Patent Abstract:
The present invention relates to a device for post-installation in-situ barrier creation. A multi-layered device provides a medium for of remedial substances such as waterproofing resins or cements, insecticides, mold preventatives, rust retardants and the like. The multi-layer device preferably consists of three conjoined layers: first layer, intermediate layer, and second layer, and at least one piping. The first layer is preferably semi-permeable; the second layer is a non-permeable layer; the intermediate layer is a void-inducing layer. The second layer, intermediate layer, and first layer are fixedly attached, with the intermediate layer interposed between the second layer and the first layer. The multi-layered device is fixedly attached to shoring system exterior surface. At least one piping is engagedly attached to a panel of the multi-layered device. A structural construction material is constructed exterior the multi-layer device. Thereafter, a free flowing substance can be pumped to the multi-layered device.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of and claims the benefit of U.S. patent application Ser. No. 11/066,927 entitled, “Device for post-installation in-situ barrier creation and method of use thereof,” filed on Feb. 25, 2005 in the United States Patent and Trademark Office. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable. 
       BACKGROUND OF THE INVENTION 
     Field of the Invention 
       [0003]    The present invention relates to a device for post-installation in-situ barrier creation, and more particularly to a multi-layered device providing a medium for post-installation injection of remedial substances such as waterproofing resins or cements, insecticides, mold preventatives, rust retardants and the like. 
         [0004]    It is common in underground structures, such as tunnels, mines and large buildings with subterranean foundations, to require that the structures be watertight. Thus, it is essential to prevent groundwater from contacting the porous portions of structures or joints, which are typically of concrete. It is also essential to remove water present in the voids of such concrete as such water may swell during low temperatures and fracture the concrete or may contact ferrous portions of the structure, resulting in oxidation and material degradation. Therefore, devices have been developed for removing water from the concrete structure and for preventing water from contacting the concrete structure. 
         [0005]    Attempts at removing groundwater from the concrete structure have included a permeable liner and an absorbent sheet. Both absorb adjacent water, carrying it from the concrete structure. This type is system is limited, however, because it cannot introduce a fluid or gaseous substance to the concrete and as the water removed is only that in contact with the system. Additionally, this system does not provide a waterproof barrier. 
         [0006]    Among attempts at preventing water from contacting the concrete structure has been the installation of a waterproof liner between a shoring system and the concrete form. This method fails if the waterproof liner is punctured with rebar or other sharp objects, which is common at construction sites. In such an occurrence, it may be necessary for the concrete form to be disassembled so a new waterproof liner may be installed. Such deconstruction is time consuming and expensive. It would therefore be preferable to install a system that provides a secondary waterproof alternative, should the initial waterproof layer fail. Additionally, attempts at preventing water from contacting a concrete structure have included installation of a membrane that swells upon contact with water. While this type of membrane is effective in absorbing the water and expanding to form a water barrier, this type of membrane is limited in its swelling capacity. Therefore, it would be preferable to provide a system that is unlimited in its swelling capacity by allowing a material to be added until the leak is repaired. 
         [0007]    Another attempt to resolving this problem was disclosed in “Achieving Dry Stations and Tunnels with Flexible Waterproofing Membranes,” published by Egger, et al. on Mar. 2, 2004 discloses a flexible membrane for waterproofing tunnels and underground structures. The flexible membrane includes first and second layers, which are installed separately. The first layer is a nonwoven polypropylene geotextile, which serves as a cushion against the pressure applied during the placement of the final lining where the membrane is pushed hard against the sub-strata. The first layer also transports water to the pipes at the membrane toe in an open system. The second layer is commonly a polyvinyl chloride (PVC) membrane or a modified polyethylene (PE) membrane, and is installed on top of the first layer. The waterproof membrane is subdivided into sections by welding water barriers to the membrane at their base. Leakage is detected through pipes running from the waterproof membrane to the face of the concrete lining. The pipes are placed at high and low points of each subdivided section. If leakage is detected, a low viscosity grout can be injected through the lower laying pipes. However the welding and the separate installation of the first and second layers make this waterproof system difficult to install, thus requiring highly skilled laborers. 
         [0008]    It would therefore be advantageous to provide an in-situ multi-layered device for post-installation concrete sealing, and more particularly a providing a medium for post-installation injection of waterproofing resin. 
       BRIEF SUMMARY OF THE INVENTION 
       [0009]    One object of the invention is to provide a single application which includes a first layer providing an initial waterproof surface. Another object of the invention is to provide a secondary, remedial layer that is operable should the first layer fail. A further object of the invention is to provide that such multi-layer system be quickly and easily installed. An additional object of the present invention allows selective introduction of a fluid substance to specific areas of a structure. 
         [0010]    Accordingly, it is an object of the present invention to provide a dual-layered layer that:
       has a waterproof layer providing a first level of protection from water penetration;   has a second, remedial protection from water penetration through delivering a fluid substance to a structure;   allows the introduction of a fluid substance in situ;   allows selective introduction of a fluid substance to specific areas of a structure;   fixable to a variety of surfaces; and   easily and quickly installable.       
 
         [0017]    Other features and advantages of the invention will be apparent from the following description, the accompanying drawing and the appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1  is a cross sectional view of the preferred embodiment of fluid delivery system. 
           [0019]      FIG. 2  is an isometric view of fluid delivery system with interlinking extension. 
           [0020]      FIG. 3  is a front view of a plurality of fluid delivery systems installed onto a shoring system. 
           [0021]      FIG. 4  is a side view of fluid delivery system installed between rebar matrix and shoring system. 
           [0022]      FIG. 5  is a side view of fluid delivery system installed between concrete structure and shoring system. 
           [0023]      FIG. 6  is an isometric view of compartmentalized fluid delivery system with fluid dispensing mechanisms attached. 
       
    
    
     DESCRIPTION OF THE INVENTION 
       [0024]      FIG. 1  depicts the preferred embodiment of substance delivery system  100 . Substance delivery system  100  is a multi-layer system for delivering substances to a structure, in situ, wherein the multi-layer system has at least two layers. In the preferred embodiment, substance delivery system  100  consists of three conjoined layers: first layer  130 , intermediate layer  120 , and second layer  110 , and at least one piping  150  (shown in  FIG. 6 ). While the preferred embodiment of the invention consists of three layers joined together, alternate multiple-layer configurations are possible. 
         [0025]    First layer  130  is preferably semi-permeable. In the preferred embodiment of the invention, first layer  130  should be made of a material suitable for permeating fluids therethrough, while prohibiting passage of concrete or other similar structural construction materials. A polypropylene or polyethylene non-woven geotextile is suitable. Additionally, other materials known in the art may be preferable depending on the particular application. 
         [0026]    Second layer  110  is a non-permeable layer that is preferably waterproof and self-sealing. Second layer  110  can be an asphalt sheet, or other like material known in the art. Second layer  110  may have an adhesive affixed to second layer interior side  112 , second layer exterior side  114 , or both sides  112  and  114 . Adhesive on second layer interior side  112  permits joining of adjacent panels of substance delivery system  100 . Adhesive on second exterior layer  114  aids in affixing substance delivery system  100  to shoring system  20  (seen in  FIGS. 4 and 5 ). 
         [0027]    Intermediate layer  120  is a void-inducing layer, conducive to permitting a free-flowing substance to flow throughout substance delivery system  100 . Intermediate layer  120  may be formed by an open lattice of fibers of sufficient rigidity to maintain the presence of the void when an inward force is exerted against substance delivery system  100 . A polypropylene lattice or other similarly rigid material is preferable. The presence of intermediate layer  120  permits the channeling of free-flowing substances through substance delivery system  100 . Intermediate layer  120  either channels water away from structural construction material  200 , or provides a medium for transporting a free-flowing substance to structural construction material  200 . 
         [0028]    Referring to  FIG. 2 , second layer  110 , intermediate layer  120 , and first layer  130  are fixedly attached, with intermediate layer  120  interposed between second layer  110  and first layer  130 . Second layer  110 , intermediate layer  120 , and first layer  130  are each defined by a plurality of sides, respectively forming second layer perimeter  112 , intermediate layer perimeter  122 , and first layer perimeter  132 . In the preferred embodiment, intermediate layer perimeter  122  and first layer perimeter  132  are dimensionally proportional, such that permeable layer perimeter  122  and semi-permeable layer perimeter  132  are equivalently sized. Intermediate layer  120  and first layer  130  have a first width that extends horizontally across the layers. Second layer perimeter  112  is partially proportional to intermediate layer perimeter  122  and first layer perimeter  132 , such that at least two sides of second layer perimeter  112  are equivalently sized to the corresponding sides of intermediate layer perimeter  122  and first layer perimeter  132 . Second layer  110  has a second width that extends horizontally across second layer  110 . The second width of second layer  110  is greater than the first width of intermediate layer  120  and first layer  130 . Thus, referring to  FIGS. 2 and 3 , when the bottom edges of first layer  130 , intermediate layer  120 , and second layer  110  are aligned, a first layer extension  114  outwardly extends an extension distance  115  from at least one side of first layer  130  and intermediate layer  120 . First layer extension  114  provides an underlay for installing substance delivery system  100  thereupon, thereby eliminating potential weakness at the splice where panels of substance delivery system  100  abut. 
         [0029]    In the preferred embodiment, seen in  FIGS. 4 and 5 , shoring system  20  is installed to retain earth  10  when a large quantity of soil is excavated. Shoring system  20  includes common shoring techniques such as I-beams with pilings and shotcrete. Substance delivery system  100  is fixedly attached to shoring system exterior surface  22 . As previously discussed, substance delivery system  100  can be attached to shoring system exterior surface  22  by applying an adhesive to second layer exterior side  112  and affixing second layer exterior side  112  to shoring system exterior surface  22 . Alternatively, substance delivery system  100  can be attached to shoring system exterior surface  22  by driving nails, or other similar attachment means, through substance delivery system  100  and into shoring system  20 . In the preferred embodiment second layer  110  is self-sealing. Thus, puncturing second layer  110  with a plurality of nails will negligibly affect second layer&#39;s  110  ability to provide a waterproof barrier. 
         [0030]    Referring to  FIGS. 3 and 6 , substance delivery system  100  canvases shoring system exterior surface  22 . Substance delivery system  100  can be cut to any size, depending on the application. If a single substance delivery system  100  does not cover the desired area, a plurality of panels of substance delivery system  100  are used in concert to provide waterproof protection. As previously discussed, substance delivery system  100  may include first layer extension  114  for reinforcement at the abutment between adjacent panels of substance delivery system  100 . Thus, a first panel of substance delivery system  100  is fixedly attached to shoring system exterior surface  22 , with first layer extension  114  extending outwardly onto shoring system exterior surface  22 . A second panel of substance delivery system  100  overlays first layer extension  114  of the first panel of substance delivery system  100 , thereby interlinking the first and second panels of substance delivery system  100 . This process is repeated until the plurality of panels of substance delivery system  100  blanket shoring system exterior surface  22 . The area of overlap between to adjacent panels of substance delivery system  100  preferably extends vertically. The upper terminal end of substance delivery system  100 , proximate the upper edge of the constructed form (not shown), is sealed with sealing mechanism  105 . Sealing mechanism  105  prevents the injected fluid from being discharged through the top of substance delivery system  100 . Sealing mechanism  105  may be a clamp or other similar clenching device for sealing the upper terminal end of substance delivery system  100 . 
         [0031]    Referring to  FIG. 6 , division strip  162  is fixedly attached in a vertical orientation between the junction points of adjacent substance delivery systems  100 . In the preferred embodiment division strip  162  has an adhesive surface, thereby allowing division strip  162  to be quickly and safely installed. Alternatively, division strip  162  may be installed by driving a plurality of nails, or similar attaching means, through division strip  162 . First layer extension  114  may be of such width as to accommodate division strip  162  and still permit joining to an adjacent panel of substance delivery system  100 . 
         [0032]    Division strip  162  is preferably comprised of a material that swells upon contact with water. When water interacts with division strip  162 , division strip  162  outwardly expands, thereby eliminating communication between the abutting substance delivery systems  100 . Thus, division strip  162  compartmentalizes each panel of substance delivery system  100 . Compartmentalization enables selective injection of a fluid or gas into a predetermined panel of substance delivery system  100 . Alternatively, division strip  162  is formed from a non-swelling material. When division strip  162  is non-swelling, the structural construction material  200  forms around division strip  162 , thereby filling in any voids and forming a seal between adjacent substance delivery systems  100 . 
         [0033]    Referring to  FIGS. 4 and 6 , at least one piping  150  is engagedly attached to a panel of substance delivery system  100 . Piping  150  is tubular, with inlet  152 , outlet  154 , and cylinder  156  extending therebetween. A plurality of teeth (not shown) outwardly extend from outlet  154 , and engage first layer  130  as to permit injection of fluid into first layer  130  through to intermediate layer  120 . Cylinder  156  extends through rebar matrix  210 , with inlet  152  terminating exterior the structural construction material form (not shown). Cylinder  156  can be secured to rebar matrix  210  through ties, clamps, or other similar means of attachment. The number of piping  150  necessary is dependent on the size of chamber  160 . In the preferred embodiment of the invention, piping  150  should be positioned at lower point  164 , mid point  166 , and upper point  168 . 
         [0034]    In the preferred embodiment depicted in  FIG. 4 , a structural construction material  200  is inserted into form (not shown). The structural construction material  200  can be concrete, plaster, stoneware, cinderblock, brick, wood, plastic, foam or other similar synthetic or natural materials known in the art. Second layer  110  of substance delivery system  100  provides the primary waterproof defense. If it is determined that second layer  110  has been punctured or has failed, resulting in water leaking to structural construction material  200 , a free flowing substance can be pumped to the panel of substance delivery system  100  located proximate the leak. The free flowing substance is introduced to such panel of substance delivery system  100  via piping  150  in an upward progression, wherein the free flowing substance is controllably introduced to lower point  164  of panel of substance delivery system  100 , then to mid point  166  of panel of substance delivery system  100 , and then to upper point  168  of panel of substance delivery system  100 . A dye may be added to the free flowing substance, allowing for a visual determination of when to cease pumping the free flowing substance to panel of substance delivery system  100 . When the dye in the free flowing substance leaks out of structural construction material  200 , thereby indicating that the selected substance delivery system  100  is fully impregnated, pumping is ceased. 
         [0035]    First layer  130  permeates the free flowing substance into the space between first layer  130  and structural construction material  200 . When the free flowing substance is a hydrophilic liquid, the free flowing substance interacts with any water present, thereby causing the free flowing substance to expand and become impermeable, creating an impenetrable waterproof layer. Thus, a secondary waterproof barrier can be created if a failure occurs in second layer  110 . 
         [0036]    Alternatively, different free flowing substances may be introduced to substance delivery system  100 , depending on the situation. If the integrity of structural construction material  200  is compromised, a resin for strengthening structural construction material  200  can be injected into substance delivery system  100  to repair structural construction material  200 . Alternatively, a gas may be injected into substance delivery system  100  for providing mold protection, rust retardation, delivering an insecticide, or other similar purposes. 
         [0037]    In a separate and distinct embodiment of the invention, intermediate layer  120  may be completely replaced with first layer  130 . 
         [0038]    In a separate and distinct embodiment of the invention, substance delivery system  100  is directly attached to the earth, such as in a tunnel or mine. In this embodiment, substance delivery system  100  is inversely installed on tunnel surface  300  (not shown). First layer  130  faces tunnel surface  300  and second layer  110  inwardly faces tunnel space  310 . Substance delivery system  100  can be fixedly attached by applying an adhesive to first layer  130 , driving nails through substance delivery system  100 , or similar attaching means known in the art. Substance delivery system  100  is installed in vertical segments, similar to the method described above for the preferred embodiment. However, the plurality of piping  150  is not necessary in the alternative embodiment. 
         [0039]    Once substance delivery system  100  is installed on tunnel surface  300 , the structural construction material  200  can be installed directly onto second layer  110 . 
         [0040]    In the alternative embodiment (not shown) should a failure occur in substance delivery system  100 , an operator can drill a plurality of holes through the structural construction material  200 , ceasing when second layer  110  is penetrated. Such holes would provide fluid access to intermediate layer  120 . A fluid substance (not shown) would then be pumped through the holes, thereby introducing the fluid substance to intermediate member  120 . Intermediate layer  120  channels the fluid substance throughout substance delivery system  100 , ultimately permitting first layer  130  to permeate the fluid substance therethrough. 
         [0041]    The foregoing description of the invention illustrates a preferred embodiment thereof. Various changes may be made in the details of the illustrated construction within the scope of the appended claims without departing from the true spirit of the invention. The present invention should only be limited by the claims and their equivalents.

Technology Classification (CPC): 4