Patent Description:
In the field of maritime transport, containment booms are temporary floating barriers used to contain spills of floating pollutants, such as oil spills. A containment boom can be used to prevent the floating pollutant from reaching a shoreline, where it can otherwise cause harm to shore ecosystems. A containment boom can also be used to corral a floating pollutant to a smaller area, where it can be more easily removed from the water surface by a suitable method such as skimming, suction, and the like.

As spills of floating pollutants typically result from accidents, containment booms generally need to be installed at the site of the spill as rapidly as possible in order to prevent the size of the spill from becoming too large to contain, and/or to prevent the spill from reaching a shoreline.

Containment booms have been described. For example, <CIT>describes a boom that includes a plurality of boom sections joined end to end. Each boom section includes two or more parallel inflatable chambers that are joined with a weighted curtain which is reinforced for strength. Boom sections are stored compactly on respective reels. A substantial number of reels are arranged compactly in the hold of a carrier vessel which is smaller in size and has greater speed and maneuverability than vessels carrying known oil spill containment systems. Boom sections are consecutively unwound from their respective reels and connected end-to-end as they are deployed to form a continuous boom. The boom sections unwind naturally from the reels as the carrier vessel moves through the water away from a tender vessel holding the first end of the boom. The boom's deployment is controlled by a brake on an idler roller and a hydraulic crane's drive wheel on the reel, thus limiting manual handling to lighter-weight tasks. The carrier vessel, or, preferably, the tender vessel inflates the chambers of the boom sections as they are deployed. The system is self-contained, as the carrier vessel is adapted to carry the tender vessel on its aft deck, releasing it when arriving at the spill site.

Connectors for containment booms have also been described. For example, <CIT> describes a method, system, and device for deploying an oil spill containment boom at the side of a ship, barge, or other steel structure. Each end of the boom is connected to its own device that is configured to attach to a generally vertical surface of a steel-hulled ship. Attachment occurs through the use of magnetic force. Instead of encircling the entire ship with a boom, the device permits the establishment of specific containment areas around the ship. The device engages and disengage the side of the ship through the use of a cam and lever assembly to counter the magnetic force.

<CIT> describes a removable fluid barrier.

<CIT> describes a local containment boom and standoff.

<CIT> describes an air-inflated oil fence maintaining a constant shape.

Improvements are generally desired. It is therefore an object at least to provide a novel removable containment boom anchor.

In one aspect, there is provided a removable containment boom anchor, comprising: an anchor support comprising a flexible body fabricated of at least one resilient material, the flexible body having a base and a tab extending from the base, the flexible body encapsulating a plurality of permanent magnets; a containment boom connector fastened to the anchor support; and a reinforcement sheet encapsulated within the flexible body, characterized in that the reinforcement sheet extends from the base into the tab.

The permanent magnets may be disposed within the base. The containment boom connector may be fastened to the tab.

The flexible body may have a single, unitary structure. The flexible body may be formed by a single casting.

The reinforcement sheet may comprise a partial loop that extends generally the height of the tab. The reinforcement sheet may be selected from the group consisting of fiberglass cloth, Kevlar cloth, Kevlar mesh, and a resilient fabric or a resilient mesh fabricated of one or more other materials. The removable containment boom anchor may further comprise first and second reinforcement sheets encapsulated within the flexible body, the first reinforcement sheet being disposed between the plurality of permanent magnets and a first face of the base, the second reinforcement sheet being disposed between the plurality of permanent magnets and second face of the base.

The removable containment boom anchor may further comprise at least one reinforcement grid encapsulated within the flexible body. The at least one reinforcement grid may comprise a wire mesh.

The removable containment boom anchor may further comprise a handle fastened to the anchor support.

The flexible body may have a face comprising a textured surface. The textured surface may have a non-planar topography.

The plurality of permanent magnets may comprise one or more rare earth magnets. Each of the permanent magnets may comprise an epoxy coating. Each of the permanent magnets may comprise a magnet body and ferromagnetic plate. The ferromagnetic plate may be a steel disc.

The at least one resilient material may comprise a polymer. The flexible body may be fabricated of polyurethane.

Embodiments will now be described more fully with reference to the accompanying drawings in which:.

Turning now to <FIG> a containment boom is shown in use, and is generally indicated by reference numeral <NUM>. Containment boom <NUM> is configured to provide a temporary floating barrier to contain a floating pollutant, such as an oil spill, a quantity of floating debris, and the like. Containment boom <NUM> comprises a boom string <NUM> comprising a series of connected, floating boom segments, with each end of the boom string <NUM> being connected to a removable containment boom anchor <NUM>.

The removable containment boom anchor <NUM> is configured to be removably attached to a ferrous structure, namely a structure that comprises or that is fabricated of steel or other ferrous material, by magnetic force of attraction. In the example shown, the boom string <NUM> is being towed along the water surface W by a first boat <NUM> and a second boat <NUM> to generally contain an oil spill S, with a first end of the boom string <NUM> removably attached to the steel hull of the first boat <NUM> by a removable containment boom anchor <NUM>, and with a second end of the boom string <NUM> removably attached (not shown) to the steel hull of the second boat <NUM> by another removable containment boom anchor <NUM>.

The removable containment boom anchor <NUM> may be better seen in <FIG>. The removable containment boom anchor <NUM> is configured to be magnetically fastened to a ferrous structure to provide a connection point for the boom string <NUM>. The removable containment boom anchor <NUM> comprises an anchor support <NUM>, a connector <NUM> fastened to the anchor support <NUM>, and one or more handles <NUM> fastened to the anchor support <NUM>.

The anchor support <NUM> may be better seen in <FIG> and <FIG>. The anchor support <NUM> has an "inverted T-shape", and comprises a flexible body <NUM> that is fabricated of one or more resilient materials and that has a base <NUM> and a tab <NUM> that extends from the base <NUM>. The flexible body <NUM> encapsulates a plurality of permanent magnets <NUM> and reinforcement elements, described below. In particular, the flexible body <NUM> has a single, continuous and unitary structure formed by casting. During casting, the base <NUM> and the tab <NUM> are formed together, and the permanent magnets <NUM>, together with reinforcement elements described below, are encapsulated and are thereby enclosed in the flexible body <NUM>. In this embodiment, the flexible body <NUM> is fabricated of polyurethane, and is formed by a single casting to define the single, continuous and unitary structure.

In the example shown, the base <NUM> has a generally square shape, and has dimensions of about thirty (<NUM>) inches × about thirty (<NUM>) inches × about one-half (<NUM>) inches (about <NUM> x <NUM> x <NUM>,<NUM>) and the tab <NUM> has dimensions of about thirty-eight (<NUM>) inches × about eight (<NUM>) inches × about one-quarter (<NUM>) inches ( about <NUM> x <NUM> x <NUM>,<NUM>). The base <NUM> has two opposing faces, namely a first face <NUM> and a second face <NUM>. At least a portion of the first face <NUM> comprises a textured surface <NUM>, which is formed by casting the flexible body <NUM> against a textured plate <NUM> during fabrication, as described below.

The permanent magnets <NUM> are encapsulated within the flexible body <NUM> generally adjacent the first face <NUM> of the base <NUM>. In this embodiment, the flexible body <NUM> also encapsulates a first reinforcement sheet <NUM>, a second reinforcement sheet <NUM>, and at least one wire reinforcement grid <NUM>. The first reinforcement sheet <NUM> is disposed within the flexible body <NUM> between the permanent magnets <NUM> and the first face <NUM>. The second reinforcement sheet <NUM> is disposed within the flexible body <NUM> between the permanent magnets <NUM> and the second face <NUM>, and is loosely gathered to define a partial loop <NUM> that extends generally the height of the tab <NUM>. The first and second reinforcement sheets <NUM> and <NUM> are each fabricated of a flexible, resilient material, and are configured to provide reinforcement to the flexible body <NUM> for strengthening the removable containment boom anchor <NUM>. In this embodiment, the reinforcement sheets <NUM> and <NUM> are each fabricated of fiberglass cloth. The first reinforcement sheet <NUM> is separated from the first face <NUM> by a thin layer of the one or more resilient materials of which the flexible body <NUM> is fabricated, as may be seen in <FIG>. Similarly, the permanent magnets <NUM> are separated from the reinforcement sheet <NUM> by a thin layer of the one or more resilient materials of which the flexible body <NUM> is fabricated, as may be seen in <FIG>.

The wire reinforcement grid <NUM> is disposed within the flexible body <NUM> between the second reinforcement sheet <NUM> and the second face <NUM>. Each wire reinforcement grid <NUM> is fabricated of a steel wire mesh. In the example shown, there are two (<NUM>) wire reinforcement grids <NUM> disposed within the flexible body <NUM>, with each wire reinforcement grid <NUM> having a triangular shape and being disposed on either side of the partial loop <NUM> of the second reinforcement sheet <NUM>.

In the example shown, each permanent magnet <NUM> is disc shaped, and comprises a rare earth magnet body <NUM> fabricated of an alloy comprising one or more rare earth elements. Rare earth magnets are known to have a high magnetic strength, and more specifically a high energy product. As a result, the array of permanent magnets <NUM> enables the removable containment boom anchor <NUM> to be very strongly magnetically fastened to ferrous structures. Each permanent magnet <NUM> may be, for example, a grade N42 neodymium iron boron magnet.

Each permanent magnet <NUM> also comprises a ferromagnetic disc <NUM> that is magnetically fastened to the magnet body <NUM>. It has been found by the inventor that the ferromagnetic disc <NUM> increases the magnetic force of attraction of the permanent magnet <NUM>, and thereby increases the magnetic force of attraction of the removable containment boom anchor <NUM> to the steel structure. In this embodiment, the ferromagnetic disc <NUM> is fabricated of a ferromagnetic material, such as steel, for example. Each permanent magnet <NUM> further comprises a thin epoxy coating (not shown) disposed on the outer surfaces of the magnet body <NUM> and the ferromagnetic disc <NUM>, such that the epoxy coating encapsulates the permanent magnet <NUM>. As will be understood, the epoxy coating increases the strength of the interface between the permanent magnet <NUM> and the one or more resilient materials of which the flexible body <NUM> is fabricated.

The connector <NUM> may be better seen in <FIG>. Connector <NUM> is generally of the "slide connector" type, and is configured to slidably and matingly engage another connector (not shown) connected to the boom string <NUM>. In the example shown, the connector <NUM> has a configuration that complies with ASTM International standard F2438-<NUM>, "Standard Specification for Oil Spill Response Boom Connection: Slide Connector", and comprises a first longitudinal tab <NUM>, and a second longitudinal tab <NUM> spaced from the first longitudinal tab <NUM> so as to define a channel <NUM> therebetween. As will be understood, the channel <NUM> is shaped to matingly receive a first longitudinal tab <NUM> of another connector (not shown) of similar configuration, such as another connector <NUM>. The connector <NUM> further comprises a flange <NUM> having a plurality of boreholes <NUM> defined therein. Each borehole <NUM> is sized to accommodate a fastener (not shown), such as a bolt, for fastening the connector <NUM> to the tab <NUM> of the anchor support <NUM>.

Turning again to <FIG>, the removable containment boom anchor <NUM> has at least one handle <NUM> fastened to the anchor support <NUM>, for enabling the removable containment boom anchor to be more easily carried before and after use, and for facilitating separation of the removable containment boom anchor <NUM> from the ferrous structure after use. Each handle <NUM> is fastened to the second face <NUM> of the anchor support <NUM> by an adhesive layer (not shown) disposed therebetween. The handle <NUM> may be a plastic boat grab handle, for example. In the example shown, the removable containment boom anchor <NUM> has two (<NUM>) handles <NUM> fastened to the anchor support <NUM>.

<FIG> shows a portion of an assembly <NUM> used to fabricate the anchor support <NUM>. The assembly comprises a first face plate <NUM> fabricated of a ferromagnetic material, a base spacer frame <NUM>, a tab spacer frame <NUM> having a rectangular aperture <NUM> defined therethrough, and a second face plate <NUM>. In this embodiment, the first face plate <NUM> is fabricated of steel. The first face plate <NUM>, the base spacer frame <NUM>, the tab spacer frame <NUM>, and the second face plate <NUM>, when assembled, define a mold cavity <NUM> for fabricating the anchor support <NUM>. The first face plate <NUM> has a first aperture <NUM>, through which liquid polymer resin used to fabricate the flexible body <NUM> is delivered, and a second aperture <NUM>, through which air displaced by the liquid polymer resin flowing through the mold cavity <NUM> is vented.

During fabrication of the anchor support <NUM>, the assembly <NUM> is assembled by placing the base spacer frame <NUM> onto first face plate <NUM>. The textured plate <NUM> is then disposed on the first face plate <NUM> and is generally centered within the area bordered by the base spacer frame <NUM>, and the first reinforcement sheet <NUM> is then disposed on the textured plate <NUM>. The textured plate <NUM> has non-planar surfaces and is fabricated of a non-ferromagnetic material. As will be understood, the non-planar surfaces of the textured plate <NUM> provide conduits through which the liquid polymer resin can flow during casting of the flexible body <NUM>, so as to enable the reinforcement sheet <NUM> and the permanent magnets <NUM> to be encapsulated. In the embodiment shown, the textured plate <NUM> has dimpled surfaces, and is fabricated of an aluminum alloy. The permanent magnets <NUM> are then disposed on the portion of the reinforcement sheet <NUM> covering the textured plate <NUM>, such that the textured plate <NUM> is interposed between each of the permanent magnets <NUM> and the first face plate <NUM>. Each of the permanent magnets <NUM> is disposed on the reinforcement sheet <NUM> such that the ferromagnetic disc <NUM> is oriented away from the first reinforcement sheet <NUM>, as shown in <FIG> and <FIG>. As will be understood, placement of the permanent magnets <NUM> in this manner causes the permanent magnets <NUM> to be magnetically attracted to the first face plate <NUM>, through the textured plate <NUM> and the reinforcement sheet <NUM>. The second reinforcement sheet <NUM> is then disposed on the permanent magnets <NUM>, and a suitable amount of the material is pulled upward or loosely gathered to form the partial loop <NUM>. Excess portions of the second reinforcement sheet <NUM> may be trimmed, as necessary, to enable the second reinforcement sheet <NUM> to fit within the area bordered by the base spacer frame <NUM>. The at least one wire reinforcement grid <NUM> is then disposed on the second reinforcement sheet <NUM> around the partial loop <NUM>. In the example shown, two (<NUM>) wire reinforcement grids <NUM> are disposed on either side of the partial loop <NUM>. The tab spacer frame <NUM> is then placed onto the base spacer frame <NUM>, and the partial loop <NUM> is fed into the longitudinal slot <NUM> to generally near the top of the longitudinal slot <NUM>. The second face plate <NUM> is then placed onto the tab spacer frame <NUM> to define the mold cavity <NUM>.

The first face plate <NUM>, the base spacer frame <NUM>, the tab spacer frame <NUM> and the second face plate <NUM>, with the textured plate <NUM>, the first reinforcement sheet <NUM>, the permanent magnets <NUM>, the second reinforcement sheet <NUM>, and the at least one wire reinforcement grid <NUM> inside, are then removably fastened together using one or more suitable fasteners (not shown). In this embodiment, the fasteners are C-clamps (not shown). Once fastened, the assembly <NUM> is oriented such that the second aperture <NUM> is positioned at or near the uppermost portion of the assembly <NUM>. The flexible body <NUM> is then cast by injecting the liquid polymer resin, which is delivered from a source (not shown) of liquid polymer resin via a suitable conduit (not shown), through the first aperture <NUM> into the mold cavity <NUM>. Air in the mold cavity displaced by the rising liquid polymer resin is vented through the second aperture <NUM>. The liquid polymer resin fills the mold cavity <NUM> and encapsulates the first reinforcement sheet <NUM>, the permanent magnets <NUM>, the second reinforcement sheet <NUM>, and the at least one wire reinforcement grid <NUM>, by flowing, in no particular order: around the permanent magnets <NUM>, between the permanent magnets <NUM> the first reinforcement sheet <NUM>, between the permanent magnets <NUM> and the second reinforcement sheet <NUM>, between the reinforcement sheet <NUM> and the textured plate <NUM>, into the longitudinal slot <NUM> and along all sides of the partial loop <NUM>, and around and through the at least one wire reinforcement grid <NUM>. The liquid polymer resin is then allowed to cure. Once cured, the flexible body <NUM>, which encapsulates the permanent magnets <NUM>, the reinforcement sheets <NUM> and <NUM>, and the at least one wire grid, is formed. The first face plate <NUM>, the base spacer frame <NUM>, the tab spacer frame <NUM> and the second face plate <NUM> are then unfastened, and the flexible body <NUM> with the textured plate <NUM> attached thereto are removed. The textured plate <NUM> is then separated from the flexible body <NUM> to yield the anchor support <NUM>.

During fabrication of the removable containment boom anchor <NUM>, the connector <NUM> is fastened to the anchor support <NUM> by forming boreholes through the tab <NUM> by a suitable method, such as drilling. Fasteners <NUM> are then inserted through the boreholes formed in the tab <NUM> and through the boreholes <NUM> of the connector <NUM> and to fasten the connector <NUM> to the anchor support <NUM>. In the example shown, the fastener is a bolt and nut. At least one handle <NUM> is optionally fastened to the second face <NUM> of the flexible body <NUM> by applying a layer of adhesive to the underside of the handle <NUM> or to the second face <NUM> of the anchor support <NUM>, or to both, and then applying suitable pressure for a suitable amount of time to bond the handle <NUM> to the anchor support <NUM>.

In use, the removable containment boom anchor <NUM> is applied to a ferrous structure, such that the first face <NUM> contacts the ferrous structure. The permanent magnets <NUM> provide a magnetic force of attraction to the ferrous structure. This magnetic force of attraction causes the anchor support <NUM> to conform to and to become magnetically fastened to the ferrous structure. As will be understood, the flexibility of the anchor support <NUM> enables the anchor support <NUM> to conform to any curvature of the ferrous structure. The boom string <NUM> is then connected to the removable containment boom anchor <NUM> by slidably and matingly engaging the connector at the end of the boom string <NUM>, which is identical in shape to connector <NUM>, with the connector <NUM> of the removable containment boom anchor <NUM>. Alternatively, the boom string <NUM> may be connected to the removable containment boom anchor <NUM> before magnetically fastening the removable containment boom anchor <NUM> to the ferrous structure.

The removable containment boom anchor <NUM> may be removed by pulling the handle <NUM> away from the ferrous structure, and with sufficient force to overcome the magnetic force of attraction provided by the permanent magnets <NUM>. Alternatively, the removable containment boom anchor <NUM> may be removed by pulling an edge of the anchor support <NUM> away from the ferrous structure, and with sufficient force to overcome the magnetic force of attraction provided by the permanent magnets <NUM>.

As will be appreciated, the anchor support <NUM> of the removable containment boom anchor <NUM> has a generally simple construction and consists of generally only five (<NUM>) components, namely the flexible body <NUM>, the plurality of permanent magnets <NUM>, the reinforcement sheets <NUM> and <NUM>, and the wire reinforcement grid <NUM>. The simple construction advantageously allows the anchor support <NUM>, and in turn the removable containment boom anchor <NUM>, to be manufactured at lower cost as compared to conventional removable containment boom anchors having more complex construction.

As will be appreciated, the anchor support <NUM>, which is formed by a single casting during which the permanent magnets <NUM> are encapsulated, has a single, unitary structure, and therefore lacks a seam surface or weld surface that would otherwise be present in conventional removable containment boom anchors comprising flexible bodies that are fabricated by more than one (<NUM>) casting and that comprise multiple layers. As will be understood, the single, unitary structure of the anchor support <NUM> improves the structural integrity of the removable containment boom anchor <NUM>, as compared to conventional removable containment boom anchors comprising multiple layers.

As will be appreciated, the second reinforcement sheet <NUM>, which is a single element, provides internal reinforcement to both the base <NUM> and the tab <NUM> of the anchor support <NUM>. As will be understood, this advantageously allows tensile forces exerted upon the tab <NUM> during operation to be distributed to the base <NUM>. This configuration improves the structural integrity of the removable containment boom anchor <NUM>, as compared to conventional removable containment boom anchors constructed without such reinforcement.

As will be appreciated, the permanent magnets <NUM> fabricated of rare earth alloy advantageously provide a stronger magnetic force of attraction as compared to permanent magnets fabricated of other materials, such as for example ferrous permanent magnets. As will be understood, the stronger magnetic force of attraction provided by the permanent magnets <NUM> enables the anchor support <NUM> to become more strongly magnetically fastened to the ruptured ferrous structure, and to thereby withstand greater tensile forces upon the removable containment boom anchor <NUM>, as compared to conventional removable containment boom anchors comprising ferrous permanent magnets.

As will be appreciated, the permanent magnets <NUM> allow the removable containment boom anchor <NUM> to be magnetically fastened to the ferrous structure in a facile manner, and without the need to provide an electrical current and means for delivering such a current, as would be required for conventional removable containment boom anchors comprising electromagnets. The permanent magnets <NUM> advantageously enable the removable containment boom anchor <NUM> to be fastened quickly, which is particularly beneficial for emergency situations such as oil spills.

Other configurations are possible. For example, the anchor support <NUM> may alternatively have an embedded handle in the shape of a loop formed at one or more corners, and/or at one or more sides thereof. The embedded handle may comprise a component integrated into the anchor support during fabrication, and which either protrudes from the anchor support or is accessible from the surface of the anchor support.

Although in the embodiment described above, the anchor support <NUM> comprises a textured surface <NUM> that is formed by casting the liquid polymer resin against a textured plate <NUM>, in other embodiments, the textured surface <NUM> may alternatively be formed by casting the liquid polymer resin against any surface having a non-planar topography, so as to create a textured surface having a non-planar topography. In one such embodiment, the surface having the non-planar topography may be, for example, a plate having a one or more of a grooved surface, a ridged surface, a dimpled surface, a perforated surface, a scored surface, and the like. As will be understood, the non-planar topography may comprise a patterned topography or a non-patterned topography.

Although in the embodiment described above, the permanent magnet <NUM> comprises a ferromagnetic disc <NUM> that is magnetically fastened to the magnet body <NUM>, in other embodiments, two or more of the magnet bodies <NUM> may alternatively be magnetically fastened to a single ferromagnetic plate fabricated of a ferromagnetic material. In one such embodiment, the single ferromagnetic plate may be a steel sheet, a steel plate, and the like, to which the plurality of magnet bodies <NUM> are magnetically fastened. Although in the embodiment described above, the reinforcement sheets are fabricated of fiberglass cloth, in other embodiments, one or both reinforcement sheets may alternatively be fabricated of any flexible, resilient material, such as Kevlar fabric, Kevlar mesh, or a resilient fabric or a resilient mesh fabricated of one or more materials having adequate strength to provide reinforcement to the removable containment boom anchor <NUM>.

Claim 1:
A removable containment boom anchor, characterized in that it comprises:
an anchor support (<NUM>) comprising a flexible body (<NUM>) fabricated of at least one resilient material, the flexible body (<NUM>) having a base (<NUM>) and a tab (<NUM>) extending from the base (<NUM>), the flexible body (<NUM>) encapsulating a plurality of permanent magnets (<NUM>);
a containment boom connector (<NUM>) fastened to the anchor support (<NUM>); and
a reinforcement sheet (<NUM>) encapsulated within the flexible body (<NUM>), and in that the reinforcement sheet (<NUM>) extends from the base (<NUM>) into the tab (<NUM>).