets retain moisture in the soil under the blanket for a much longer period of time. The extended presence of moisture enables the seed to germinate much more quickly than without blanket cover. 
     In addition, erosion blankets retard weed growth when grass seed is planted in the late spring and early summer months. Due to the consistent shade that is provided by the erosion blanket the vast majority of noxious weed seed will not germinate. 
     In the landscaping industry, two alternative products are often used to encourage seed germination. These products are straw mulch and hydro mulch, both of which are typically mechanically blown or dropped onto the soil. However, bales of straw which are broken apart and spread on the soil as straw mulch can blow away which leads to mixed results. Hydro mulch, a paper component with seed and fertilizer mixed in slurry of water, helps the seed germinate but does not control erosion. Furthermore, hydro mulch is a poor medium to keep moisture in the soil during critical dry times of the growing season. While straw mulch and hydro mulch are less effective than erosion blankets, their use is popular due to their lower associated costs, especially the labor costs involved in installing the mulch on the soil. 
     Erosion blankets are typically installed after a site has been fine graded (soil prepared for seed) and seeded. The seed may be broadcast or installed using a mechanical seeder. For use with small plant plugs, the erosion blanket is installed and the plant plugs are manually planted into the blanket. In either use, after the erosion blanket has been laid on the ground, stakes must be manually driven through the blanket into the ground to keep the blanket in correct position. The stakes are typically six inches long and must be driven deep enough such that they are flush with the erosion blanket so that mowers do not strike them. The manual operations dealing with the installation of stakes significantly increase the cost of installing an erosion blanket and often lead landscapers to use the less labor-intensive products mentioned above for reasons involving both time and costs. 
     Therefore, there is a continuing significant need in the field of erosion prevention and seed germination promotion for improvements related to the installation of erosion blankets and for more efficient installation thereof. An improved device and method achieving these goals would lead to better erosion protection and, therefore, higher quality lawns and prairies, as well as cleaner lakes, creeks, streams, rivers and oceans. 
     OBJECTS OF THE INVENTION 
     It is an object of the invention to provide an improved device which efficiently installs erosion blankets. 
     Another object of the invention is to provide an erosion blanket installation device which is simple in structure and operation in order to facilitate effective installation. 
     Another object of the invention is to provide an erosion blanket installation device which mechanically drives stakes into the ground to hold the blanket in position. 
     Another object of the invention is to provide an erosion blanket installation device which mechanically drives staples into the ground to hold the blanket in position. 
     Another object of the invention is to provide an erosion blanket installation device which simultaneously unrolls and pins to the ground the erosion blanket. 
     Another object of the invention is to provide a method of mechanically installing an erosion blanket on the ground. 
     Still another object of the invention is to provide a method of installing an erosion blanket on the ground which minimizes the need for manual operations during installation. 
     Still another object of the invention is to provide an easy penetration point in the ground for the insertion of a stake which automatically pins an erosion blanket to the ground. 
     Yet another object of the invention is to provide a method of automatically pinning an erosion blanket to the ground during installation. 
     These and other objects of the invention will be apparent from the following descriptions and from the drawings. 
     SUMMARY OF THE INVENTION 
     This invention is an improved method and device for efficiently and effectively installing erosion blankets on ground surfaces. The invention represents a significant advance over the state of the art by providing a novel device, which allows for an automatic method of installation which is heretofore unknown in the art. 
     The erosion blanket installation device is able to install a 500 yard roll of a straw erosion blanket on the ground while securing the blanket in place until the turf or vegetation naturally stabilizes the ground soil via a staple or a pneumatically driven stake which enters a 5″-6″ furrow. 
     The device for installing an erosion blanket, i.e., laying and securing the blanket along a pathway on the ground, is comprised of a vehicle frame, an axle arm connected with respect to the vehicle frame and engaging an axle around which the blanket roll is sleeved, at least one staple or stake gun connected with respect to the frame and at least one staple or stake cartridge connected with respect to the gun for supplying staples or stakes to pin the blanket to the ground. 
     The erosion blanket is rolled so that it may be sleeved around the blanket axle before use of the device. The blanket is positioned in the vehicle frame by sliding the roll around the blanket axle. As the device is propelled along the pathway the blanket is unwound from the roll and is placed on the ground. The device preferably includes a blanket guide roller for which directs the blanket to the ground upon unwinding. The gun pins the blanket in position by driving a staple or stake through it into the ground. 
     For use with a stake gun, rather than a staple gun, the device also preferably includes at least one furrow blade connected with respect to the frame. Preferably three furrow blades are supported by a furrow bar which is connected to a hydraulic cylinder which urges the blades into the ground. The blades furrow the ground during movement of the device and are urged to stay in position by their arcuate shape. 
     The preferable device includes at least one hitch connection point connected with respect to the frame. The hitch connection points are designed to connect to a hitch of a tractor or other vehicle which is able to tow the device. There are preferably three hitch connection points to provide sufficient connection to the towing vehicle. 
     The preferable device further includes an air compressor which is connected to each gun for forcing staples or stakes through the blanket into the ground. An air compressor is connected to each gun via a compressor hose and allows for pneumatic pinning of the blanket. 
     It is also preferred that the device include a retractable arm which is connected with respect to the frame. The retractable arm is movable between an open position which allows the roll to be loaded by sliding over the blanket axle and a closed position in which the retractable arm engages the free end of the blanket axle to hold the roll in place. A spring-loaded retractable-arm pin is connected with respect to the frame and pivotably supports the retractable arm with respect to the frame. A retractable-arm brace connects the retractable-arm pin to the frame. In use, the retractable arm is pivoted so that the erosion blanket may be positioned within the vehicle. After the blanket roll is in position within the device, the retractable arm is pivoted so that the second end of the blanket axle may engage the retractable arm to hold the roll in place. 
     In another preferred embodiment the device includes at least one compression wheel for pressing the blanket against the ground as the blanket unwinds. The compression wheel is supported by a compression-wheel frame. The compression-wheel frame preferably supports each gun and staple or stake cartridge as well. 
     The novel method of installing erosion blankets on ground surfaces comprises (a) propelling a blanket-laying device along a pathway, (b) rotating the roll of the erosion blanket supported in the device such that the blanket unwinds and is positioned on the surface along the pathway; and (c) in conjunction with the rotating step, mechanically pinning the blanket to the ground. 
     It is preferred that the rotating and pinning steps are performed simultaneously. The rotating and pinning steps are also preferably performed continuously until the roll expires. Furthermore, the rotating step is preferably performed in conjunction with, and as a result of, the propelling step. That is, the propelling of the device causes the roll to rotate and unwind. In the novel method, the blanket is preferably initially anchored to the ground surface by manually driving staples or stakes through the blanket into the yard. However, alternate embodiments of the invention allow for the blanket to be anchored to the ground without any manual manipulation. 
     The preferred method includes the step of pressing the blanket to the surface as it unwinds from the roll to allow for effective surface coverage. Such step is preferably performed by compression wheels, and more preferably by at least 3 axially-spaced compression wheels, e.g., one wheel pressing the left side of the blanket, one wheel pressing the middle of the blanket, and one wheel pressing the right side of the blanket. 
     The preferred method also includes the step of furrowing the surface before the pinning step. Such a step is preferably performed by at least 3 blades which are aligned with the means for mechanically pinning the blanket to the ground. 
     The device is preferably propelled along the pathway at at least about 3 miles per hour (mph). A tractor or similar vehicle can be connected to the device via a hitch in order to tow the device at the proper velocity. It is preferred that the erosion blanket is installed on the surface at a rate of at least about 400 yards every 3 minutes, or 400 feet/minute. Even more preferably, the erosion blanket is installed on the surface at a rate of at least about 500 yards every 3 minutes, or 500 feet/minute. 
     The pinning step is preferably performed using staples or stakes. Such staples or stakes are preferably biodegradable. The staples or stakes are preferably forced through the blanket into the ground by an air compressor included in the vehicle. As discussed above, the air compressor is connected to a gun which fires the staples or stakes into the ground. The gun is connected to a staple or stake cartridge which supplies the staples or stakes. 
     It is preferable that the number of staples or stakes held by the device be proportional to the length of the roll. Upon expiration of the roll positioned in the device, the preferred method includes the steps of loading staples or stakes and another roll of the blanket with respect to the device; propelling the device along a pathway; rotating the roll such that the blanket unwinds and is positioned on the surface along the pathway; and in conjunction with the rotating step, mechanically pinning the blanket to the ground. 
     The step of loading staples or stakes and another roll is preferably accomplished in less than about 15 minutes. The preferred method uses blanket rolls which are 500 yards long and at least 15,000 yards of blanket are installed in 8 hours. 
     An alternate method of installing an erosion blanket along a pathway on a ground surface comprises providing a roll of an erosion blanket; supporting the roll in a device; propelling the device in a direction along a pathway; and unwinding the roll so that the blanket covers the pathway, the device automatically pinning the blanket to the ground surface as it unrolls. 
     The preferred alternate method further comprises the step of pressing the blanket to the surface as it unwinds to allow for effective surface coverage. Such a step is preferably performed by compression wheels, and more preferably by at least 3 axially-spaced compression wheels. 
     The preferred alternate embodiment also comprises the step of furrowing the surface simultaneous with the propelling step. The furrowing step is preferably performed by at least 3 blades 
     The pinning step is preferably performed using staples or stakes. The staples and stakes are preferably biodegradable and are forced through the blanket into the ground by an air compressor included in, or connected to, the device. 
     In the preferred alternate method, the erosion blanket is installed on the surface at a rate of at least about 400 feet/minute. More preferably, the erosion blanket is installed on the surface at a rate of about 500 feet/minute. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a front view of the erosion-blanket-laying device in accordance with the invention. 
     FIG. 2 is a rear view of the erosion-blanket-laying device in accordance with the invention. 
     FIG. 3 is a view from the right side of the erosion-blanket-laying device in accordance with the invention. 
     FIG. 4 is a view from the left side of the erosion-blanket-laying device in accordance with the invention. 
     FIG. 5 is a overhead plan view of the erosion-blanket-laying device in accordance with the invention. 
     FIG. 6 is a detailed view of the compression wheel, gun and cartridge in accordance with the invention. 
     FIG. 7 is a detailed view of the compression wheel in accordance with the invention. 
     FIG. 8 is a detailed view of typical stakes for use with the erosion-blanket-laying device in accordance with the invention. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     FIG. 1 is a front view of the erosion-blanket-laying device  10  in accordance with the invention. Device  10  includes a frame  20  which comprises five frame supports (two external frame supports  20   a ,  20   e  and three internal frame supports  20   b ,  20   c ,  20   d ) which, as seen in FIGS. 3 and 4, extend horizontally from the front before arcing downwardly toward the rear of device  10 . Frame supports  20   a ,  20   b ,  20   c ,  20   d ,  20   e  are connected by front frame crossbars  30   a ,  30   b  and rear crossbars  30   c ,  30   d . Each frame support and crossbar is preferably 2″ by 2″ steel framing (hollow square framing with a thickness of ¼″). Alternatively, each frame support and crossbar is 90-degree angle bar. Preferably, the frame supports and crossbars are 1018 Cold Roll steel. 
     Connected to front frame crossbars  30   a ,  30   b  is a vertical stabilizer frame  24  comprising five vertical stabilizer bars  24   a ,  24   b ,  24   c ,  24   d ,  24   e . Vertical stabilizer bars  24  are preferably flat pieces which are 4″ wide, ½″ thick and 1′11″ to 2′ long. Lower end  25   b  of vertical stabilizer bar  24   b  is connected to hitch-connection point  35   b . Upper portion  23   c  of vertical stabilizer bar  24   c  is connected to hitch-connection point  35   c . Lower end  25   d  of vertical stabilizer bar  24   d  is connected to hitch-connection point  35   d . The three hitch connection points  35  provide for connection of device  10  to a tractor or other towing vehicle. Such a vehicle preferably has a category 2, three-point hitch and at least a 100 hp engine. All connections between frame supports  20 , cross bars  30  and hitch-connection points  35  are weldings. 
     As seen in FIG. 3, fixed axle arm  26  is welded to a rear portion of external frame support  20   a  and extends forward. Axle arm is preferably 2″ by 2″ steel framing. Axle arm  26  includes a connection point for erosion blanket axle  92 . Preferably, blanket axle  92  is welded to axle arm  26  at distal end  92   a  of blanket axle. Erosion blanket  90  (shown in FIGS. 3 and 4) is wound into a roll so it can be slipped onto blanket axle  92  when being positioned in device  10 . Blanket axle  92  is preferably made of lightweight polished steel with ⅜″ thick wall. Blanket axle preferably has a diameter of 3½″ and a length of about 6′7″. Blanket axle  92  must have sufficient strength to hold a 500 yard blanket roll which has an approximate mass of 150 lbs. 
     As seen in FIG. 4, retractable arm  27  is connected to external frame support  20   e  through retractable arm pivot  28  so that retractable arm  27  may swing about pivot  28 . Retractable arm  27  is preferably constructed from flat bar steel. The lower end of retractable arm  27  has an opening provide for connection to the proximal end  92   b  of blanket axle  92 . Pressure clips (not shown) are provided at the opening to hold the connection to blanket axle  92  in place. Such pressure clips can be opened manually in order to disconnect blanket axle  92  from retractable arm  27 . 
     Retractable-arm brace  29  is connected to frame support  20   e . Provided on retractable-arm brace  29  is a connection point for spring-loaded retractable-arm lock  31 . Retractable-arm lock  31  is preferably a spring-loaded pin which passes through retractable arm  27  and retractable-arm brace  29  to prevent retractable arm  27  from pivoting about retractable-arm pivot  28 . In order to load a roll of erosion blanket  90 , retractable-arm lock  31  is removed from retractable arm  27  and retractable arm  27  is pivoted about retractable-arm pivot  28  so that the lower end of retractable arm  27  is moved toward frame support  20   e . Retractable arm  27  may be suspended in the blanket loading position by connection to pin hole  32 . Erosion blanket  90  is positioned within the opening created by slipping blanket  90  over blanket axle  92  after retractable arm is pivoted out of the way. Then retractable arm  27  is pivoted back to its original locked position and proximal end  92   b  of blanket axle  92  is connected to the lower end of retractable arm  27 . Retractable-arm lock  31  is reconnected to retractable arm  27  and retractable-arm brace  29  to lock blanket  90  in position. 
     Compression wheels  70  are connected with respect to the lower end of interior frame supports  20   b ,  20   c ,  20   d . Such connection is preferably through a spring-mounted piston-like arrangement (shown in FIG. 6) for reasons discussed below. Compression wheels  70  are preferably composite cement rollers epoxied with a textured rubber coating and have lengths of 9″ and diameters of 6″. The composite cement is preferably formed from poured concrete and fiberglass fibers which add strength and durability. The rubber surface is preferably ½″ thick. Wheels  70  preferably weigh about 18.5 lbs each. Compression wheels  70  rotate about compression-wheel axles  71  which pass through forked wheel brackets  72 . Compression-wheel axles are preferably of the ball bearing type. 
     As shown in FIG. 7, wheel brackets  72  upwardly terminate in hollow bracket shafts  73  which house springs  74  with lengths of 12″ and diameters of ¾″. Bracket shafts  73  are preferably 1⅜″ by 1⅜″ and are received within the interior frame supports  20   b ,  20   c ,  20   d . Springs  74  extend out of bracket shafts  73  and engage spring stops  21  which are positioned within interior frame supports  20   b ,  20   c ,  20   d . Thus compression wheels  70  are urged downward from frame supports  20   b ,  20   c ,  20   d . This configuration allows wheels  70  to support the weight of the device (approximately 1200 lbs.) while absorbing the vibrations encountered when the device is propelled along a pathway on the ground. 
     Mounted to the rear side  72   a  of each wheel bracket  72  is a gun  60 . The mounting arrangement is preferably designed to allow for gun  60  to be easily removed from and reattached to wheel brackets  72 . Preferably, each gun  60  is connected to each wheel bracket  72  with self-locking nuts. Each gun  60  has an outer hard metal casing with an airtight finish to prevent dust and water from entering the internal motor. 
     Each gun  60  is powered by air compressor  40  which is secured to the top of center frame support  20   c  (as seen in FIG.  5 ). Air compressor  40  is preferably comprised of a 2½ gallon steel tank with various air valves. The tank is pressurized by a compressor motor which is powered by a power take-off  45  from the tractor or other towing vehicle. Device  10  preferably includes a female power take-off fitting for connection to a male power take-off at the rear of the towing vehicle. Air-compressor hoses  41  extend from air compressor  40  and lead to guns  60 . Air compressor  40  has a preferred operating pressure of between about 75 and 115 psi. Such pressure is sufficient to force staples or stakes  61  through blanket  90  and into the ground. 
     Before use, the air compressor is turned on and each pneumatic gun  60  is calibrated for a predetermined tractor speed and the number of staples or stakes to be installed per yard. 
     Cartridge  62  is connected to gun  60  to provide staples or stakes  61  for pinning blanket  90  to the ground. For use with stakes, each cartridge  62  holds approximately 170 stakes. By firing a stake every  3  feet,  170  stakes are used for  510  feet of erosion blanket. Therefore, three cartridges  62  are loaded into each gun  60  to provide enough stakes for a 500 yard roll of erosion blanket. Stakes  60  are preferably biodegradable and breakdown in the environment after about 6 months. Each stake  60  is preferably 6 inches long. 
     Guide chamber  63  (best shown in FIG. 5) allows stakes  61  to be forwarded to gun  60  and set into position for “hammer,” one at a time, from the roll of stakes in cylindrical cartridge  62 . Hammer mechanism  64  shoots stakes  61  into the ground one at a time when triggered by trigger wire  65 . 
     Trigger wire  65  extends from hammer mechanism  64  to a position 2.87″ from each wheel axle  71 . Trigger wire  65  monitors each wheel  70  and triggers each hammer mechanism  64  every two revolutions of each wheel  70  (approximately every 3′ the device travels). The middle trigger wire (connected to middle gun  60   c ) is preferably offset from the outer trigger wires (connected to outer guns  60   b ,  60   d ) by 1½ so that staples or stakes  60  are fired into blanket  90  in a pattern which more strongly secures blanket  90  to the ground. 
     Blanket guide roller  80  (FIGS. 3 and 4) is connected with respect to axle arm  26  and exterior frame support  20   e . Guide roller  80  rotates about roller axle  81  which connects to roller bracket  82  and axle arm  26  through greased ball bearing fittings. Guide roller  80  preferably is lightweight steel with a ⅜″ thick steel wall cylinder with a ¼″ thick textured rubber surface covering. Roller axle  81  is preferably a 1″ ball bearing axle. Roller bracket  82  is connected to exterior frame support  20   e . When blanket  90  unwinds, it is directed between guide roller  80  and frame supports  20   b ,  20   c ,  20   d . Blanket  90  is then directed downward to compression wheels  70  where blanket  90  is positioned on the ground surface. 
     Furrow bar  50  is pivotally mounted with respect to exterior frame supports  20   a ,  20   e  (shown in FIGS. 3 and 4) and supports three furrow blades  55 . (shown in FIGS.  1  and  2 ). Each furrow blade  55  is aligned with a compression wheel  70  and gun  60 . Each furrow blade  55  is preferably formed from A-36 Steel or a chromium based hardened steel. The blades  55  must be durable and replaceable in case of breakage. Each blade  55  is preferably 9″ long and curved forward so that it digs into the ground during the forward motion of device  10 . 
     Furrow bar  50  is preferably primarily 1″ by 1″ steel with ends which are ¾″ diameter cylindrical steel to allow for pivoting with respect to device  10 . Furrow bar  50  is pivotally attached to exterior frame supports  20   a ,  20   e  (shown in FIG.  5 ). Furrow bar  50  is not attached to wheel bracket  72 . A 1″ by 1″ by 4″ piece of steel is welded at the end of furrow bar  50  to attach to a commercially available hydraulic cylinder  58  with a steel eye bracket. The upper end of hydraulic cylinder  58  is connected to axle arm  26  with another steel eye bracket. Hydraulic hose  59  extends from the upper end of cylinder  58  and leads to a hitch connection point. A hydraulic control lever is positioned near the driver&#39;s seat in the tractor (not shown) so that the driver may activate the cylinder to raise or lower furrow bar  50  and, thus, furrow blades  55 . 
     The total weight of the preferred device (including a 500 yard blanket roll) is approximately 1250 lbs. The total weight of the alternative device which uses 90 degree angle steel is approximately 975 lbs. 
     In order to begin use of the erosion blanket installation device, an erosion blanket roll must first be loaded into the device. The end of the blanket roll is threaded over the guide roller and under the compression wheels and is then manually stapled or staked into place by hand. This is done to ensure that the end of the roll stays in place and the roll unwinds properly as the device is towed forward. The tractor driver will lower the furrow blades via the hydraulic control lever mounted near the driver&#39;s seat. The blades cause the device to rise about 6″ from the ground. Then the driver will engage the power take-off which powers the air compressor. 
     For use with stakes, a furrow blade preferably readies the ground for penetration. Once the tractor begins towing the device at the predetermined speed, the furrow blades will immediately dig into the ground to a depth of 5″ to 6″ and the device will be lowered onto the spring-loaded compression wheels. Because blanket  90  is positioned between wheels  70  and the ground, blanket  90  will unroll. At the same time, three guns  60  will fire stakes  62  through blanket  90  into the furrows in the ground. Stakes  62  lock in the ground and anchor the blanket in place until turf or vegetation grows through blanket  90  and naturally stabilizes the ground. 
     When the roll expires, another blanket roll is installed in the device and the cartridges are refilled. The end of the new roll is again manually stapled or staked and the process is repeated. 
     Use of the novel device with a tractor connected via a three-point hitch allows an erosion blanket to be installed and stapled or staked in place with 3 rows of staples or stakes. A 500 yard erosion blanket roll can be installed and sufficient staples or stakes can be reloaded in the device in 15 minutes. Such a device allows two people to install a 500 yard roll in the device. For use with stakes, the device preferably creates 3 rows of 6″ deep furrows into which the 6″ biodegradable stakes are driven by a pneumatic gun. Such furrows are created by 9″ curved blades connected to the bottom of the device. Furrows are not necessary for use with staples. 
     Thus, it should be apparent that there has been provided, in accordance with the present invention, a novel device for efficiently and effectively installing erosion blankets on ground surfaces that fully satisfies the objectives and advantages set forth above. 
     Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.