Patent Publication Number: US-11655596-B2

Title: Spill containment system

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to and benefit of U.S. Provisional Patent Application No. 62/897,898, filed Sep. 9, 2019, the contents of which are incorporated herein by reference in their entirety. 
    
    
     FIELD 
     This disclosure relates in general to spill containment, and in particular, a portable and deployable spill containment system for catching spills. 
     BACKGROUND 
     Spills of chemicals, oils, sewage and other liquids are oftentimes contained within a barrier system in order to avoid seepage into the surrounding areas (soil, rivers, lakes, etc.) to avoid contamination. Conventional spill containment devices or methods may use an inflatable stopper, metal frames or other configurations to support a spill proof surface. Such designs are easily damaged, difficult to store, transport or assemble 
     SUMMARY 
     This disclosure presents a deployable spill containment device, system, and method. In one embodiment, the spill containment device forms a shallow container covering a large area, such as, for example, an area of 11 feet (3.35 m) by 60 feet (18.29 m), for less than 12 inches (0.3 m) deep. The coverage area may vary, for example, to a smaller area such as 8 feet (2.44 m) by 8 feet (2.44 m), for 4 inches (0.1 m) deep. The spill containment device may have deformable walls that allow vehicles to drive over and into the protection area during and/or after deployment. Furthermore, the spill containment device may be rolled, folded, or both, for storage and transportation, such as fitting in a bed of a pickup truck. The spill containment system includes replaceable components for easy repair, exchange, and modification when needed. 
     In a first general aspect, a deployable spill containment device includes a pan made of a spill-proof material; an elastic entrance berm; and one or more side support berms, the one or more side support berms affixed to the pan and raising an edge of the pan to a predetermined height. In some embodiments, the one or more side support berms are spaced apart for a distance facilitating folding of the pan. 
     In one specific aspect, the elastic entrance berm is configured to be compressed to allow passage of a vehicle and to return to the original shape when unloaded. For example, a vehicle may drive over the elastic entrance berm, compressing it against the ground, and releasing the compression when it passes. The elastic entrance berm can then return to the original shape to maintain the containment depth of the pan. 
     In another specific aspect, the elastic entrance berm includes an elastic foam core and a spill-proof skin configured to wrap around the foam core and affixed to the pan and raising an edge of the pan to the predetermined height, in some embodiments, the spill-proof skin includes an adhesive strip to secure onto the foam core. 
     In yet another specific aspect, the spill-proof material may include closed cell polyethylene. 
     In one specific aspect, the elastic entrance berm and the one or more side support berms respectively include a high density crosslinked foam. 
     In another specific aspect, the pan is riveted onto an extended surface of the one or more side support berms and the elastic entrance berm to reach the predetermined height. 
     In yet another specific aspect, the pan is rectangular in shape and further including a second elastic entrance berm, in some embodiments, the elastic entrance berm and the second elastic entrance berm abut on opposing ends of two rows of the one or more side support berms to form the rectangular shape. 
     In one specific aspect, the elastic entrance berm and the one or more side support berms are at least 4 inches tall. 
     In a second general aspect, a foldable spill-proof pan includes a spill-proof surface having raised edges; a side support berm raising the edges to a predetermined height; and an entrance berm abutting the side support berm, the entrance berm configured to be compressed to allow for a vehicle to pass by. 
     In one specific aspect, the foldable spill-proof pan may further include a number of side support berms spaced apart for a distance facilitating folding for storage and transportation. 
     In another specific aspect, the number of side support berms has a height of about four to six inches. 
     In yet another specific aspect, the entrance berm is detachable from the side support berm such that the spill-proof surface is configured to be partially rolled upon the side support berm. 
     In one specific aspect, the edges of the spill-proof surface may be riveted onto an extended surface of the side support berm, in some embodiments, the extended surface is formed from an extra portion of spill-proof skin wrapped around and extending away from a foam core. 
     In another specific aspect, the spill-proof surface and the spill-proof skin are formed by closed cell polyethylene. 
     In a third general aspect, a method is disclosed for deploying a spill containment pond. The method includes: providing a number of side support berms; spacing the number of side support berms at a predetermined distance; attaching a first edge of a pan to some of the number of side support berms and raising the first edge of the pan to a predetermined height; providing an elastic entrance berm; abutting the elastic entrance berm to the number of side support berms at a distal end of the number of side support berms; and attaching a second edge of the pan to the elastic entrance berm and raising the second edge of the pan to the predetermined height. 
     In one specific aspect, providing the elastic entrance berm includes wrapping a spill-proof skin around a foam core and extending a portion of the spill-proof skin for attachment with the second edge of the pan. 
     In another specific aspect, spacing the number of side support berms at the predetermined distance is based on a number of folds and the predetermined height such that the predetermined distance accommodates one or more of the number of side support beams stacked when folded for storage and transportation. 
     In yet another specific aspect, providing the elastic entrance berm includes allowing the elastic entrance berm to be compressed upon receiving a compressive load and returning to an original shape to maintain the predetermined height of the second edge when the compressive load is removed. 
     In one specific aspect, attaching the first edge and the second edge includes riveting the first edge and the second edge of the pan to a respective extended spill-proof skin of the number of side support berms and the elastic entrance berm. 
     In another specific aspect, the predetermined height is about four to six inches and the predetermined distance is about eight to twelve inches. 
     Other aspects, features, and advantages will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, which are a part of this disclosure and which illustrate, by way of example, principles of the inventions hereof. 
    
    
     
       DESCRIPTION OF THE FIGURES 
       The accompanying drawings facilitate an understanding of the various embodiments. 
         FIG.  1    is a top view of a spill containment system in a deployed configuration. 
         FIG.  2    is a perspective view of the spill containment system of  FIG.  1   . 
         FIG.  3    is a cross sectional front view of the spill containment system of  FIG.  1    taken along the line  3 - 3  of  FIG.  1   . 
         FIG.  3 A  is a detail view of the of a portion of the spill containment system of  FIG.  3   . 
         FIG.  3 B  is a section view taken along the line  3 B- 3 B of  FIG.  1     
         FIGS.  4 A and  4 B  illustrate the outer skins of the berms of  FIG.  1   . 
         FIGS.  5 A- 5 E  illustrated the folding configuration of the containment system. 
         FIG.  6    is an example of the spill containment system in a folded configuration for compact transportation. 
         FIGS.  7  and  8    illustrate an embodiment of an anchoring device. 
     
    
    
     Like numerals refer to like elements. 
     DETAILED DESCRIPTION 
     This disclosure presents embodiments of a spill containment system. In general, a portable and deployable spill containment system (e.g., a shape of a pan or pond) for catching spills is described. The spill containment system is made of a spill-proof material such that it will not disintegrate when in contact with the spilled content, such as chemicals or fuels that would otherwise pollute the environment when absorbed into the ground. The spill containment system may be carried by one or more people and assembled/unfolded cover a large area, such as, for example, 11 feet wide by 60 feet long. The spill containment system may have, in some embodiments, a depth of about 4 inches to 6 inches, but may be customized to different depths. The depth of the spill containment system is provided by side supports that form a wall or a berm. The side support berms may be made of elastic and other resilient materials such that they can be reused and withstand substantial deformation, such as when being driven over by a vehicle. The side support berms raise and otherwise support edges of the pan to enable the pan to catch and temporarily contain spilled liquid. The spill containment system provides advantages, including withstanding of forces causes from large and heavy vehicles driving over the side berms, ease of configuration to cover different area sizes, ease of exchange or repair of components, and being easily and quickly foldable in a compact fashion for storage and transportation. Other advantages not expressly summarized may be understood from the detailed description below. 
       FIG.  1    is a top view of a spill containment system  100  in a deployed configuration to accommodate a vehicle  115  and/or any other type of equipment (a tank, a fuel trailer, fracking equipment, etc.) susceptible to leaking of fuels and/or other fluids during operation. The spill containment system  100  includes a pan  110  surrounded and supported by end or entrance berms  122  and a plurality of side berms  124 . In the embodiment illustrated in  FIGS.  1  and  2   , the side berms  124  are spaced apart a predetermined distance to, as discussed in greater detail below, enable ease of folding for storage and/or transport. In the embodiment illustrated in  FIGS.  1  and  2   , a plurality of spaces  126  separate three side berms  124  on each side of the containment system  100 ; however, it should be understood that depending on the desired length of the containment system  100  and/or the respective sizes of the side berms  124 , a different number of spaces  126  and/or berms  124  may be utilized. 
     With continued reference to  FIG.  1   , the end berms  122  extend laterally across the entirety of the containment system  100 . The sidewall portion of the berms  122  at each end of the berm  122  connect or otherwise attach to respective ends of the side berms  124 . In other embodiments, the end berms  122  extend between the side berms  124  such that the ends of the berms  122  abut the sidewalls of the berms  124  (not illustrated). 
       FIG.  3    is a cross sectional view of the spill containment system  100  taken along the line  3 - 3  of  FIG.  1   .  FIG.  3 A  is a detail view of a portion of the containment system of  FIG.  2   . As shown in the embodiment illustrated in  FIGS.  3  and  3 A , the side support berms  124  are formed having a generally rectangular cross-sectional shape with a height  218 , which is of a sufficient length to support the sidewall  210  of the pan  110 . It should be understood that any cross-sectional shape (i.e., square, round, oval, etc.) may be utilized. As illustrated, the pan  110  rests on the ground  201  and has an edge  212  raised above the side support berms  124  by an extended height  220  to facilitate, as discussed in greater detail below, connection of the berms  124  to the pan  110 . 
     According to some embodiments, the side support berms  124  includes a core  214  wrapped or otherwise enclosed by a spill-proof skin  310  (e.g., the spill-proof skins  310  of  FIG.  4 A ). In some embodiments, the core  214  is formed of a foam material such as, for example, a closed cell polyethylene foam or a high density crosslinked foam. However, it should be understood that the core  214  may be otherwise formed, including other types of foam and non-foam materials. In some embodiments, the core  214  may be an expandable/compressible bladder for holding air, water or any other type of fluid that is strong enough to support the pan sidewall  210  and contain liquids that are collected within the pan  110 . 
     Referring to  FIG.  3 A , the skin  310  has an additional length/segment  311  extending beyond the perimeter of the side support berm  124  after it is wrapped around the core  214  to align and connect with the edge  212  and material adjacent the edge  212  of the pan  110 . For example, the skin  310 , and thus the berm  124 , may be fastened to the pan  110  adjacent the edge  212  using a fastener  240  such as a rivet or screw, or by an adhesive, or via other attachment mechanisms such as Velcro™ to secure the segment  311  to the area adjacent the edge  212 . In some embodiments, the edge segment  311  may also be sewed to the pan  110 . 
     Referring to  FIGS.  3 B and  4 B , a similar configuration is illustrated for the end berms  122 . In particular, the skin  312  of the end berm  122  forms a tubular configuration similar to the tubular configuration of skin  310 . In  FIG.  4 B , for example, the skin  312  has an additional length/segment  311  extending beyond the perimeter of the end berms  122  after it is wrapped around the core  214  to align and connect with the edge  212  and the area around the edge  212  of the pan  110 . In  FIGS.  3 B and  4 B , the skin  312  is preferably fastened to the pan  110  using a Velcro fastener  240  so as to facilitate ease of removal/separation of the berms  122  from the pan  110  when it is desired to fold and store the system  100 . 
     Referring back to  FIGS.  1  and  2   , the space  126  between the berms  124  is of a predetermined length to enable the open area created by the space  126  to act as a hinge as the side berms  124  are folded and stacked on top of each other when transitioning the pan  110  from the deployed position (e.g.,  FIGS.  1  and  2   ) to the folded position for storage or transport (e.g.,  FIG.  5 A- 5 E ). With specific reference to  FIGS.  5 A- 5     e  (drawings not to scale), the method of folding the system  100  is illustrated. In  FIGS.  5 A and  5 B , which illustrate respectively, a side view and end view of the system  100 , the end berms  122  are detached from the pan  110  and the pan  110  is rolled up such that the side berms  124  are adjacent each other ( FIG.  5 B ). Once in this position, berm  124   a  is rotated in the direction of arrow  300  until it is positioned on top of berm  124   b . Once stacked in this configuration, the berms  124   a  and  124   b  are rotated together in the direction of arrow  300  ( FIG.  5 D ) until they are stacked on top of the berm  124   c  ( FIG.  5   e   ) for ease of transport and storage. It should be understood that the process continues for each additional berm  124  in the event the containment system  100  is more than three berm lengths. Once folded in the storage position, the containment system  100  can be stored for transport, such as illustrated, for example, in  FIG.  6   . In order to set up, the above-described steps are performed in reverse order. 
     According to some embodiments, the extended height  220  may be about 1 inch (25.4 mm). In still other embodiments, the extended height  220  may be of a different value depending on the intended application. 
     During use, the vehicle  115  may move in and out of the pan  110  by directly driving into or out of the pan  110  crossing the entrance/end berms  122  on either end. The entrance berms  122  are formed so as to be elastically compressed in order to allow passage of a vehicle. The entrance berms  122  are formed to return to original shape after the compression loads have been removed. In some embodiments, like the side support berms  124 , the entrance berms  122  include a core  214  and a spill-proof skin (e.g., the spill-proof skin  312  of  FIG.  4 B ) wrapped around the core  214 . The spill-proof skin is affixed to the side  210  of the pan  110  and raises the pan edges  212  to a predetermined height, such as, for example, 4 inches. 
     It should be understood that the height of the pan edges  212  can be higher or even lower, depending on the application. The entrance berms  122  may be 11 feet wide, or any width sufficient to cover a width of a truck. The entrance berms  122  may also have a square cross section profile having a side dimension of 4 inches, 6 inches, or the like. 
     In some embodiments, the spill-proof material includes closed cell polyethylene. In other embodiments, a tough, non-porous flexible film or sheet material may be used. The foam core may include a high density crosslinked foam that is elastic even after compression by a vehicle driven over. Although the entrance berms  122  function to return to its original shape, substantial return to its original shape is sufficient. As shown, the entrance berms  122  abut both ends of the two rows of the side support berms  124 . When folded or otherwise not in use, the entrance berms  122  may be detached from the side support berms  124 , or the pan  110 , or both, until next deployment. Although the entrance berms  122  and the side support berms  124  are illustrated or described to have at least 4 inches in depth, different dimensions may be used or customized to specific use or projects. 
     Referring specifically to  FIG.  4 A , the skin  310  is configured to wrap around the core  214  to form the side berm  124  for use in the spill containment system  100  of  FIGS.  1  and  2   . The spill-proof skin  310  includes an edge  350  such that when assembling the skin  310 , the edge  350  can be positioned adjacent to and secured along the attachment line  301  via an adhesive, a mechanical attachment (Velcro, buttons, etc.), sewing or any other method. Once the edge  310  is secured along the sew line  301 , the skin  310  forming an open ended tube to receive the core  214  therein from either end. Once inserted therein, the ends  352  of the skin  310  are folded and otherwise positioned to enclose the ends of the tube. The ends  352  are secured to enclose the tube by Velcro 600 or any other suitable attachment means, as illustrated in  FIG.  4 A . According to some embodiments, the spill-proof skin  310  for the side support berm  124  may have an operational length of 9′4″ and a total width of 18″ for wrapping a foam core having a square cross-section of a side dimension of 4″ and an extended height  220  for 1″. 
       FIG.  4 B  is a schematic diagram illustrating spill-proof skin  312  configured to wrap around a foam core to form an elastic entrance berm  122  for use in the spill containment device  100  of  FIG.  1   . The overall dimensions are similar to the side berms  124  except that the elastic entrance berm  122  has an operational length of 11′ instead of 9′4″. As discussed above, the 11′ operational length enables vehicles to drive over the entrance berm  122 . 
     Referring back to  FIG.  2   , the deployment of the spill containment device  100  is illustrated with the vehicle  115  driven thereon. In some embodiments, the vehicle  115  and the foldable spill containment device  100  may together form a spill containment system. For example, the vehicle  115  may include a dedicated space for accommodating the folded spill containment device  100 . In other embodiments, the foam cores for the entrance berms  122  and the side support berms  124  may be replaced using inflatable cores (for exchange, backup, replacement, or other purposes). The vehicle  115  may provide supply for equipment (such as pump) and power to operate such exchange. 
     According to embodiments disclosed herein, the spill containment system  100  may be anchored down to the earth via a plurality of stakes or other types of anchors. For example, in some embodiments, all or select berms  122  and  124  may include one or more stakes  500  or other anchor devices that maintain the position of the system  100  relative to the earth, as seen for example in  FIGS.  7  and  8   . According to some embodiments, the stakes  500  can be that as described in U.S. Pat. No. 7,534,073, entitled “Earth Anchor”, U.S. Design U.S. Pat. No. D572,546 entitled “Ground Anchor” and/or U.S. Pat. No. 8,011,860 entitled “Ground Anchor”, each of which are hereby incorporated by reference in their entireties for all purposes. As illustrated in the embodiment shown in  FIGS.  7  and  8   , the stake  500  can be secured via a cable  502  through one more grommets  504  disposed on berms  122  and/or  124  to secure the system  100  to the earth. 
     Although only three side support berms  124  on each side of the pan  110  are illustrated in  FIG.  1   , in practice or in other embodiments, different number of the side support berms  124  may be used depending on the desired total dimensions. Similarly, the entrance berms  122  may be made of different dimensions, such as 8′ instead of 11′ depending on application. 
     In the foregoing description of certain embodiments, specific terminology has been resorted to for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes other technical equivalents which operate in a similar manner to accomplish a similar technical purpose. 
     In the specification and claims, the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of”. A corresponding meaning is to be attributed to the corresponding words “comprise”, “comprised” and “comprises” where they appear. 
     In addition, the foregoing describes only some embodiments of the invention(s), and alterations, modifications, additions and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive. 
     Furthermore, invention(s) have described in connection with what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the invention(s), as defined solely by the appended claims. Also, the various embodiments described above may be implemented in conjunction with other embodiments, e.g., aspects of one embodiment may be combined with aspects of another embodiment to realize yet other embodiments. Further, each independent feature or component of any given assembly may constitute an additional embodiment.