Abstract:
A self-deploying float assembly to support mechanical equipment such as aerators and mixers for use in water, wastewater and process water stream treatment basins and a method of installing same.

Description:
FIELD OF THE INVENTION 
       [0001]    The present inventions relate to floats typically used in the water and wastewater treatment industry. More particularly, the present inventions relate to floats that may be installed in a folded position and which unfold, i.e., self-deploy, upon placement in water or other liquid. 
       BACKGROUND OF THE INVENTION 
       [0002]    Floats to suspend a mechanical device on the surface of liquid in a basin are fairly well known in the water and wastewater treatment industry. For example, surface mechanical aerators are floated on the surface of water or wastewater to be aerated. Typical surface mechanical aerators are sold by Aqua-Aerobic Systems, Inc. of Rockford, Ill. under the trade names AquaJet® and AquaJet II®. In general, these devices have an aerator mounted to a rigid, typically circular float that must be of sufficient size to generate enough buoyancy to support the aerator equipment. Similarly, surface mechanical mixers are also supported on floats on the surface of water or wastewater in a lagoon or basin. A typical surface mechanical mixer is available from Aqua-Aerobic Systems, Inc. under the trade same AquaDDM®. Like an aerator, a mixer is mounted on a generally circular, solid float. Again, such floats must have fairly large diameters (if circular) so that they generate sufficient buoyancy to support the associated mechanical equipment. The floats are typically moored into place in the desired location so that they do not move during use or otherwise. 
         [0003]    Installing aerators, mixers and other mechanical devices and their associated floats is straightforward in open basins. Because the lagoons or basins are open, the size of the mechanical device and associated float does not impede installation or impose a size restriction on the equipment that may be used. Similarly, in new facilities, consideration may be made in advance for the installation, repair and replacement of equipment. However, many existing basins are enclosed in a building or other structure. There is limited ability in such structures to provide access to install new or replacement equipment. Thus, there is a physical limitation on the size of equipment that may be installed in existing enclosed locations, because access through existing roofs, walls and even doors is limited. Accordingly, while it is relatively easy to accommodate installation of equipment in new and open basins, many existing facilities have enclosed basins and have limited access to the interior, making it more difficult to retrofit different devices into the location to accommodate changing needs or requirements. 
         [0004]    For example, many drinking water treatment installations or treatment steps are enclosed. In the treatment of drinking water, certain by-products of disinfection, such as trihalomethanes (THMs) are formed. Increasing government regulations require the removal of THMs, which may effectively be done using surface mechanical aeration, the most common form for which is floating aeration. However, because many existing drinking water treatment facilities are enclosed, having roof structures with limited openings available for the introduction of new equipment, traditional and known floats that support aerators and other equipment on the surface of the basin are too large to fit within the available openings of such installations. 
         [0005]    Thus, there is a need, particularly in the water and wastewater treatment industry, to provide a float assembly that may fit through a fenestration or other reasonably available or created opening of an enclosed treatment basin, while at the same time providing sufficient buoyancy to support the associated equipment such as aerators, mixers and the like. 
       SUMMARY OF THE INVENTION 
       [0006]    The present inventions preserve the advantages of known floats for mechanical or other equipment and also provide new features and advantages. 
         [0007]    Therefore, it is an object of the present invention to provide a float assembly that is sufficiently compact so that it may be installed through a fenestration in an enclosed basin. 
         [0008]    It is another object of the present invention to provide a float assembly that self-deploys upon placement into a liquid in a basin and provides sufficient stability to support mechanical equipment. 
         [0009]    An additional object of the present invention is to provide a float assembly that may be used with a variety of mechanical equipment, which may also be installed through a fenestration of an enclosed facility. 
         [0010]    A further object of the present invention is to provide a float assembly that may be in a folded condition for transportation and installation and which becomes unfolded and self-deployed upon placement in a liquid in a basin. 
         [0011]    Still another object of the present invention is to provide a surface mechanical mixer or aerator that may be retrofitted into an enclosed basin used in conjunction with a self-deploying float assembly. 
         [0012]    Yet an additional object of the present invention is to provide a foldable float assembly, the floats of which may be opened from a folded position and locked into an unfolded or deployed position. 
         [0013]    Yet a further object of the present invention is to provide a float assembly having segmented floats that fold vertically for shipping and installation through a structure opening and which self-deploys or may be otherwise deployed to a horizontal, unfolded position. 
         [0014]    Yet another object of the present invention is to provide a float assembly having a compact footprint (or taking-up a small volume of space) for reduced shipping costs and ease of handling and installation, while at the same time having sufficient buoyancy to support mechanical equipment. 
         [0015]    Accordingly, the present inventions provide a self-deploying float assembly including a central support bracket for use in a basin having a liquid level. The assembly further includes a plurality of floats, each float having a proximal and distal end, a length and a cross-sectional shape. A plurality of hinges, each hinge pivotably mounting the proximal end of each float to the central support bracket such that each float may pivot between a downward, generally vertical or folded position and an upward, generally horizontal or unfolded position for use, are also provided. Preferably, the cross-sectional shape of each of the plurality of floats is a hexagon or a diamond. The central support bracket of the float assembly is capable of accepting and securing a mechanical device and may include hoisting hooks for use during installation and removal of the assembly. Hinges and/or the central support bracket of the float assembly may also be configured to prevent the floats from pivoting beyond a generally horizontal position. In other embodiments of the inventions, the floats may be secured to the central support bracket when in a generally horizontal and deployed position. A mooring bracket may also be provided. 
         [0016]    The present inventions also provide a folding float assembly to support a mechanical device (such as a mixer or aerator) on a liquid in a basin, the float assembly including a support bracket; a plurality of floats, each float having a proximal end, a distal end, a length and a cross-sectional shape; a plurality of hinges, each hinge pivotably mounted to the proximal end of each float to the support bracket such that when each float may pivot from a downward, generally vertical position upward to a generally horizontal position. The cross-sectional shape of the floats may be a hexagon, diamond or other cross-sectional shapes. Means for locking the floats to the support bracket in the generally horizontal and deployed position may also be provided. At least one float may also include a mooring bracket and hoisting hooks on the support bracket may also be provided. 
         [0017]    The present inventions further provide for a method of installing a self-deploying float assembly through a fenestration in a structure and into a basin containing a liquid having a liquid level. The steps of the method include lowering a self-deploying float assembly through the opening in a roof so that the float deploys upon contact with the liquid, the self deploying float assembly including a central support bracket, a plurality of floats pivotably attached to the central support bracket with a plurality of hinges which permit the plurality of floats to pivot between a generally vertical position to a generally horizontal position when placed in the liquid; locking the plurality of floats to the central support bracket in the generally horizontal position; and installing mechanical equipment into said float assembly. The method may also include the step of mooring the float assembly and associated mechanical equipment to a stationary post in the basin. 
         [0018]    The present inventions still further provide a foldable float assembly for installation in an empty or dry basin, having a central support bracket; a plurality of floats, each float having a proximal end and a distal end, a length and a cross-sectional shape; and, a plurality of hinges, each hinge pivotably mounting the proximal end of each float to the central support bracket such that each float may pivot between a downward, generally vertical position and an upward, generally horizontal position. The floats may also be secured to the central support bracket when in the generally horizontal position and the hinges and the central support bracket may prevent the floats from pivoting beyond a generally horizontal position. The foldable float of the present inventions may also provide a central support bracket that is capable of accommodating a mechanical device. Preferably the cross-sectional shape of each of the plurality of floats is hexagonal. 
       INVENTOR&#39;S DEFINITION OF THE TERMS 
       [0019]    The following terms which may be used in the various claims and/or specification of this patent are intended to have their broadest meaning consistent with the requirements of law: 
         [0020]    “Basin,” as used herein, is used in its broadest sense and includes, among other things, basins, tanks, lagoons and reservoirs used for at least one step in the treatment of water, wastewater and process water. 
         [0021]    “Structure opening” or “fenestration,” as used herein, is used in its broadest sense to refer to any opening, whether existing or created, in a roof, wall or other structure enclosing and/or covering a basin. 
         [0022]    “Mechanical equipment,” as used herein, is used in its broadest sense to include any equipment to be supported by a float assembly in a basin, including but not limited to aerators, mixers and the like. 
         [0023]    Where alternative meanings are possible, in either the specification or claims, the broadest meaning is intended. All words used in the claims are intended to be used in the normal, customary usage of grammar, the trade and the English language. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0024]    The stated and unstated objects, features and advantages of the present inventions (sometimes used in the singular, but not excluding the plural) will become apparent from the following descriptions and drawings, wherein like reference numerals represent like elements in the various views, and in which: 
           [0025]      FIG. 1  is a perspective view of a preferred embodiment of the present invention shown deployed in a basin and supporting a typical aerator on the surface of a liquid; 
           [0026]      FIG. 2  is a top plan view of a preferred float assembly of the present invention (without the associated mechanical equipment) in an unfolded or deployed position; 
           [0027]      FIG. 3  is a side plan view of the preferred float assembly of  FIG. 2 ; 
           [0028]      FIG. 3A  is a detailed side view of the attachment of a float to the central support bracket of the present invention using a preferred single point hinge assembly, taken from insert  3 A of  FIG. 3 ; 
           [0029]      FIG. 3B  is a side view of the preferred hinge assembly of  FIG. 3A , taken along line  3 B- 3 B of  FIG. 3A ; 
           [0030]      FIG. 4  is a top plan view of the float assembly of the present invention shown with the floats in a folded position; 
           [0031]      FIG. 5  is a front plan view of a preferred float assembly of the present invention showing the central support bracket and one preferred float attached thereto; 
           [0032]      FIG. 6  is a side plan view of a portion of the central support bracket and one attached float of  FIG. 5 , also showing the preferred center of gravity of the attached float; 
           [0033]      FIG. 7  is a perspective view of the float assembly of the present invention showing a representative installation through a fenestration of a typical enclosed basin; 
           [0034]      FIG. 7A  is a close-up perspective view of the preferred float assembly during its initial stage of installation through the fenestration on the roof: 
           [0035]      FIG. 7B  is a perspective view of the float assembly of  FIG. 7A  shown during a later stage of a typical installation; 
           [0036]      FIG. 7C  is a perspective view of the preferred float assembly in still further stages of installation, the assembly in dashed lines showing partial deployment upon initial contact with the liquid in the basin and the assembly in solid lines showing the fully deployed position; 
           [0037]      FIG. 7D  is a side view of the preferred float assembly shown in a partially deployed position similar to the stage of installation of the embodiment shown in dashed lines in  FIG. 7C ; 
           [0038]      FIG. 7E  is a side view of the preferred float assembly shown in a fully deployed or unfolded position similar to the embodiment shown in solid lines in  FIG. 7C ; and, 
           [0039]      FIG. 8  is a perspective view of a representative aerator being installed through an opening in the roof for placement onto the fully deployed float assembly. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0040]    Set forth below is a description of what is currently believed to be the preferred embodiments or best representative examples of the inventions claimed. Future and present alternatives and modifications to the embodiments and preferred embodiments are contemplated. Any alternatives or modifications which make insubstantial changes in function, purpose, structure or result are intended to be covered by the claims of this patent. 
         [0041]    Although not limited thereto, the present inventions have particular applicability to use in existing water or wastewater treatment facilities include a basin  10  having a liquid level  14  that is enclosed by walls and a roof  11  (see  FIGS. 7 and 8 ). In such facilities, often the most efficient way to access the interior of the facility to install equipment is through a fenestration  12  or other opening in the roof  11  at a point above the basin  10 . Because of joists, beams and other structural members of the roof, only a modest fenestration or opening  12  exists or may be created in the roof  11  for purposes of installing equipment. It is through such an opening that the present inventions may be introduced and are most advantageous. 
         [0042]    It will also be understood by those of skill in the art that the present inventions may be employed in basins  10  that are not enclosed or are dry at the time of installation, since the present inventions provide decreased shipping and storage costs. And, even in enclosed basins  10 , the present inventions do not have to be introduced into the facility through a fenestration  12  in the roof  11 . Instead, for example, the present inventions may be introduced through a door or loading bay and then installed in the basin  10 . In addition, it will be understood that the present inventions are also applicable to and may be installed into facilities in which the basin has been drained and there is no liquid level, such that deployment of the floats is manual. 
         [0043]      FIG. 1  shows a preferred embodiment of a float assembly  20  of the present invention shown fully deployed and supporting a typical piece of mechanical equipment  60  (an aerator) installed in a typical basin  10 . The float assembly  20  is moored in place in basin  10  using mooring post  13 . Details of a preferred embodiment of the self-deploying float assembly  20  of the present invention is shown in more detail in  FIGS. 2-6 . The stages of the installation and self-deployment of preferred float assembly  20  is shown in  FIGS. 7-8 . 
         [0044]    Float assembly  20  includes a central support bracket  30 . Support bracket  30  includes an upper surface  31  and a lower surface  32 . In the preferred embodiment, support bracket  30  is circular. However, it will be understood by those of skill in the art that other shapes, such as square, trapezoid or rectangle, may also be used. Support bracket  30  is also provided with an equipment opening  29  that is designed to accommodate an aerator, mixer or other mechanical equipment  60 . It will also be understand that while opening  29  is shown as circular, any shaped opening may be used consistent with the requirement of the mechanical equipment  60  to be used and supported. 
         [0045]    The lower surface  32  of central support bracket  30  is provided with a plurality of pivot brackets  33  ( FIGS. 3, 5 and 6 ). Each pivot bracket  33  is attached to and projects downwardly from the lower side  32  and each pivot bracket  33  includes an aperture  34 . Pivot bracket  33  and associated aperture  34  are intended to mate with double pivot brackets  50  and their associated apertures  51  which are attached to the proximal end  41  of the float  40  to pivotably mount float  40  to support member  30  in a hinged fashion as hereinafter described. In the preferred embodiment, there are four pivot brackets  33  spaced evenly around the circumference of support member  30  to accommodate four floats  40  as hereinafter described. It will be understood by those of skill in the art that more or less than four floats  40  may he utilized, depending upon the application and required buoyancy. 
         [0046]    Upper surface  31  of support surface  30  is provided with a plurality of hoisting hooks  35 . Hoisting hooks  35  are provided to enable the float assembly  20  to be lowered into the facility as hereinafter described (see e.g.  FIG. 7 ). The support bracket  30  is also provided with a plurality of locking holes  36  that are used to secure floats  40  in an unfolded or generally horizontal position when fully deployed and installed, also as hereinafter described. 
         [0047]    Each of the plurality of floats  40  has a proximal end  41 , a distal end  42  and a length L. Preferably, each float  40  is formed to have three upper surfaces; namely, a generally horizontal top surface  44  and two non-horizontal upper surfaces  43  and  45 . It will be understood by those of skill in the art that the three upper surfaces  43 ,  44  and  45  may be formed from a single sheet of material or separate pieces of material. Preferred float  40  also includes three lower surfaces; namely, a lower generally horizontal surface  47  and two non-horizontal lower surfaces  46  and  48 , which also may be formed from a single sheet of material or multiple pieces of material. The surfaces  43 - 48  of float  40  form a generally hexagonal cross-section that is preferred for reasons of compactness and buoyancy. It will be understood by those of skill in the art that float  40  may have other cross-sectional shapes resulting in more or less float surfaces, such as a rectangle, circle, diamond and the like. However, the generally hexagonal cross-sectional shape is preferred because it is more compact when in the folded position (see  FIGS. 4 and 7A ) and provides sufficient buoyancy to support the mechanical equipment  60 . In addition, the generally horizontal top surface  44  enables float  40  to be locked to central support bracket  30  in the installed position, if desired. 
         [0048]    In the preferred embodiment, float  40  is constructed from stainless steel. Surfaces  43 - 48 , along with proximal end  41  and distal end  42 , form a hollow, generally waterproof interior which is filled with polyurethane foam to provide the desired buoyancy. It will be understood by those of skill in the art that other materials of construction and fillers for buoyancy may be used. In addition, one or more floats  40  of float assembly  20  may include a mooring bracket  15  that cooperates with mooring post  13  to keep the float assembly  20  and mechanical equipment  60  in place within the basin  10  (see e.g.,  FIGS. 1 and 8 ). 
         [0049]    The proximal end  41  of float  40  is provided with a double pivot bracket  50 . Double pivot bracket  50  includes a hole  51  (see  FIGS. 3, 5 and 6 ). Double pivot bracket  50  is designed to sandwich single pivot bracket  33  suspended from support bracket  30 . Holes  34  of single pivot brackets  33  align with holes  51  on double pivot brackets  50 . A hinge bolt  38  is inserted through holes  34  and  51  and secured in place with hinge nuts  39 . In this manner, float  40  may pivot on support bracket  30  from a downward, generally vertical or folded position, upward to a generally horizontal or unfolded position (compare  FIGS. 7A and 7E ). 
         [0050]    In a preferred embodiment, the center of gravity of floats  40  is located inside of the vertical pivot point as shown in  FIG. 6 . As a result, the floats  40  are naturally biased or spread slightly outward as shown in  FIGS. 6 and 7B . This is beneficial, since it allows the float  40  to more easily and surely deploy as the float assembly  20  is lowered into the water  14  (see e.g.,  FIGS. 7C and 7D ). To keep the silhouette of float assembly  20  as small as possible and to aid in shipping, floats  40  may be banded (not shown) into a tight cluster as shown in  FIGS. 4 and 7A . Once the assembly  20  arrives at the site and the float assembly  20  is lowered through the clears fenestration  12 , the shipping band is cut or otherwise removed (compare  FIGS. 7A and 7B ). In a preferred embodiment, the float assembly  20  is then lowered into the liquid in basin  10  and self-deploys as shown in  FIGS. 7 . Other embodiments may use manual deployment or unfolding. 
         [0051]    Once the floats  40  are fully deployed and/or unfolded, they may be locked in the horizontal position. Preferably, upper generally horizontal float surface  44  is provided with a threaded locking aperture  52  near proximal end  41 . Threaded locking aperture  52  is located on surface  44  to align with hole  36  on support bracket  30 . in this manner, when float  40  is in the unfolded, generally horizontal and deployed position, float  40  may be secured to support bracket  30  using a lock bolt  53  inserted through hole  36  into threaded locking aperture  52 . It will be understood by those of skill in the art that other ways to lock floats  40  in the horizontal position may be used consistent with the present inventions. However, it is not required to lock the floats  40  in a horizontal position. 
         [0052]    Having described the structure and arrangement of the components of a preferred embodiment of float assembly  20 , installation of a self-deploying embodiment and operation will now be described, particularly by reference to  FIGS. 7-8 . As shown in  FIG. 7 , float assembly  20  is lifted with a crane  17  or other hoisting method using straps  16  that are attached to hoisting hooks  35 . During the initial stage of installation, the floats  40  are banded together (not shown) so that float assembly  20  is in its most compact position ( FIGS. 7 and 7A ). Once float assembly  20  clears structure opening  12  (see  FIG. 7B ), the band (not shown) is cut or otherwise removed. 
         [0053]    When float assembly  20  hits liquid level  14 , floats  40  begin to deploy from the generally vertical position to a horizontal position (see  FIG. 7C , dashed line, and  FIG. 7D ). Float assembly  20  continues to be lowered until floats  40  are in a generally fully horizontal position (see e.g.,  FIG. 7C , solid line, and  FIG. 7E ). Floats  40  may then be locked in the horizontal position to support bracket  30  using locking bolt  53  through locking hole  36  into threaded locking aperture  52  on surface  44  of float  40 . Upon installation, straps  16  are removed and float assembly  40  may be moored to mooring post  13  with mooring bracket  15 . 
         [0054]    Once float assembly  40  is installed in basin  10  (see  FIG. 7 ), the desired mechanical equipment  60  is then lowered through structure opening  12  (sec  FIG. 8 ). Mechanical equipment  60  is then secured to central support bracket  30  through equipment opening  29 . It will be understood by those of skill in the art that the installation described is merely typical, and other methods of installation may be utilized depending upon the facility. For example, if installed in a dry basin, the basin bottom may be used, along with the weight of the assembly, to unfold the floats. 
         [0055]    The above description is not intended to limit the meaning of the words used in or the scope of the following claims that define the invention. Rather, it is contemplated that future modifications in structure, function or result will exist that are not substantial changes and that all such insubstantial changes in what is claimed are intended to be covered by the claims. Thus, while preferred embodiments of the present inventions have been illustrated and described, it will be understood that changes and modifications can be made without departing from the claimed invention. In addition, although the term “claimed invention” or “present invention” is sometimes used herein in the singular, it will be understood that there are a plurality of inventions as described and claimed. 
         [0056]    Various features of the present inventions are set forth in the following claims.