Patent Publication Number: US-11035141-B1

Title: Apparatus and system for protecting the interior of a structure from flood water

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the filing benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application No. 62/752,438, filed Oct. 30, 2018, which is hereby incorporated by reference. This application also claims the filing benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application No. 62/859,124 filed Jun. 9, 2019, which is hereby incorporated by reference. 
    
    
     TECHNICAL FIELD 
     The present invention pertains generally to flood damage protection for structures, and more particularly to an apparatus and system in which panels are mounted over the doors, windows, or other openings of a structure to prevent flood water from entering the interior of the structure. 
     BACKGROUND OF THE INVENTION 
     Flood damage is a common problem in low-lying areas. Flood waters can enter a structure such as a home or commercial building through leaks in closed doors and windows and cause considerable damage. One current way to prevent the water from entering a structure is to install barrier sheets made from aluminum or stainless steel. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention is directed to an apparatus and system for protecting the interior of structures from flood water. The apparatus and system include panels which are mounted over an opening (such as a window or a door) in the structure to block the entry of the flood water. The panels have a unique structural foam core with excellent mechanical properties and low weight. The foam core is covered by a reinforcing skin to form a composite sandwich. The resultant panel provides strength against static water loads, dynamic water loads, is fatigue resistant, and impact load resistant. Other features of the panel include excellent adhesion/peel strength, excellent chemical resistance, corrosion resistance, low water absorption and good thermal/acoustic insulation. Because of their high strength and low weight, the panels span further than metal panels without the need for additional structural support columns/posts. There is also no need for addition structural “kickers” for bracing the panels; kickers form an obstruction into public right-of-ways and a hazard to the general public. 
     In accordance with an embodiment, apparatus for protecting the interior of a structure having an opening from flood water includes a panel which is shaped and dimensioned to cover the opening in the structure. The panel includes a center layer which is fabricated from foam. The center layer has a first side, and an opposite second side. A first skin is connected to the first side of the center layer, and a second skin is connected to the second side of the center layer. 
     In accordance with another embodiment, the center layer has four edges. A layer of coating covers the first skin, the second skin, and the four edges. 
     In accordance with another embodiment, the center layer has a central section, the central section is fabricated from a first foam having a first density. The center layer also has a peripheral section. The peripheral section is fabricated from a second foam having a second density, the second density being greater than the first density. 
     In accordance with another embodiment, the panel includes a mounting bracket. 
     In accordance with another embodiment, the panel has one of (1) a trapezoidal shape, and (2) a horizontal top edge and a non-horizontal bottom edge. 
     In accordance with another embodiment, the panel is curved. 
     In accordance with another embodiment, the panel has a first section and an intersecting second section. The first section and the second section forming an angle. 
     In accordance with another embodiment, the panel includes a mounting bracket. A second panel includes a second mounting bracket. The mounting bracket is connected to the second mounting bracket with a gasket disposed therebetween. 
     In accordance with another embodiment, the panel has an edge. A groove is disposed along the edge. 
     In accordance with another embodiment, a spacer panel has an inward edge. The inward edge of the spacer panel is shaped and dimensioned to be received by the groove of the edge of the panel. 
     In accordance with another embodiment, the panel has a width. The spacer panel has a second width which is less than the width. 
     In accordance with another embodiment, the foam of the panel has a density. The spacer panel includes a foam which has a second density which is greater than the density. 
     In accordance with another embodiment, the spacer panel is connected to the panel, wherein the inward edge of the spacer panel is received by the groove of the edge of the panel. The spacer panel has a outward edge. A second panel has second edge with a second groove. The outward edge of the spacer panel is eived by the second groove of the second edge of the second panel. 
     In accordance with another embodiment, a buttress supports the panel. The panel has an inward side which includes a vertical groove which is shaped and dimensioned to receive the buttress. 
     Other embodiments, in addition to the embodiments enumerated above, will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the apparatus and system for protecting the interior of a structure from flood water. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a panel for protecting the interior of a structure from flood water; 
         FIG. 2  is an exploded perspective view of the panel; 
         FIG. 3  is an enlarged cross section view along the line  3 - 3  of  FIG. 1 ; 
         FIG. 4  is perspective view of the panel covering an opening of a structure; 
         FIG. 5  is a exploded perspective view of a panel with an attached mounting bracket; 
         FIG. 6  is a perspective view of the panel with the mounting bracket; 
         FIG. 7  is a side elevation view of the panel with the mounting bracket; 
         FIG. 8  is a perspective view of another panel for protecting the interior of a structure from flood water; 
         FIG. 9  is an exploded perspective view of the panel of  FIG. 8 ; 
         FIG. 10  is an enlarged cross section view along the line  10 - 10  of  FIG. 8 ; 
         FIG. 11  is a front elevation view of a panel which has a horizontal top edge and a non-horizontal bottom edge; 
         FIG. 12  is a front elevation view of a panel which has a trapezoidal shape; 
         FIG. 13  is a perspective view of a curved panel; 
         FIG. 14  is a perspective view of an angled panel; 
         FIG. 15  is a perspective view of two connected panels; 
         FIG. 16  is an enlarged cross sectional view along the line  16 - 16  of  FIG. 15 ; 
         FIG. 17  is an exploded perspective view of a panel and a spacer panel; 
         FIG. 18  is a perspective view of the spacer panel connected to the panel; 
         FIG. 19  is a perspective view of a second panel with a connected spacer panel; 
         FIG. 20  is a reduced exploded perspective view of multiple panels; 
         FIG. 21  is a reduced perspective view of the multiple panels connected to form a span; 
         FIG. 22  is a reduced top plan view of the multiple connected panels of  FIG. 21 ; 
         FIG. 23  is an enlarged cross sectional view along the line  23 - 23  of  FIG. 17 ; 
         FIG. 24  is an enlarged cross sectional view along the line  24 - 24  of  FIG. 20 ; 
         FIG. 25  is an enlarged cross sectional view along the line  25 - 25  of  FIG. 21 ; 
         FIG. 26  is a perspective view of a corner panel; 
         FIG. 27  is a perspective view of four corner panels connected to form a square; 
         FIG. 28  is a perspective view of a panel fastened to the floor and to the wall of a structure; 
         FIG. 29  is an enlarged cross sectional view along the line  29 - 29  of  FIG. 28 ; 
         FIG. 30  is an enlarged cross sectional view along the line  30 - 30  of  FIG. 28 . 
         FIG. 31  is an enlarged view of area  31  of  FIG. 28 ; 
         FIG. 32  is a perspective view of a panel connected to both the horizontal and vertical surfaces of a structure; 
         FIG. 33  is an enlarged cross sectional view along the line  33 - 33  of  FIG. 32 ; 
         FIG. 34  is a perspective view of a buttress connected to a panel; and, 
         FIG. 35  is an enlarged cross sectional view along the line  35 - 35  of  FIG. 34 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  is a perspective view of a panel  20  of an apparatus and system for protecting the interior of a structure  500  from flood water,  FIG. 2  is a an exploded perspective of panel  20 , and  FIG. 3  is a cross sectional view along the line  3 - 3  of  FIG. 1 . Panel  20  is shaped and dimension to cover an opening  502  in the structure  500  such as a window, a door, a vent, or any other opening through which water could pass (also refer to  FIG. 4 ). Panel  20  includes a center layer  22  which is fabricated from foam. 
     As used herein the term foam includes a rigid foam which has a high strength-to-weight ratio. Other properties of the foam can include, moisture resistance, solvent resistance, and laminate and adhesive compatibility. In one embodiment, the foam can be a closed cell elastomer (e.g. a PVC foam), and in particular can be an interpenetrating polymer network (IPN) elastomer. The density of the foam can vary depending upon the application, with densities of 80 Kg/M 3  and 130 Kg/M 3  having been found useful. 
     Center layer  22  (core) has a first side  24 , an opposite second side  26 , and four edges  28 . A first skin  30  is connected to first side  24  of center layer  22 . A second skin  32  is connected to second side  26  of center layer  22 . In an embodiment, first skin  30  and second skin  32  are reinforced glass fiber (e.g. 3 mm thick) and are connected to center layer  22  a with polyurethane adhesive  33 . A layer of coating  34  covers first skin  30 , second skin  32 , and four edges  28  so that panel  20  is sealed. In an embodiment, the coating is polyurea and has a thickness of between about 1/32 inches and 5/64 inches depending upon specific job requirements. It is noted that in  FIG. 3 , the various layers of panel  20  have not been shown to scale for better clarity. 
     Center layer  22  has a central section  36  which is fabricated from a first foam having a first density (e.g. 80 Kg/M 3 ). And, center layer  22  has a peripheral section  38  which is fabricated from a second foam having a second density (e.g. 130 Kg/M 3 ), wherein the second density is greater than the first density. The higher density of the peripheral section  38  provides greater compression at locations where panel  20  is attached to a structure (refer to  FIG. 4 ). In the shown embodiment the peripheral section  38  includes two sides and the bottom of the panel  20 . In another embodiment, peripheral section  38  includes two side, the bottom, and the top of the panel  20  (refer to  FIGS. 8-10 ). Center layer, including central section  36  and peripheral section  38  can be made in various thicknesses (such as 3, inches, four inches, etc.) depending upon the particular application. It is also noted that in the shown embodiment panel  20  is non-metallic. 
       FIG. 4  is a perspective view of panel  20  covering an opening  502  (a window) of structure  500  (a building). Fasteners  40  hold panel  20  over the opening  502 , and in the shown embodiment are placed along the sides and bottom of the panel. Panel  20  provides structural resistance to both the hydrostatic and hydrodynamic pressure of flood waters and intermittent impact forces from floating debris. It is noted that one window  502  has not yet been covered, but that anchors  74  have been installed to receive the fasteners  40  (refer also to  FIGS. 29-30 ). 
       FIGS. 5-7  are exploded perspective, perspective, and side elevation views respectively of a panel  20  which includes a mounting bracket  42 . The mounting bracket  42  is utilized to anchor panel  20  to a horizontal support surface  600  such as a floor when wall anchoring is not possible. In the shown embodiment mounting bracket  42  is a structural angle made from fiberglass, and is 4″×4″×0.25″. Mounting bracket  42  is attached to panel  20  with methacrylate adhesive  44 . 
       FIG. 8  is a perspective view of another panel  20  of a system for protecting a structure  500  from flood water,  FIG. 9  is a an exploded perspective of panel  20 , and  FIG. 10  is an enlarged cross sectional view along the line  10 - 10  of  FIG. 8 . This panel  20  is the same as that of  FIGS. 1-3  except that peripheral section  38  includes the two sides, the bottom, and the top. As such, fasteners  40  (refer to  FIG. 4 ) can be placed all around the pane  20 . 
       FIG. 11  is a front elevation view of a panel  20  which has a horizontal top edge  46  and a non-horizontal bottom edge  48  and two parallel side edges (i.e. the top and bottom edges are not parallel. Such a panel  20  can be utilized to accommodate sloped grades and decorative angled window styles. 
       FIG. 12  is a front elevation view of a panel  20  which has a trapezoidal shape. It may be appreciated that panel  20  can be customized to virtually any desired shape to accommodate installation requirements. 
       FIG. 13  is a perspective view of a curved panel  20 . That is, panel  20  has a radius in the plane of the face of the panel ( 20 ) to accommodate structures which have rounded features. 
       FIG. 14  is a perspective view of a panel  20  which has an angle. Panel has a first section  20 -A and an intersecting second section  20 -B. First section  20 -A and second section  20 -B form an angle A. In the shown embodiment angle A is 90°, however it may be appreciated that other angles are also possible to match structure requirements. Angled panel  20  is useful for surrounding the corners or other angled areas of structures. 
       FIG. 15  is a perspective view of two connected panels  20   a  and  20   b , and  FIG. 16  is an enlarged cross sectional view along the line  16 - 16  of  FIG. 15 . Panel  20   a  includes a mounting bracket  42   a , and second panel  20   b  includes a second mounting bracket  42   b . Mounting bracket  42   a  connected to second mounting bracket  42   b  with a gasket  56  disposed therebetween. A bolt, nut, and washers are utilized to effect the connection, and when tightened compress gasket  56  to form a water tight seal. Such a stacked panel configuration is useful to allow flood protection for high window and door openings. In the shown embodiment second panel  20   b  is connected to a horizontal support surface  600 . 
       FIGS. 17-25  depict embodiments of the apparatus in which multiple panels are connected to create a span (a wall) which covers a lengthy opening in a structure. To that end,  FIG. 17  is an exploded perspective view of a panel  20  and a spacer panel  60 , and  FIG. 18  is a perspective view of the spacer panel  60  connected to the panel  20  to form a combination panel  20 A. Panel  20  has an edge  62 . A groove  64  is disposed along edge  62 . Spacer panel  60  has an inward edge  66  which is shaped and dimensioned to be received by groove  64  of edge  62  of panel  20 . In  FIG. 18 , the inward edge  66  of spacer panel  60  is inserted into groove  64  and fastened in place with an adhesive (such as polyurethane). The combined panel  20  and spacer panel  60  are designated as panel  20 A. In an embodiment, panel  20  is fabricated from a foam which has a density. It is noted that if panel  20  is fabricated from two different density foams (refer to the  FIGS. 2 and 9  and the associated descriptions) the density of the foam of panel  20  will be an average density which lies somewhere between the two foam densities. Spacer panel  60  includes single foam which has a second density, wherein the second density is greater than the density (average density) of the foam of panel  20 . 
       FIG. 19  is a perspective view of a second panel  20  with a connected spacer panel  60 , the combination designated as panel  20 B. This configuration is similar to that of panel  20 A, except that panel  20 B also has a groove  68  disposed on the opposite edge  67 . 
       FIG. 20  is a reduced exploded perspective view of multiple panels,  FIG. 21  is a reduced perspective view of the multiple panels connected to form a span, and  FIG. 22  is a reduced top plan view of the multiple connected panels of  FIG. 21 . In the shown embodiment, four panels ( 20 A,  20 B,  20 B, and  20 C are connected to span a distance. That is, panel  20 C has a groove  70  on the opposite side from groove  64  of panel  20 A (refer to  FIG. 17 ). In  FIG. 21  the four panels ( 20 A,  20 B,  20 B, and  20 C) are connected together, and are also connected to a horizontal surface  600  of a structure (e.g. a floor) and to a vertical surface  602  of a structure (such as a wall). It is noted that panel  20 C has a groove  71  of the opposite edge from panel  20 A. Panels  20 A and  20 C are the opposite end panels of the span. Referring also to  FIGS. 18-19 , spacer panel  60  is connected to panel  20 , wherein inward edge  66  of spacer panel  60  is received by groove  64  of edge  62  of panel  20  (to form combined panel  20 A). Spacer panel  60  has an outward edge  70 . A second panel  20 B has a second edge  71  with a second groove  68 . The outward edge  70  of spacer  60  of panel  20 A is received by second groove  68  of second edge  71  of second panel  20 B. Using this tongue and groove connection methodology, it may be appreciated that other numbers of side-by-side panels can be connected to span an opening (e.g. 2, 3, 5, 6, etc.). In the shown embodiment, the length of the span can be adjusted by adding more or less panels  20 B. In  FIG. 21  the flood water side and the protected interior are indicated. 
       FIG. 23  is an enlarged cross sectional view along the line  23 - 23  of  FIG. 17 . It is noted that panel  20  has a width W, and that spacer  60  has a width W 1  which is less than width W. Also shown are groove  64  of edge  62  of panel  20 , and inward edge  66  of spacer  60 . 
       FIG. 24  is an enlarged cross sectional view along the line  24 - 24  of  FIG. 20 . This view shows the connection of panel  20 A to panel  20 B, where outer edge  70  of spacer panel  60  of panel  20 A is received by groove  68  of panel  20 B. 
       FIG. 25  is an enlarged cross sectional view along the line  25 - 25  of  FIG. 21 , showing panel  20 A connected to panel  20 B. The connection is effected by connection hardware such as a bolt, a nut, a gasket, and washers. It is noted that multiple vertical connections of the two panels are made to provide the necessary strength (refer to  FIG. 21 ). 
       FIG. 26  is a perspective view of a corner panel  20 . In the shown embodiment corner panel  20  forms a 90° angle. One edge of corner panel  20  has groove  64 , and the other edge of corner panel  20  has a spacer panel  60  with an outward edge  70 . 
       FIG. 27  is a perspective view of four corner panels  20  connected to form a square. 
     It may be appreciated that panel  20  may be combined with structure  500  having a horizontal surface  600  and a vertical surface  602  to form a system for protecting from flood water. In that regard,  FIG. 28  is a perspective view of a panel  20  which is fastened to both the floor and to the wall of a structure, in which panel  20  is both directly and indirectly fastened to the structure.  FIG. 29  is an enlarged cross sectional view along the line  29 - 29  of  FIG. 28 , and  FIG. 30  is an enlarged cross sectional view along the line  30 - 30  of  FIG. 28 . In the shown example, panel  20  is fastened to both a horizontal surface  600  (e.g. a concrete floor) and to a vertical surface  602  (e.g. a concrete wall) of the structure  500  to cover opening  502  (such as a driveway into a structure). Referring to  FIG. 29 , an indirect fastening system  80  which fastens panel  20  to the horizontal surface  600  includes the panel  20  having a mounting bracket  42  which has a hole  43 . An anchor  74  having a threaded insert is embedded in the horizontal surface  600 . A gasket  56  (such as one made of (neoprene) has a hole  58 . Gasket  56  is disposed (1) between panel  20  and the horizontal surface  600 , and (2) between mounting bracket  42  and the horizontal surface  600 . A bolt  82  having a nut  83  passes through a washer  84 , through hole  43  in mounting bracket  42 , through hole  58  in gasket  56  and engages the threaded insert of anchor  74 . When bolt  82 /nut  83  is tightened, gasket  56  is compressed to ensure a watertight seal between both (1) panel  20  and horizontal surface  600 , and (2) mounting bracket  42  and horizontal surface  600 . It may be appreciated that indirect fastening system  80  could also be utilized to fasten panel  20  to a vertical surface  602  such as a wall. In  FIG. 28  the flood water side and the protected interior are indicated. 
     Referring to  FIG. 30 , a direct fastening system  90  which fastens panel  20  to the vertical surface  602  includes the panel  20  having a hole  86 . An anchor  74  having a threaded insert is embedded in the vertical surface  600 . A gasket  56  (such as one made of (neoprene) has a hole  58 . Gasket  56  is disposed between panel  20  and the vertical surface  602 . A bolt  82  having a nut  83  passes through a washer  84 , through hole  86  in panel  20 , through hole  58  in gasket  56  and engages the threaded insert of anchor  74 . When bolt  82 /nut  83  is tightened, gasket  56  is compressed to ensure a watertight seal between panel  20  and vertical surface  602 . 
       FIG. 31  is an enlarged view of area  18  of  FIG. 15 , showing bolt  82 , nut  83 , and washer  84 . 
       FIG. 32  is a perspective view of a panel  20  connected to both the horizontal  600  and vertical  602  surfaces of a structure  500 , and  FIG. 33  is an enlarged cross sectional view along the line  33 - 33  of  FIG. 32 . A mounting bracket  42  has a first side  45  and a second side  47  with an angle therebetween, First side  45  is connected to panel  20 , and second side  47  is connected to vertical surface  602  of structure  600 . An end cap  49  is perpendicularly connected to first side  45  and second side  47  of bracket  42 . End cap  49  is connected to horizontal surface  600  of structure  500 . This configuration is useful when panel  20  cannot be directly connected to a vertical surface  602 . 
       FIG. 34  is a perspective view of a buttress  92  connected to a panel  20 , and  FIG. 35  is an enlarged cross sectional view along the line  35 - 35  of  FIG. 34 . Buttress  90  is utilized when an opening is very large and a single panel or multiple connected panels are insufficient to handle water loads. Buttress  92  provides a perpendicular support (brace) which accommodates higher water loading. The structure includes a horizontal surface  600 . Buttress  92  is connected to horizontal surface  600  in the pre-described manner. Panel  20  has an inward side  21  (the interior side). Inward side  21  includes a vertical groove which receives buttress  92 . in an embodiment, the height of buttress  90  is equal to that of panel  20 . A typical location for buttress  92  is shown in dashed lines of  FIGS. 21 and 22 . 
     The embodiments of the apparatus and system for protecting a structure from flood water described herein are exemplary and numerous modifications, combinations, variations, and rearrangements can be readily envisioned to achieve an equivalent result, all of which are intended to be embraced within the scope of the appended claims. Further, nothing in the above-provided discussions of the apparatus and system for protecting a structure from flood water should be construed as limiting the invention to a particular embodiment or combination of embodiments. The scope of the invention is defined by the appended claims.