Compressed netting sleeve for in situ manufacture of compost filter socks and method of forming compost filter socks using same

Abstract

A compressed netting sleeve for in situ formation of a compost filter sock comprises a sleeve of netting material having a pair of opposed open ends, wherein the sleeve of netting material is bunched primarily along a longitudinal axis, whereby each of the open ends of the netting material remains accessible to form a compression bundle netting material; and a protective sleeve extending through the open ends of the sleeve of netting material to extend through the interior of the sleeve of netting material and around the exterior of the sleeve of netting material thereby surrounding the compression bundle netting material with the protective sleeve.

Claims

1. A method of manufacturing a compost filter sock comprising the steps of: A) providing a bag containing a compression bundle netting sleeve, wherein the netting sleeve includes mesh openings that are small enough to maintain compost within a constructed compost filter sock and large enough to allow runoff water to flow therethrough to allow for formation of a compost filter sock; B) removing the compression bundle netting sleeve from the bag; C) placing the compression bundle netting sleeve on a pneumatic nozzle configured for conveying compost for forming the compost filter sock; D) removing one open end and a leading length of the netting sleeve from the pneumatic nozzle while maintaining an opposite end and a remainder of the netting sleeve on the pneumatic nozzle; E) sealing the open end; F) filling the netting sleeve with compost sufficient to form the compost filter sock, wherein the compost is pneumatically conveyed through the pneumatic nozzle; and G) sealing the opposite end.

2. The method of manufacturing a compost filter sock according to claim 1, further including the steps of: removing the remainder of the compression bundle netting sleeve from the pneumatic nozzle following formation of at least one compost filter sock; securing the remainder of the compression bundle netting sleeve with a mechanical fastener; and returning the remainder of the compression bundle netting sleeve to the bag.

3. The method of manufacturing a compost filter sock according to claim 2, wherein the mechanical fastener is one of a twist tie, cable tie, hose tie, zip tie or tie-wrap.

4. The method of manufacturing a compost filter sock according to claim 1, wherein the compression bundle netting sleeve is formed as a shape-holding rolled sleeve of a torus or donut shape by drawing a first open end of a netting material through an open interior of the netting material and through a second open end of the netting material, and then wrapping the netting material around an exterior of the netting material at least once.

5. The method of manufacturing a compost filter sock according to claim 1, wherein the compression bundle netting sleeve is surrounded with a protective sleeve.

6. The method of manufacturing a compost filter sock according to claim 1, wherein the compression bundle netting sleeve is formed by: providing a sleeve of netting material having two open ends; bunching the sleeve of netting material along a longitudinal axis, whereby each open end of the netting material remains accessible to form a compression bundle netting material; and forming a shape-holding sleeve of a torus or donut shape from the compression bundle netting material by one of: i) drawing one open end of the netting material through an open interior of the netting material and through the other open end, and then wrapping the netting material around an exterior of the netting material at least once; ii) securing the compression bundle netting sleeve in position within the bag with a mechanical fastener which is one of a twist tie, cable tie, hose tie, zip tie or tie-wrap; and iii) securing the compression bundle netting sleeve in position within the bag with an encapsulating mesh protective sleeve.

7. The method of manufacturing a compost filter sock according to claim 6, wherein the bag is a sealable bag, and wherein the method further includes the steps of: placing the compression bundle netting material in the sealable bag, and sealing the sealable bag.

8. The method of manufacturing a compost filter sock according to claim 7, further including the step of placing a mechanical fastener capable of securing the compression bundle netting sleeve in position within in the bag.

9. The method of manufacturing a compost filter sock according to claim 8, wherein the mechanical fastener is one of a twist tie, cable tie, hose tie, zip tie or tie-wrap.

10. The method of manufacturing a compost filter sock according to claim 9, wherein the bag is resealable.

11. The method of manufacturing a compost filter sock according to claim 1, wherein the compression bundle netting sleeve is surrounded with a protective sleeve and wherein ends of the protective sleeve are overlapped and coupled together.

12. The method of manufacturing a compost filter sock according to claim 11, wherein the ends of the protective sleeve are coupled together with a plurality of fasteners formed by one of clips, staples, or zip ties.

13. The method of manufacturing a compost filter sock according to claim 11, wherein the netting sleeve has a circular cross section.

14. The method of manufacturing a compost filter sock according to claim 13, wherein the netting sleeve has a diameter between 8″ and 24″.

15. The method of manufacturing a compost filter sock according to claim 14, wherein a material of the netting sleeve is one of polyester, polypropylene, cotton, or nylon material.

16. The method of manufacturing a compost filter sock according to claim 14, wherein the protective sleeve is formed of netting material.

17. The method of manufacturing a compost filter sock according to claim 16, wherein the protective sleeve is formed as a length of mesh tubing shorter than a length of the netting sleeve.

18. The method of manufacturing a compost filter sock according to claim 17, wherein a diameter of the protective sleeve is at least equal to a diameter of the netting sleeve.

19. The method of manufacturing a compost filter sock according to claim 1, wherein the compression bundle netting sleeve is surrounded with a protective sleeve, wherein the protective sleeve is formed of netting material, and wherein ends of the protective sleeve are overlapped and coupled together with a plurality of fasteners.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) FIGS. 1 A and B are perspective views of a compression bundle netting sleeve formed as a rolled sleeve 10 in accordance with one aspect of the present invention;

(2) FIG. 1C is a perspective view of a vacuum packed compressed netting sleeve for in situ manufacture of a compost filter stock according to one aspect of the present invention;

(3) FIGS. 2A and B are side and schematic views, respectively, of the end portions of the netting sleeve material forming the rolled sleeve of FIGS. 1 A-C;

(4) FIGS. 2 C and D illustrate the formation of a compression bundle netting sleeve from the netting sleeve of FIGS. 2A and B;

(5) FIGS. 2E-I schematically illustrates, progressive steps for forming the rolled sleeve of FIGS. 1 A-C from a compression bundle netting sleeve of FIGS. 2C and D;

(6) FIGS. 3A-F illustrate the mounting of the rolled sleeve of FIGS. 1A-C on a pneumatic nozzle and the preparation for forming a compost filter sock with the rolled sleeve of FIGS. 1A-C;

(7) FIG. 4A illustrates a compression bundle netting sleeve with a mechanical fastener holding sleeve in position;

(8) FIG. 4B illustrates the compression bundle netting sleeve with fastener stored with in a re-sealable bag;

(9) FIG. 5 schematically illustrates a compression bundle netting sleeve with protective holding sleeve holding the netting sleeve in position;

(10) FIG. 6 is a perspective view of the compression bundle netting sleeve with protective holding sleeve holding the netting sleeve in position of FIG. 5.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(11) FIGS. 1 A and B are perspective views of a compression bundle netting sleeve formed as a rolled sleeve 10 in accordance with one aspect of the present invention. The rolled sleeve is formed of netting material 12, also called mesh material, having a pair of distal open ends 14. FIGS. 2A and B are side and schematic views, respectively, of the end portions of the netting sleeve material 12 forming the rolled sleeve 10 of FIGS. 1 A-C. The netting sleeve material 12 can come in any conventional size, most typically circular cross sections of 8″, 10″, 12″, 18″ and 24″ being the most common. The mesh opening size can be of a variety of conventional sizes, provided that the mesh openings are small enough to maintain the compost within the constructed compost filter sock and large enough to allow runoff water to flow there through. The size and mesh opening constructions are generally known in the compost filter sock art. The netting sleeve material 12 is preferably formed of non-dye treated polyester, although polypropylene, cotton, nylon material are also known in the art and may be acceptable.

(12) As noted above the phrase “compression bundle” within the meaning of this application refers to compressing or bunching of netting sleeve material 12 primarily along a longitudinal axis thereof whereby each open end 14 and the opening there between, generally 16, remains accessible. As described below the “rolled sleeve” 10 within the meaning of this patent application references a compression bundle netting material sleeve in which one open end 14 is drawn through the center through the open interior 16 and through the other open end 14 and wrapped at least once around the exterior to form a donut or torus shaped self shape holding structure as shown in FIGS. 1A-C.

(13) FIG. 1C is a perspective view of a vacuum packed rolled sleeve 10 packed with a mechanical fastener 18 capable of securing a compression bundle netting sleeve in position, wherein the mechanical fastener 18 is one of a twist tie, cable tie, hose tie, zip tie or tie-wrap. The rolled sleeve 10 and fastener 18 are packed in a weatherproof vacuum bag 20 which may have access through a re-sealable closure 22 and have a handle 24. The bag 20 may be easily formed as transparent plastic material as generally known in the vacuum bag art.

(14) The essence of the formation of the vacuum packed compressed netting sleeve of the present invention can be summarized as “SLEEVE IT, HOLD IT, VACUUM PACK IT”™ which is a mark used by the applicant in promoting the compression bundle netting sleeve of the present invention.

(15) Sleeve It

(16) FIGS. 2 C and D illustrate the formation of a compression bundle netting sleeve from the netting sleeve material 12 of FIGS. 2A and B, wherein the process is compressing or bunching of netting sleeve material 12 primarily along a longitudinal axis thereof whereby each open end 14 and the opening there between, generally 16, remains accessible. In practice this bunching is accomplished on a center holding rod, which for short lengths up to a few hundred feet could be on the arm of a worker who is forming the compression bundle netting sleeve.

(17) Hold It

(18) FIGS. 2E-I schematically illustrates, progressive steps for forming the rolled sleeve 10 of FIGS. 1 A-C from a compression bundle netting sleeve material 12 of FIGS. 2C and D. The rolled sleeve 10 will hold the donut or torus shape for ease of loading onto the pneumatic nozzle for forming the compost filter sock. Essentially to form the rolled sleeve 10, following the bunching of the sleeve of netting material 12, one open end 14 of the material 12 is drawn through the open interior 16 and through the other open end 14 as shown in FIG. 2E. The open end 14 is then wrapped around the exterior as shown in FIG. 2F, at least once. To form a tight rolled sleeve 10 the open end can be pulled through a second time as shown in FIG. 2H and then wrapped around the exterior thereby forming the shape holding rolled sleeve 10, which is of a torus or donut shape.

(19) An alternative version of the present invention, rather than forming the rolled sleeve 10, is to secure a mechanical fastener 18 around the compression bundle netting sleeve to hold the compression bundle sleeve in position as generally shown in FIG. 4A. The mechanical fastener 18 may be one of a twist tie, cable tie, hose tie, zip tie or tie-wrap. One minor disadvantage of this aspect of the present invention is that the secured fastener must be removed by the operator, who may not have a convenient tool (e.g., pocket knife) for removing the fastener. As discussed below the rolled sleeve 10 version may be provided with a separate fastener 18 for use on residual portions of the sleeve material 12 after a portion has been used. It is helpful if the operator has a pocket knife or the like to reuse the fastener 18 tied residual portion, but with the rolled sleeve design, should the operator not have a convenient tool he can use new rolled sleeves 10.

(20) A further alternative of the present invention, rather than forming the rolled sleeve 10, is to wrap a protective holding sleeve 32 around the compression bundle netting sleeve to hold the compression bundle sleeve in position as generally shown in FIGS. 5 and 6, with fasteners 36 securing overlapped ends 34 of the sleeve 32 in position to hold the sleeve 32 and the associated encapsulated compression bundle netting sleeve in position. The protective holding sleeve 32 is preferably formed as a short length of heavy duty mesh tubing generally the same or slightly larger in diameter than the material 12. The protective sleeve 32 is run through the open interior 16 of the compression bundle netting sleeve and the ends 34 are overlapped and coupled with a plurality of fasteners 36, which may be clips, staples, plastic zip ties or the like. The embodiment of FIG. 5 is similar to the embodiment of FIGS. 4A and B in that a separate holding member, such as fastener 18, is used in the form of the protective holding sleeve 32. The fasteners 36 may be formed as much smaller than fasteners 18 due to their implementation and thus can represent an easier fastener to sever when using the material 12. The protective holding sleeve 32 allows the compression bundle netting sleeve to be protected in the field until use. The holding sleeve 32 and the compression bundle netting sleeve of material 12 can be placed together onto the feeding nozzle and the sleeve 32 only removed once the material 12 is needed. The sleeve 32 is particularly helpful in environments in which the compression bundle may be dragged along the ground before use or otherwise exposed to a harsh environment prior to use.

(21) Vacuum Pack It

(22) After the compression bundle netting material is held in place through the formation of a rolled sleeve 10 or through a mechanical fastener 18 or through use of protective holding sleeve 32, it is placed in a sealable vacuum bag 20. There are two embodiments of the bag 20. One is a resealable bag 20 with the resealing closure 22 (generally downstream of an original sealing line formed with original packaging). A second bag 20 type is effectively formed from a tube member with one end being heat sealed the bag then cut to length from the tube of material and filled and sealed. The use of tube material for forming bags 20 allows the system to easily form distinct sizes of product as the bags 20 will be individually customized to the desired size. The disadvantage of the tube of material is that is prevents the easy incorporation of resealing mechanism—however the resealing may not be desired, or worth the extra cost in all applications and the cost savings of customizable sealed bags 20 from a single tube of material be beneficial.

(23) An unused fastener 18 may be placed into the sealable bag 20 to allow the user an easy mechanism to hold the compression bundle shape of a remainder of the netting material 12 after the job is completed. The remnant piece of material 12 may be several hundred feet long and the use of a fastener 18 and sealable bag 20 can allow for efficient storage and easy reuse of remnant pieces of sufficient length, particularly if a resealable bag 20 is used. Such use is shown in FIGS. 4A and B. FIG. 4A illustrates a remnant length of compression bundle netting sleeve material 12 with a mechanical fastener 18 holding sleeve in position; and FIG. 4B illustrates the compression bundle netting sleeve material 12 with fastener 18 stored within the re-sealable bag 20.

(24) Following the provision of the rolled sleeve 10, or a compression bundle with fastener 18 or a compression bundle with protective holding sleeve 32, within the bag 20, a vacuum is drawn within the bag 20 to compress the compression bundle or rolled sleeve 10 and the volume reduced bag 20 is sealed. The sealing is easily accomplished with a heat sealing, and if the closure 22 is present then the sealing line is closer to the end than the closure. In some bags 20 the closure 22 itself may be used to seal the bag 20, however this requires the closure to be designed to hold the vacuum and may unnecessarily increase the cost of the bag 20. Heat sealing spaced from the closure 22 allows the closure 22 to only be sufficient for sealing. Further as identified above, the use of a tube of material for forming customizable bags 20 with two heat sealed ends is very cost effective, but generally eliminates the resealing aspects of the bag 20 by eliminating the closure 22. The shape of the rolled sleeve 10 allows for effective vacuum packing of the present invention which in turn results in substantial reduction in volume and associated reduction in shipping costs and ease in provision of material 12 to the field, which field location may and often is a remote, difficult to access location.

(25) Pneumatic Nozzle Loading

(26) The self holding compressed netting sleeve material 12 allows for rapid loading of the pneumatic nozzle in the field. FIGS. 3A-F illustrate the mounting of the rolled sleeve 10 of FIGS. 1A-C on a pneumatic nozzle and the preparation for forming a compost filter sock with the rolled sleeve 10 of FIGS. 1A-C. The method of manufacturing a compost filter sock using the rolled sleeve 10, or fastener 18 or sleeve 32 held compression bundle netting sleeve material 12, first comprising the step of providing a bag 20 containing a compression bundle netting sleeve such as shown in FIG. 1C and formed as discussed above. The compression bundle netting sleeve material is removed from the bag 20. Next the torus or donut shaped netting material 12 is loaded or placed onto the pneumatic nozzle as shown in FIG. 3A.

(27) Following this loading, one open end 14 and a leading length of the netting sleeve 12 is removed or pulled from from the pneumatic nozzle while maintaining the opposite end 14 and the remainder of the netting sleeve 12 on the pneumatic nozzle. For the rolled sleeve 10 this entails un-wrapping the leading open end 14, effectively reversing the process used to form the rolled sleeve 10, as shown in the sequential steps of FIGS. 3B-E. For the fastener 18 held embodiment, or for use of a remnant which also uses a fastener 18, this entails removing the fastener 18, typically by cutting, and then merely pulling the leading open end 14 off as shown in FIG. 3E. For the sleeve 32 held embodiment this entails removing the sleeve 32, such as by cutting the fasteners 36, pulling off the sleeve 32, and then merely pulling the leading open end 14 off as shown in FIG. 3E.

(28) The next step for forming a compost filter sock is sealing the leading open end 14 such as by simply tying a knot 26 in the leading length as shown in FIG. 3F.

(29) Once loaded the compost filter sock is formed in a conventional fashion by filling the netting sleeve 12 with compost using the nozzle (and a supply of compost from a hopper or storage area). After a filter sock of a desired length has been formed the trailing end of the netting material 12 is sealed, such as by another knot 26. IF there is a substantial length of unused netting material 12 after formation of the compost filter sock of a desired length then the material may be severed, generally near where the trailing knot 26 is to be formed and the remaining length of material 12 forming a reusable remnant.

(30) As discussed above the present invention easily accommodates storage of relevant lengths of remnant material 12 after a job is completed. Small remnant lengths will likely be scrapped, or possibly used to fill a leading end of the next compost filter sock.

(31) While the invention has been shown in several particular embodiments it should be clear that various modifications may be made to the present invention without departing from the spirit and scope thereof. The scope of the present invention is defined by the appended claims and equivalents thereto.