Textured Core Sheets for Fluid Drainage Unit

Abstract

A core sheet includes a primary textured surface and separate secondary cuspations or corrugations. The core sheets are configured for use within a fluid or wastewater treatment unit that typically includes one or more fabric layers. The primary textured surface enhances retention of wastewater fluid received by the unit, which over time causes an increase in build-up of biomatter on the surface, which in turn enhances the efficacy of treatment of the wastewater. An inline process of making the core sheet includes extrusion forming a smooth flat sheet from raw polymeric material and immediately feeding the smooth flat sheet through texturizing rollers, followed by rolling flat textured sheets. Cuspations are added to the flat textured sheets, optionally at a different site, and then cut to preferred dimensions for incorporation into a wastewater unit.

Claims

1. A process of forming a core sheet for use within a fluid treatment unit, comprising: (a) extruding raw material to form a flat sheet of material having substantially flat and smooth surfaces; (b) directing the substantially flat sheet between a pair of rollers with cooperative texturizing surfaces to impart primary texturized surfaces on the sheet and thereby forming a texturized sheet; (c) rolling the texturized sheet; (d) feeding the texturized sheet from the roll to a secondary cuspation unit to form secondary cuspations in the texturized sheet; and (d) optionally cutting the texturized sheet to a preferred dimension.

2. The process of claim 1, wherein the substantially flat sheet is directed to the pair of rollers immediately after the step of extrusion.

3. The process of claim 1, wherein the substantially flat sheet has a temperature over 250° F. when it contacts the rollers in step (b).

4. The process of claim 3, wherein the substantially flat sheet has a temperature over 350° F. when it contacts the rollers in step (b).

5. The method of claim 1, wherein the cuspations are formed via plungers pressing one or more surfaces of the texturized sheet.

6. The method of claim 5, wherein the cuspations are formed via plungers pressing opposite surfaces of the texturized sheet in opposite directions.

7. The method of claim 1, wherein the raw material is a plastic.

8. The method of claim 1, wherein the rolled texturized sheet is transported to a secondary location between steps (c) and (d).

9. The method of claim 1, wherein the secondary cuspations include a first set in a first direction and a second set in a second direction opposite the first direction.

10. The method of claim 1, wherein the primary surface texture includes one or more of undulations, dents, crevices, peaks, dimples, points, scrapes, scratches, perforations, pores, and micropores.

11. The method of claim 10, wherein the primary surface texture is formed as a series of undulations or dents.

12. A method of constructing a fluid treatment unit, comprising: (a) providing a flat sheet of material having substantially flat and smooth surfaces; (b) directing the substantially flat sheet through a texturizing unit to impart a primary texturized surface on the sheet, thereby forming a texturized sheet; (c) rolling the texturized sheet to form a rolled texturized sheet; and (d) feeding the texturized sheet from the roll to a secondary structural component forming unit to form secondary structural components on the texturized sheet.

13. The method of claim 12, wherein the secondary structural component forming unit comprises at least one plunger for pressing one or more surfaces of the texturized sheet to form a cuspation.

14. The method of claim 12, wherein the flat sheet of material is formed via extrusion.

15. The method of claim 12, wherein the primary surface texture is formed via a pair of cooperative rollers between which the flat sheet is rolled.

16. A method of constructing a fluid treatment unit, comprising: (a) providing a flat sheet of material having substantially flat and smooth surfaces; (b) forming primary texture on at least one surface of the flat sheet to yield a texturized sheet; (c) forming a plurality of secondary structural components on the texturized sheet to yield a structured texturized sheet; (d) cutting the structured texturized sheet into multiple core sheets having preferred dimensions; (e) assembling two or more core sheets in a face to face configuration; and (f) placing at least one layer of a filter fabric adjacent one of the core sheets.

17. The method of claim 16, wherein multiple core sheets are arranged adjacent one another and substantially upright to form a channel and a layer of fabric is wrapped around at least two surfaces of the channel.

18. The method of claim 16, wherein multiple core sheets are arranged adjacent one another and substantially upright to form a channel with a layer of fabric wrapped around at least two surfaces of the channel, the channel has a pipe extending through at least two surfaces, and the pipe is configured to deliver wastewater to the channel between the fabric wrapped surfaces when fluidly connected to a source of wastewater.

19. The core sheet of claim 16, wherein the plurality of secondary structural components are cuspations.

20. The core sheet of claim 21, wherein the cuspations include a first set in a first direction and a second set in a second direction opposite the first direction.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Aspects of the preferred embodiments will be described with reference to the Drawings, where like numerals reflect like elements:

[0011] FIG. 1 shows an example of a flat polymeric core sheet material typically used as a starting material for forming cuspated core sheets in accordance with the disclosure;

[0012] FIG. 2 shows an exemplary cuspated core sheet as known in the prior art;

[0013] FIG. 3 shows a core sheet with a texturized primary surface and without cuspations;

[0014] FIG. 4 shows a cuspated core sheet with texturized primary surface according to the disclosure;

[0015] FIG. 5 shows another embodiment of a cuspated core sheet with texturized primary surface;

[0016] FIG. 6 depicts the texturized cuspated core sheet of FIG. 5 from a side edge view;

[0017] FIG. 7 is a simple flow chart with representative steps of a process of forming the inventive textured core sheets;

[0018] FIG. 8 depicts a representative embossing roller assembly for use in providing the texturized surface on the core sheets;

[0019] FIG. 9 is a representation of a surface of a roller showing a pattern of peaks for creating surface texture;

[0020] FIG. 10 depicts an exemplary embossing roller assembly and line for use in providing texture to the surface of core sheets and a representative roller pattern;

[0021] FIG. 11 is a first example of a fluid drainage units within which the inventive core sheets are configured for use;

[0022] FIG. 12 is another example of a fluid drainage units within which the inventive core sheets are configured for use; and

[0023] FIG. 13 is a flow chart with representative steps of another process of forming the inventive textured core sheets, different from the process of FIG. 7.

DETAILED DESCRIPTION

[0024] Among the benefits and improvements disclosed herein, other objects and advantages of the disclosed embodiments will become apparent from the following wherein like numerals represent like parts throughout the several figures. Detailed embodiments of a textured core sheets for use within fluid drainage and treatment systems are disclosed; however, it is to be understood that the disclosed embodiments are merely illustrative of the invention that may be embodied in various forms. In addition, each of the examples given in connection with the various embodiments of the invention which are intended to be illustrative, and not restrictive.

[0025] Throughout the specification and claims, the following terms take the meanings explicitly associated herein, unless the context clearly dictates otherwise. The phrase “in some embodiments” as used herein does not necessarily refer to the same embodiment(s), though it may. The phrases “in another embodiment” and “in some other embodiments” as used herein do not necessarily refer to a different embodiment, although it may. Thus, as described below, various embodiments may be readily combined, without departing from the scope or spirit of the invention.

[0026] In addition, as used herein, the term “or” is an inclusive “or” operator, and is equivalent to the term “and/or,” unless the context clearly dictates otherwise. The term “based on” is not exclusive and allows for being based on additional factors not described, unless the context clearly dictates otherwise. In addition, throughout the specification, the meaning of “a,” “an,” and “the” include plural references. The meaning of “in” includes “in” and “on”.

[0027] Further, the terms “substantial,” “substantially,” “similar,” “similarly,” “analogous,” “analogously,” “approximate,” “approximately,” and any combination thereof mean that differences between compared features or characteristics is less than 25% of the respective values/magnitudes in which the compared features or characteristics are measured and/or defined.

[0028] As background to the inventive textured cuspated core sheets described herein and shown generally as reference numeral 10, it is understood that they are configured to be used in cooperation with elements in fluid treatment systems. Non-limiting examples of appropriate fluid treatment systems within which the textured cuspated core sheets 10 are configured for use include the GSF and Mantis° systems sold by Eljen Corporation of Windsor, Conn., examples of which are shown in FIGS. 11 and 12. However, the inventive core sheets 10 can be incorporated into any number of other wastewater treatment systems for distribution, support and treatment. Exemplary installations, uses and additional aspects of these types of systems are described in co-owned U.S. Pat. Nos. 8,104,994 and 6,048,131, and U.S. patent application Ser. No. 16/732,392, disclosures of which are incorporated herein by reference for background. Still further, the feature of a primary surface texture on core sheets 10 may be employed in other varieties of drainage systems, including plastic chambers, to encourage growth of biomat-like organic deposits from bio-impacted fluid for enhancing treatment efficacy of the respective system.

[0029] The exemplary treatment systems, like the GSF and Mantis® systems respectively shown in FIGS. 11 and 12, utilize core sheets as internal support around which fluid-permeable fabric is wrapped. The fluid is maintained within the module or channel provided by the core material and gradually passes through the fabric layers and eventually into the external environment of sand, soil or other backfill that surrounds each treatment system or module. The systems are all generally self-supporting and self-contained and comprise cuspated polymeric core sheets because the sheets are non-absorbent, and surrounding layers of treatment fabric, that allow fluid flow and air movement into the surrounding environment (backfill) through the fabric layer. Over time, organic deposits develop primarily on the surface of the fabric (the interface between the fabric and surrounding soil), commonly referred to in the fluid treatment field as a biomat layer. The biomat layer is a significant contributor for naturally (passively) treating bio-related fluid, such as septic fluid or drainage, in the soil and which make the products useful for their intended purpose.

[0030] Within the GSF and Mantis® system embodiments shown in FIGS. 11 and 12, the prior art distribution media is formed of several polymeric core sheets 20 with cuspated configuration, somewhat similar in appearance to an egg crate. The cuspation peaks are shown graphically as reference numeral 24 in the non-textured products shown in FIGS. 2, 11 and 12. In practice, embodiments exist with cuspations in both relative directions of the sheet surface and may be formed via sets of pistons or plungers punching the opposite surfaces from opposite sides of a flat sheet toward one another. Commonly, the flat sheet is fed from a roll and heated above ambient temperature such that it is in a somewhat malleable state prior to punching. While the depicted embodiments show cuspation peaks 24 that are flat and solid, embodiments of the inventive core sheets 10 exist with holes or slots in at least a portion of the peaks. The holes further aid fluid surface retention, and thus growth of biomaterial.

[0031] The non-absorbent support media (core sheets 20) is commonly referred to as “distribution media” while the fabric 26 in the system is referred to as “treatment media.” Previously, it was believed only treatment media contributed to treatment of wastewater effluent, and that the distribution media only contributed to support of the system and distribution of the effluent. It has since been discovered that organic deposits can build up on the core sheets themselves in addition to on the fabric treatment media (biomat). Surfaces of core sheets that are exposed to the most wastewater for a longer duration of time have been shown to build up the most organic deposits. However, the smooth surfaces 22 of the prior art core sheets do not promote adherence of the fluid effluent to it as the fluid is received from a drainpipe or conduit.

[0032] With reference to FIG. 4, a core sheet 10 is provided with a primary textured or rough surface 12 and secondary cuspations 14, which appear as larger peaks and valleys in FIGS. 4-6. The textured surface may include a variety of surface irregularities such as one or more of fine undulations, dents, crevices, peaks, points, dimples, scrapes, scratches, perforations, pores, and micropores. The primary textured surface 12 has been shown to promote adhesion of bio-impacted fluid and lead to an additional buildup of biomat-like organic material on the internal core sheets 10 in addition to on the fabric-soil interface, thereby increasing the efficacy and overall treatment capacity of a given system. Typically, the core sheet 10 is formed from a flat sheet 10′ that has undergone a texturizing step to add the surface irregularities 12 that form the primary textured surface.

[0033] One process for forming the cuspated core sheets that are currently known in the art and which are shown in the products of FIGS. 5 and 6 is in an assembly line process that starts with raw rolled flat polymeric sheet material 30 with a smooth surface 32, similar to that shown in FIG. 1. The flat sheet 30 undergoes a heating step wherein it is heated above ambient temperature in a heating unit (B), which may be a heated roller, to impart a malleability property to the raw polymeric starting material. In the known process, the heated flat sheet is fed from the heater (B) to a cuspation forming unit (D) that includes several plungers or pistons on each side of the sheet that move relative to each other from one surface side of the sheet toward the other to “punch” cuspations 24 as shown in FIGS. 2 and 11. The plungers may reciprocate in a single direction from one side of the sheet (to form cuspations in one direction) or from both directions from opposite sides of the sheet (to form cuspations in both directions). The depicted sheet 10 includes secondary cuspations 14 in both directions and surface texture 12 on approximately the entire surface, as seen most clearly in the side view of FIG. 6 (note surface texture is not shown on entire surface in FIGS. 4-6 in the interest in more clearly showing the cuspations). After the sheets are fit with cuspations, the cuspated sheet is fed to a cutting unit (E) for cutting into preferred dimensions for the particular unit within which it will be installed, thereby forming a cuspated core sheet 20.

[0034] With reference to FIG. 7, in the inventive process, a step of adding primary texture to the heated flat sheet material 30 in a texturizing unit (C) is incorporated into the assembly line prior to punching to form the cuspated contour (D). Multiple specific embodiments of a texturizing unit (C) exist, including without limitation, a roller unit with one or more irregular surfaced rollers, a stamping unit with irregular platform surfaces, and a tooth projection unit (for forming scrapes in the surface). After the texturizing step (C), the texturized flat sheet is fed to the cuspation forming unit (D), and then to the cutting unit (E). The end product is a cuspated core sheet 10 with textured surface 12 and cuspations 14 useful for promoting surface retention of the wastewater fluid and eventual buildup of biomaterial for enhanced treatment when incorporated into passive wastewater treatment systems.

[0035] FIG. 8 depicts a representative heated embossing rolling assembly 40 used to form the primary texturized surface 12 on the disclosed sheets 10, and FIG. 10 depicts a system within which the heated roll assembly 40 is utilized. As shown, the rolling assembly includes a first (male) roller 42 and a corresponding second (female) roller 44. In a preferred embodiment, hot oil is circulated through the interior of the rollers, 42 and 44, to heat the surfaces of the rollers that receive the flat polymer sheet 40 starting material fed from a roll 46 upstream of the heated rolling assembly 40. In a preferred embodiment, the hot oil is fed through serpentine channels arranged on the inner wall surface the respective rolls, however this particular configuration of oil delivery and heating is non-limiting. In the assembly line of FIG. 10, the flat textured sheet material is fed directly from the rolling assembly 40 to the punching unit or plungers D to form the dual sided cuspations 14, and thereafter cut to desired dimensions for incorporation into a wastewater treatment unit. As also shown in FIG. 8, the hot oil may be flowed cyclically through the respective rollers and returned back to an initial bath from which oil is again flowed to the rollers.

[0036] In the rolling assembly 40 of FIG. 8, the first roll 42 is the male roll and includes a series of projections, like the irregular projections shown as black dots in FIG. 9. The second roll 44 is the female roll and includes surface indentations, each of which corresponds to a projection in the first roll 42. As such, a flat sheet 30 fed through the texturizing rolling assembly 40 between the first and second rollers is fit with surface undulations approximately matching the pattern of the projections shown in FIG. 9. Another roller pattern for creating a comparable surface texture pattern is shown in the upper portion of FIG. 10. As one can readily understand, the patterns shown in FIGS. 9 and 10 are merely exemplary, as virtually any number of different patterns can be utilized.

[0037] FIG. 13 shows an alternate process of forming the disclosed sheets 10. In the preferred process of FIG. 13, raw polymer material (F) is fed through an extruder (G) to form a continuous thin flat sheet 30 that is fed directly to rollers at step (H) to add the primary surface texture 12 in a single line process. The flat sheet 30 remains hot (approximately 350-500° F.) from the extruder when it is immediately fed through the rollers, which assists in application of the texture 12 to the surface. The textured flat sheet is thereafter rolled in step (I). The textured flat sheets can thereafter be fed from its rolled form to a cuspation forming unit (J) and then cut to preferred dimensions (K) for use in assembly of a particular wastewater unit. This embodiment provides a significant degree of manufacturing versatility in that rolled textured sheets can optionally be shipped and transported to alternate locations prior to adding cuspations 24 at step (J) and assembling wastewater units. Further, feeding the flat sheets 30 directly from the extruder to the texturizing rolls significantly simplifies the instrumentation in that the rolls need not be heated themselves, which is unlike with the process of FIG. 7.

[0038] Like the primary texture, various specific forms of secondary structure exist without departing from the inventiveness of the core sheets disclosed herein. For example, in another non-limiting embodiment, the secondary structure takes the form of a wave shape across a length of a texturized core sheet, rather than individual cuspations formed by plungers.

[0039] In yet another embodiment, a textured sheet is formed via a form molding process, rather than via rollers, prior to being rolled or prior to the secondary structural components (cuspations, for example) being formed.

[0040] When incorporated into passive wastewater treatment units with layers of filter fabric 26, like the GSF and Mantis® systems discussed above, for example, the disclosed core sheets 10 with texturized primary surface 12 and secondary cuspations 14 have shown a significant increase in surface buildup of biomaterial as compared to cuspated core with smooth surface, like that shown generally as reference numeral 20 and previously utilized in such passive systems as structural members. Bio-impacted fluid is retained on the textured primary surface 12 more effectively compared to the smooth surface of the prior art core sheets 20, especially in the areas around the cuspations 14. This causes a denser and more rapid buildup of organic deposits, which, along with the biomat layer at the fabric-soil interface, improves treatment of the wastewater effluent received by the system.

[0041] In another embodiment, a flat sheet 30 is run through a pair of rollers with cooperative teeth and cavities for forming small slits, micro-slits, micropores or similar in the sheet to yield the primary texturized surface, rather than surface indentations or undulations. Use of such a pair of rollers is possible in each of the processes of FIGS. 7 and 13.

[0042] Another embodiment comprises only a single roll with teeth over which a flat sheet 30 rolls to form slits, micro-slits, micropores or similar. This is also applicable to either of the processes of FIGS. 7 and 13.

[0043] The disclosed core sheet 10 with primary textured surface 12 and secondary cuspations 14 are primarily configured to be used within wastewater treatment units or systems as support, wherein the sheets are subject to wastewater flow when the respective wastewater unit is connected to a wastewater source. For example, in a unit like that shown in FIG. 12, one or more core sheets 10 are arranged upright and adjacent one another (in place of the non-textured cuspated core sheets 20 known in the prior art) and then wrapped in fabric 26 to form a module. As shown, a pipe may extend through a front and rear face of each module. The pipe may include one or more holes aligned with the inner area of each module (between the fabric) and be fluidly connected to a source of wastewater, thereby introducing wastewater to the textured cuspated core sheets 10. The textured surface 12 of the core sheets 10 improves surface fluid retention and promotes growth of biomaterial, which in turn enhances the treatment efficacy of each wastewater unit relative to a comparable prior art unit without textured core sheets. In this manner, it can be said that the textured cuspated core sheets 10 provide a cyclical treatment advantage over comparable non-textured core sheets.

[0044] In units like that depicted in FIG. 11, with serpentine fabric 26 wrapping textured cuspated core sheets 10, a pipe is typically placed on top of the unit for delivery of wastewater to the unit via gravity, with at least a portion of the wastewater being directed to the core sheets.

[0045] The specific units or systems shown in FIGS. 11 and 12 are merely exemplary of the types of wastewater treatment systems within which the inventive textured and cuspated core sheets 10 are configured for use. Numerous other specific systems and units exist within which the core sheets 10 can be used to enhance wastewater treatment efficacy. Additionally, numerous other specific wastewater delivery mechanisms are possible within similar systems, including delivery from the side, bottom and/or any combination of the disclosed delivery mechanisms. For example, as noted above, ATUs may incorporate upright core sheets 10 to enhance surface adherence of fluid and thus, improve growth of biomaterial. Core sheets 10 may be wrapped around a distribution pipe or placed intermediate a distribution pipe and other treatment units.

[0046] While preferred embodiments of the foregoing have been set forth for purposes of illustration, the foregoing description should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations and alternatives may occur to one skilled in the art without departing from the spirit and the scope of the present invention.