Abstract:
Devices, apparatus, systems and methods for forming rolled up spiral shaped tubular inserts of interlocking seams of elongated strip material and for inserting the inserts into damaged channels such as culverts, sewer lines, pipes, and the like. The inserts are released to expand outward and unravel until the walls of the unraveling insert abut against interior walls of the damaged channel forming a protective interior wall for the damaged channel. One side of the insert strips can have a hook, and an opposite side of the strips can have a longitudinal groove wherein the hook attaches to and slides within the groove. Slidable surfaces such as bushings, Teflon coatings and O-rings can be used along the interlocking seams to allow for reduced friction as the strip materials are rolled into contracted positions and later expanded out.

Description:
[0001]    This invention is a Divisional Application of U.S. patent application Ser. No. 13/117,566 filed May 27, 2011, now U.S. Pat. No. 8,496,048, which claims the benefit of priority to U.S. Provisional Application Ser. No. 61/351,632 filed Jun. 4, 2010. The entire disclosure of each of the applications listed in this paragraph are incorporated herein by specific reference thereto. 
     
    
     FIELD OF INVENTION 
       [0002]    This invention relates to culverts, in particular to apparatus, devices, systems and methods of making spiral cut pipe materials into expandable inserts for damaged channels such as culverts, drainage canals, sewer lines, pipes, and the like, and installing a spiral cut pipe liner insert into the channels, and expanding the insert to become an pipe liner for the damaged channel that can be used under driveways, sidewalks and roadways, and the like. 
       BACKGROUND AND PRIOR ART 
       [0003]    Culverts are permanent structures that are generally installed underneath driveways, sidewalks, and roadways to allow for storm water drainage. These permanent structures are often formed from materials such as concrete, steel, combinations, thereof, and the like, and are intended to last for many years. However, these culverts and pipes do not last forever, and can crumble and collapse after many years of use. 
         [0004]    Since the culverts are considered to be permanent solid structure, cracks are only repaired with temporary patches and are not done for long lasting effects. After years of use and damage, the culverts usually need to be replaced when they&#39;re life as run out. Currently, it is a very costly endeavor to have to physically dig up the driveways, sidewalks, roadways etc. in order to install new culverts when the old ones are needed to be replaced. Additionally, replacing a culvert can take up to a couple of days or more time which can result in the driveways, sidewalks, and roadways around the culverts not able to be used. Culvert repairs can require multiple permits and large amounts of labor and material costs. In addition, businesses and travelers have to detour about the areas where the culverts are being replaced causing further delays and hardships. 
         [0005]    Thus, the need exists for solutions to the above problems with the prior art. 
       SUMMARY OF THE INVENTION 
       [0006]    A primary objective of the present invention is to provide apparatus, devices, systems and methods of fixing damaged culverts by leaving the existing culverts in place. 
         [0007]    A secondary objective of the present invention is to provide apparatus, devices, systems and methods of fixing damaged culverts that is substantially less expensive than having to remove and replace the existing culvert. 
         [0008]    A third objective of the present invention is to provide apparatus, devices, systems and methods of fixing damaged culverts that takes substantially less time than having to remove and replace the existing culvert. 
         [0009]    A fourth objective of the present invention is to provide apparatus, devices, systems and methods of fixing damaged culverts that is substantially less disruptive to vehicle and pedestrian traffic than having to remove and replace the existing culvert. 
         [0010]    A preferred embodiment of the culvert insert can include a spiral cut pipe material, with cut sections hooked together along the seam lines with one another. Initially, a PVC type pipe can be cut along a spiral line from one end of the pipe to the other. Next, the separated spiral cut sections(or strips) can be joined together by a sliding hook, into an expandable or contractable pipe insert. The insert can be placed inside of a damaged culvert and then twisted to expand against the interior walls of the damaged culvert. Twisting the insert in a clockwise direction contracts the diameter of the insert, and lengthens the insert. Twisting the insert counter-clockwise at a job site (inside of a damaged culvert) expands the insert against interior walls of the damaged culvert and shortens the length of the insert. 
         [0011]    A culvert insert can include an elongated rectangular strip of semi-rigid planar material having longitudinal sides, with at least one side having an elongated hook, and an opposite side having a longitudinal groove running therethrough, where the hook slidably attaches to and slide within the longitudinal groove when the strip is rolled into a spiral wrapped tube. 
         [0012]    The elongated rectangular strip can be formed from PVC. The elongated hook can include an elongated seam having one side that is attached to the one side of the rectangular strip, and the seam edge having another side with the hook thereon. 
         [0013]    The culvert insert can include a lock attached to at least one end of the spiral wrapped tube that keep the tube in a contracted rolled state. The culvert insert can include an opening in at least one end of the spiral wrapped tube to allow for a lever to be inserted in order to allow the culvert insert to expand. 
         [0014]    The elongated seam can include a compressible and expandable O-ring for allowing the one side to slide against an opposite side of the strip. 
         [0015]    The hook edge can include a finger portion protruding substantially perpendicular to the strip. The finger portion can include a substantially sharpened tip. The finger portion can include a substantially rounded tip. The finger portion can include an angled tip. The finger portion can include a pair of substantially perpendicular finger portions each facing one another. 
         [0016]    A method of repairing a damaged culvert, can include the steps of inserting a rolled up tube into a damaged culvert, releasing the rolled up tube to unravel, expanding the unraveling tube, locking the expanding tube to interior walls of the culvert to form a protective lining for the inside of the culvert. 
         [0017]    The method can further include the step of rolling an elongated strip of a rigid material into a spiral shape to form the rolled up tube before the inserting the tube in the culvert. The method can further include the step of slidably interlocking hook edges about longitudinal sides of the strip with one another while the strip is being rolled into the spiral shape. 
         [0018]    The method can further include the step of providing a slidable surface on the hook edges, the slidable surface being selected from one of an O-ring, a bushing and a Teflon coating. 
         [0019]    The releasing step can include the step of removing a lock about the at least one end of the rolled up tube. 
         [0020]    The method can include the step of slidably attaching the hook edge into an elongated groove. The hook edges can include a substantially perpendicular finger portion. The hook edges can include a pair of substantially perpendicular finger portions each facing one another. 
         [0021]    Further objects and advantages of this invention will be apparent from the following detailed description of the presently preferred embodiments which are illustrated schematically in the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0022]      FIG. 1  is a perspective view of the expandable culvert insert in a contracted configuration. 
           [0023]      FIG. 1A  is an enlarged view of a portion of the expandable culvert insert of  FIG. 1 . 
           [0024]      FIG. 1B  is an end view of the expandable culvert of  FIG. 1  in contracted position. 
           [0025]      FIG. 2  is another perspective view of the expandable culvert insert of  FIG. 1  in an expanded configuration. 
           [0026]      FIG. 2A  is an enlarged view of the expandable culvert insert portion of  FIG. 1 . 
           [0027]      FIG. 2B  is an end view of the expanded expandable culvert insert of  FIG. 2 . 
           [0028]      FIG. 3  is a side view of the culvert insert of  FIG. 1  in an expanded configuration. 
           [0029]      FIG. 3A  is a side cross-sectional view of the culvert insert of  FIG. 3  along arrows  3 A. 
           [0030]      FIG. 4A  is an enlarged view of the connecting strip with o-ring seal and connecting strip retaining groove in the expandable culvert insert of  FIG. 3A . 
           [0031]      FIG. 4B  is an exploded view of the connecting strip, o-ring seal and connecting strip retaining groove of  FIG. 4A . 
           [0032]      FIG. 5A  is a cross-sectional view of another connecting strip seam for the invention. 
           [0033]      FIG. 5B  is a cross-sectional view of still another connecting strip seam for the invention. 
           [0034]      FIG. 5C  is a cross-sectional view of still another connecting strip seam for the invention. 
           [0035]      FIG. 5D  is a cross-sectional view of still another connecting strip seam for the invention. 
           [0036]      FIG. 6  is a perspective view of culvert installation bridle for the invention. 
           [0037]      FIG. 6A  is an enlarged view of bridle hook for the bridle of  FIG. 6  that is used to secure to a hole in a culvert insert wall. 
           [0038]      FIG. 6B  is an enlarged view of a cable hooked to a plate for the bridle of  FIG. 6 . 
           [0039]      FIG. 7  is a cross-sectional view of a damaged culvert being installed with the expandable culvert insert being pulled into the culvert. 
           [0040]      FIG. 8  is another cross-sectional view of the damaged culvert with culvert insert in a position ready to be expanded. 
           [0041]      FIG. 9  is another cross-sectional view of the culvert insert being expanded into place. 
           [0042]      FIG. 10  is a cross-sectional view with the culvert insert fully expanded into place and the ends cut off to conform to the old exterior walls. 
           [0043]      FIG. 11  is a front perspective view of a pipe cleaning bucket which is pulled through the old culvert prior to installation of the culvert insert. in order to clear debris for the installation of the expandable culvert. 
           [0044]      FIG. 12  is a rear perspective view of the pipe cleaning bucket of  FIG. 11  showing winch cable affixed to the bottom ring. 
           [0045]      FIG. 13  is a cross-sectional view of an old damaged culvert with the installation showing cleaning bucket being pulled through to clear debris. 
           [0046]      FIG. 14  is a cross-sectional view of an old damaged culvert showing the bucket pulled completely through and debris cleared. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0047]    Before explaining the disclosed embodiments of the present invention in detail it is to be understood that the invention is not limited in its applications to the details of the particular arrangements shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation. 
         [0048]    A listing of components will now be described.
     10  Expandable culvert insert in contracted configuration.     20  Expandable culvert insert in expanded configuration.     30  Axial contraction motion.     40  Radial expansion motion.     50  Lever rod to help the culvert insert to expand.     60  Shipping lock.     70  Shipping lock has be cut to allow the spiral sections to slide against each other.     80  Holes in culvert insert wall to fit lever rod into so that lever can be used to twist and expand culvert insert.   Also used to attach bridle hooks and pull culvert insert into position inside of old culvert.     90  Connecting strip seam.     100  Twisting motion that expands culvert insert.     110  Culvert insert wall.     112  one edge of insert wall     118  opposite edge of insert wall     120  O-Ring seal.     130  Connecting strip retaining groove in culvert insert wall.     140  Connecting strip is glued onto culvert insert wall on one side of seam.     150  Connecting strip retaining finger locks connecting strip into to groove in culvert insert wall while allowing the strip to slide along the wall when the culvert insert is twisted to expand.     152  indented outer portion of finger tip     158  enlarged rear base portion of finger tip     160  Optional configuration. Connecting strip molded as part of the culvert insert wall.     170  Rounded lead on retaining finger allows assembly of strip to culvert insert wall.     180  Alternate configuration on retaining finger.     190  Alternate configuration on retaining finger with hook molded to strip.     192  downwardly facing prong finger     198  upwardly facing prong finger     200  Installation bridal used to pull culvert into position before expanding.     210  Bridle hook secures to hole in culvert wall.     220  Bridle cable fixes hook to bridle plate.     230  Bridle plate.     240  Ring fixed to bridle plate to attach winch cable hook onto.     250  Winch cable with hook (prior art).     260  Existing damaged culvert.     270  Lubricant to ease sliding of culvert wall against connecting strip.     280  Culvert cut off to conform to the shape of the existing installation.     290  Pipe cleaning bucket.     300  Bucket.     310  Bucket cables connect bucket to bucket plate.     320  Bucket plate.     330  Ring fixed to bottom of bucket allows bucket to be pulled out of the culvert backwards to empty the bucket or clear a snag.     340  Ring fixed to bucket plate allows bucket to be pulled through old culvert to clear debris.     350  Debris in old culvert installation.   
 
         [0091]    A preferred length of the installed culvert insert for residential use can be approximately 10 feet to approximately 40 feet, and having diameters of approximately 4 inches to approximately 8 feet. Shorter lengths can also be used. For an approximately 30 foot length existing culvert, having approximately 24 inches a preferred embodiment of the culvert can be twisted to approximately 20 inches in width. A single strip can have width of approximately 12 inches to approximately 16 inches in width before being rolled up in a spiral configuration. 
         [0092]    For a residential application, the strips can be formed from extruded PVC (polyvinyl chloride) and/or ABS plastic. Other types of material can be formed from composite material that can include composites, fiberglass, combinations, and the like. 
         [0093]    A machine can be used roll up the strips in a spiral pattern where each of the connecting strips is being rolled up into a spiral type roll configuration. For example, a rolling machine can be used for the PVC strips, and/or an extruding machine can be used for PVC, plastics, composites and the like. Likewise, an extruding machine can be used plastics, composites and the like. 
         [0094]      FIG. 1  is a perspective view of the expandable culvert insert  10  in a contracted configuration.  FIG. 1A  is an enlarged view of a portion of the expandable culvert insert  10  of  FIG. 1 .  FIG. 1B  is an end view of the expandable culvert  10  of  FIG. 1  in contracted position. 
         [0095]      FIG. 2  is another perspective view of the expandable culvert insert  10  of  FIG. 1  in an expanded configuration  20 . Axial and radial motion arrows are shown to illustrate that the culvert is getting shorter and wider.  FIG. 2A  is an enlarged view of the expandable culvert insert portion of  FIG. 1 .  FIG. 2B  is an end view of the expanded expandable culvert insert of  FIG. 2 . 
         [0096]      FIG. 3  is a side view of the culvert insert  10  of  FIG. 1  in an expanded configuration.  FIG. 3A  is a side cross-sectional view of the culvert insert  10  of  FIG. 3  along arrows  3 A. 
         [0097]      FIG. 4A  is an enlarged view of the connecting strip  110  with O-ring seal  120  and connecting strip retaining groove  130  in the expandable culvert insert  110  of  FIG. 3A .  FIG. 4B  is an exploded view of the connecting strip  110 , O-ring seal  120  and connecting strip retaining groove  130  of  FIG. 4A . 
         [0098]    Referring to  FIGS. 1-4B , the culvert insert  10  can include an elongated culvert strip  110  having one edge  112  with a connecting strip seam  90  having a hook  130 , fixably attached thereto, and an opposite edge  118  with a longitudinal groove  130  into a side of the culvert wall strip  110 . The connecting seam  90  can have an H-configuration, with one side  92  having a C shape  140  that can attach to the one edge  112  of the strip  110  by an adhesive, such as but not limited to glue, contact cement, and the like. The opposite side  98  of the connecting seam  90  can have upper and lower legs  270 , with at least the upper leg having an inwardly protruding finger portion  150 . The inwardly protruding finger portion  150  locks the connecting strip seam  90  into the groove  130  in culvert insert wall  110  while allowing one edge  112  of the strip  110  with attached seam  90  to slide along the other edge  118  of the strip  110  when the culvert insert  10  is twisted to expand. 
         [0099]    The tip of the finger  150  can have an indented outer portion  152 , and an enlarged rear base portion  158 , where the indented outer portion  152  enhances the sliding of the finger  150  within the groove  130 . A lubricant  270  can be inserted within the right C shape legs  98  to ease in sliding of the culvert strip edge  118  against the inside of the C shape legs  98  of the connecting strip seam  90 . 
         [0100]    Referring to  FIGS. 1-3 , a shipping lock  60  can be used to adhere at least the adjoining strips at one end of the culvert insert  10  together, which will hold a wound up culvert insert  10  into a generally pipe shaped configuration. The lock  60  can be tape or another type of band that adheres to both adjoining strips. When the culvert insert  10  is to be used, the shipping lock  60  is cut  70  to allow the spiral wrapped strips  110  to slide against each other, and rotate opposite to one another. 
         [0101]    A hole  80  in at least one of the walls of the culvert strips  110  can allow use of a lever rod  50  to be inserted into. The lever rod  50  can be moved in the direction of arrow R to help the culvert insert  10  expand into an expanded version  20 . Arrows  40  show the radial expansion of the culvert insert  10  into the expanded position  20  while the axial dimension of the culvert insert contracts as shown by arrows  30 . 
         [0102]    Working prototypes of the invention were constructed between August and October 2010, and resulted in demonstrating the H seam functioned and operated to hold the wound strips together in a spiral pipe configuration to be used as a culvert insert. 
         [0103]      FIG. 5A  is a cross-sectional view of another connecting strip seam  90  for the invention where the tip has an outer rounded lead  170  on the retaining finger which allows easier sliding of the strip  110  to the groove  130 .  FIG. 5B  is a cross-sectional view of still another connecting strip seam  90  for the invention with an angled side  180 .  FIG. 5C  is a cross-sectional view of still another connecting strip seam  90  for the invention with an inwardly angled finger  190 .  FIG. 5D  is a cross-sectional view of still another connecting strip seam  160  for the invention with the connecting seam molded onto one side of the culvert wall  100 . A still another alternative connecting seam can have a two fingers(an upper one  192  and a lower one  198 , each inwardly protruding and facing one another. 
         [0104]      FIG. 6  is a perspective view of culvert installation bridle  200  for the invention that can be used to pull the culvert insert  10  into position before expanding.  FIG. 6A  is an enlarged view of a bridle hook  210  of the bridle  100  of  FIG. 6 .  FIG. 6B  is an enlarged view of a winch cable  250  that is attached to a ring  240  fixed to a bridle plate  230 , where a plurality of bridle cables  220  are attached thereto. At the end of each bridle cable  220  can be a bridle hook  210 . 
         [0105]      FIG. 7  is a cross-sectional view of an existing damaged culvert  260  being installed with the expandable culvert insert  10  being pulled into the damaged culvert  260 . 
         [0106]    Referring to  FIGS. 6-7 , bridle hooks  210  at the end of the plurality of bridle cables  220  can be attached to holes  80  along a circumferential perimeter of the rear of the culvert insert, while the winch cable  250  passes through the inside of the culvert insert  10  and can be pulled in the direction of arrow P through the inside of a damaged culvert  260   
         [0107]      FIG. 8  is another cross-sectional view of the damaged culvert  260  with culvert insert  10  centered in a position ready to be expanded. 
         [0108]      FIG. 9  is another cross-sectional view of the culvert insert  10  being expanded into an expansion position  20  with the lever rod  50  being inserted into an opening  80  and rotated in order to help culvert insert  10  twist and expand outward. Motion arrows M 1 , M 2  indicate the culvert insert  10  getting shorter in length (arrow  30 ) and wider in diameter arrows  40 . 
         [0109]      FIG. 10  is a cross-sectional view with the culvert insert  10  fully expanded into place  20  and the ends of the culvert insert  10  cut off at  280  to conform to the old exterior walls of the damaged culvert  260 . 
         [0110]      FIG. 11  is a front perspective view of a pipe cleaning bucket  290  which is pulled through the old culvert prior to installation of the culvert insert  10 .  FIG. 12  is a rear perspective view of the pipe cleaning bucket  290  of  FIG. 11  showing winch cable  250  affixed to the bottom ring  330 . 
         [0111]    The pipe cleaning bucket  290  can include a generally cylindrical bucket  300  formed out of plastic, aluminum, galvanized metal, and the like having perforations therethrough the sidewalls. A winch cable  250  can be attached to a ring  340  that is fixed to a bucket plate  320  by a plurality of bucket cables  310  that connect to a front end of the bucket  300 . 
         [0112]      FIG. 13  is a cross-sectional view of an old damaged culvert  260  with the installation showing cleaning bucket  300  being pulled through the damaged culvert  260  to clear debris.  FIG. 14  is a cross-sectional view of an old damaged culvert showing the bucket pulled completely through and debris  350  cleared. The pipe cleaning bucket  290  can be pulled through the damaged culvert  260  cleaning debris  350  out of the way in order to allow for the culvert insert  10  to be used. 
         [0113]    The embodiment describes a seam pre-attached to one side of the strip  110 , the invention can be formed from extruded and/or a molded and/or welded and/or machined on hook edge of the strip. 
         [0114]    While PVC and ABST plastic are described, the invention can be formed from other types of material such as but not limited to CPVC that has the ability to bend, shape and weld, and the like, as well as be fire retardant can be used. Other types of material can also be used that can provide good structural and memory capability can also be used. 
         [0115]    Although a lock has been described to keep the spiral strip in a tube configuration, other types of components, such as bands, and the like, can be used. 
         [0116]    While an O-ring has been described, the invention can be used with other types of depressible and slidable components, such as but not limited to bushings and Teflon coatings. 
         [0117]    Although the primary applications refer to culverts, the invention can be used in other types of channels, such as but not limited to storm drains, sewer lines, septic inlet and outlet pipes. 
         [0118]    Although the invention shows straight channels, culverts, the invention can be used in channels and culverts that have bends, and the like. 
         [0119]    Pipe inserts can be joined to each other end to end by a coupler, having a male protruding end and a female receiving end. This would allow for greater lengths of damaged culverts to be repaired. Additionally, the coupling can allow for turns and bends in a damaged culvert. 
         [0120]    Although a bridle and winch has been described as pulling the insert into a damaged culvert, other insertion methods and techniques can be used. For example, if the damaged culvert is filled with water, the insert can be floated into position with floats, such as but not limited to buoys or air bags, and the like. Alternatively, another method of installation can allow for the insert to be pushed in by a shovel type truck or shovel type machine, and the like. 
         [0121]    While the invention refers to hook edges to form the seams, the invention can be used with other types of slidable/moveable seams, such as but not limited to using shifting/sliding tracks. For example, T or L type members can be slidable within a mateable channel member. Although the finger is described as a longitudinal protruding hook, the finger can be more than a single finger, and can include spaced apart fingers, and the like. 
         [0122]    Although a mechanical lever is described, a machine operated torqueing wheel which can be inserted into one end of the insert, with outwardly protruding spokes which pass into the holes in the insert. Rotating the wheel counter-clockwise would assist in expanding the diameter of the insert. For example, up to approximately an  18  degree twist can be all that is needed to twist the insert from a contracted position to an expanded position. Twisting can be at one end or both ends of the insert as needed to expand or contract the diameter of the insert. 
         [0123]    While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended.