U.S. patent application number 14/012848 was filed with the patent office on 2015-03-05 for liquid covering disks and systems.
The applicant listed for this patent is Matt Alirol. Invention is credited to Matt Alirol.
Application Number | 20150059079 14/012848 |
Document ID | / |
Family ID | 52581124 |
Filed Date | 2015-03-05 |
United States Patent
Application |
20150059079 |
Kind Code |
A1 |
Alirol; Matt |
March 5, 2015 |
Liquid Covering Disks and Systems
Abstract
Liquid covering disks configured to float on the surface of a
body of liquid, including a body with an aperture at a periphery of
the body, the aperture configured to allow a liquid to pass
through, a plurality of ribs projecting from the body, and a wall
protruding at the periphery of the body. A portion of the body, a
portion of the plurality of ribs, and a portion of the wall define
a cavity allowing a volume of a gas to be trapped in the cavity
when the disk is deployed on the surface of the body of liquid. In
some examples, a system of floating disks covers the surface of a
body of liquid. Each disk includes an interlocking element
configured to interact with a complementary interlocking element at
an adjacent disk to form a floating arrangement of disks.
Inventors: |
Alirol; Matt; (The Dalles,
OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Alirol; Matt |
The Dalles |
OR |
US |
|
|
Family ID: |
52581124 |
Appl. No.: |
14/012848 |
Filed: |
August 28, 2013 |
Current U.S.
Class: |
4/499 ;
126/566 |
Current CPC
Class: |
E04H 4/08 20130101; B65D
88/36 20130101 |
Class at
Publication: |
4/499 ;
126/566 |
International
Class: |
E04H 4/10 20060101
E04H004/10 |
Claims
1. A disk configured to float on the surface of a body of liquid,
comprising: a body including a top surface, a bottom surface, and
an aperture at a periphery of the body, the aperture configured to
allow a liquid to pass through the aperture; a plurality of ribs
projecting from the body; a sidewall protruding at the periphery of
the body; and a cavity defined by a portion of the body, a portion
of the plurality of ribs, and a portion of the sidewall, the cavity
allowing a volume of a gas to be trapped in the cavity when the
disk is deployed on the surface of the body of liquid, wherein the
volume of gas trapped in the cavity serves to fluid dynamically
resist the disk separating from the surface of the body of liquid
on which the disk floats.
2. The disk of claim 1, wherein the body defines a polygonal
shape.
3. The disk of claim 2, wherein the plurality of ribs radiate
outward from the center of the polygonal shape towards the edges of
the polygonal shape.
4. The disk of claim 1, wherein the plurality of ribs extend from
the top surface and from the bottom surface of the body.
5. The disk of claim 1, wherein the plurality of ribs have a height
above the body that decreases from a center of the body towards the
periphery of the body.
6. The disk of claim 1, wherein the body includes a cross-sectional
profile that decreases from a center of the body to the periphery
of the body.
7. The disk of claim 1, wherein the sidewall protrudes from the top
surface and from the bottom surface.
8. The disk of claim 1, wherein the sidewall includes a concave
portion.
9. The disk of claim 1, wherein the sidewall includes a convex
portion.
10. The disk of claim 1, wherein the aperture is positioned
adjacent the sidewall.
11. The disk of claim 1, wherein the sidewall includes a sigmoidal
curvature along the periphery of the body.
12. The disk of claim 11, wherein the aperture follows a contour of
the curvature.
13. A system for covering a surface of a body of liquid,
comprising: a plurality of disks configured to float on the surface
of the body of liquid, each disk comprising a body including a top
surface, a bottom surface, and an aperture at a periphery of the
body, the aperture allowing a liquid to pass through, a plurality
of ribs projecting from the body, a sidewall protruding from the
body at the periphery, and wherein a portion of the body, a portion
of the plurality of ribs, and a portion of the sidewall define a
cavity allowing a volume of a gas to be trapped in the cavity when
the disk is deployed on the surface of the body of liquid; wherein
the plurality of disks unite when floating on the surface of the
body of liquid to form an arrangement of floating disks; and
wherein each of the plurality of disks includes an interlocking
element configured to interact with a complementary interlocking
element at an adjacent disk to assist in keeping the arrangement of
floating disks together.
14. The system of claim 13, wherein the interlocking element
includes a portion of the sidewall.
15. The system of claim 13, wherein the interlocking element
includes a curvature of the sidewall.
16. The system of claim 13, wherein the interlocking element
includes a sigmoidal curvature of the sidewall extending from the
bottom surface of the body and an inverse curvature extending from
the top surface at a corresponding location of the body.
17. A system for covering a surface of a body of liquid,
comprising: a plurality of disks configured to float on the surface
of the body of liquid, each disk comprising a body having a
substantial polygonal shape in the horizontal floating plane, the
body including a top surface and a bottom surface, a plurality of
ribs projecting from the top surface and the bottom surface of the
body, each rib having a height above the body that decreases from
the center of the body towards the periphery of the body, a
sidewall protruding from the top surface and from the bottom
surface at the periphery of the body and coupled to at least some
of the plurality of ribs, wherein a portion of the body, a portion
of the plurality of ribs, and a portion of the sidewall define a
cavity allowing a volume of a gas to be trapped in the cavity when
the disk is deployed on the surface of the body of liquid; wherein
the plurality of disks unite when floating on the surface of the
body of liquid to form an arrangement of floating disks; and
wherein each of the plurality of disks includes an interlocking
element configured to interact with a complementary interlocking
element at an adjacent disk to assist in keeping the arrangement of
floating disks together.
18. The system of claim 17, further comprising a plurality of
apertures at the periphery of the body, the aperture allowing a
liquid to pass through the top surface and the bottom surface.
19. The system of claim 17, wherein the plurality of ribs are
arranged in a pattern that is substantially identical at the top
surface and at the bottom surface of the body.
20. The system of claim 17, wherein the body includes a
cross-sectional profile that that decreases from a center of the
body towards the periphery of the body.
Description
BACKGROUND
[0001] The present disclosure relates generally to liquid covering
disks and systems. In particular, this disclosure describes
floating disks including a shape and a structure that provide
stability to the disks and adherence to the surface when the disks
are deployed on a surface of a body of liquid.
[0002] Ponds, reservoirs, and open tanks are often used to store
and treat liquids. Liquids having large open surfaces are common in
the fields of chemical production, anodizing, galvanizing, plating,
dying, sewage treatment, oil waste storage, and other such fields.
In many of these fields, unimpeded access to the liquid is desired.
However, having large open liquid surfaces may lead to evaporation
of the stored liquid, unintended plant and organism growth on the
liquid surface, emission of noxious fumes, and exposure to
wildlife.
[0003] Reducing fluid loss, toxic vapors emission, and heat loss
are major environmental and financial concerns. Reducing
evaporation and heat transfer is influenced by a variety of
factors, such as wind conditions above the liquid surface, liquid
temperature, environment temperature, liquid density, and the
concentration of the substance evaporating in the air. Reducing
evaporation will also reduce noxious fumes.
[0004] Some liquid covers presently understood in the art are
polygonal shaped covers designed to be placed on the surface in
concert, covering the liquid body. Examples of references
describing such covers include U.S. Pat. Nos. 4,270,232 and
8,342,352 and European Patent No. 1,697,234. The complete
disclosures of these patents and patent applications are herein
incorporated by reference for all purposes.
[0005] In high velocity wind conditions, however, known liquid
covers tend to be blown off the surface of the ponds, leaving
significant surface on the liquid body exposed. Heavier designs
that are less affected by the wind suffer from high shipping
costs.
[0006] As a result, known liquid covering disks are not entirely
satisfactory for the range of applications in which they are
employed. Specifically, there exists a need for liquid coverings
that protect against the harms listed above, while being wind
resistant, easily adaptable to various liquid bodies, and of
limited cost to manufacture. Examples of new and useful liquid
covering disks relevant to the needs existing in the field are
discussed below.
SUMMARY
[0007] The present disclosure is directed to liquid covering disks
and systems. In some examples, a disk configured to float on the
surface of a body of liquid includes a body, a plurality of ribs
projecting from the body, and a sidewall protruding at the
periphery of the body. The body has a top surface, a bottom
surface, and an aperture at a periphery of the body. The aperture
is configured to allow a liquid to pass through. A portion of the
body, a portion of the plurality of ribs, and a portion of the
sidewall define a cavity allowing a volume of a gas to be trapped
in the cavity when the disk is deployed on the surface of the body
of liquid and providing buoyancy to the disk.
[0008] In some embodiments, the body may include a polygonal shape.
In other embodiments, the plurality of ribs radiate outward from
the center of the polygonal shape towards the edges of the
polygonal shape. In some embodiments, the plurality of ribs extend
from the top surface and from the bottom surface of the body. In
further embodiments, the ribs have a height above the body that
decreases from a center of the body towards the periphery of the
body.
[0009] In some embodiments, the body includes a cross-sectional
profile that decreases from a center of the body to the periphery
of the body. In other embodiments, the sidewall protrudes from the
top surface and from the bottom surface. The sidewall may include a
concave portion and/or a convex portion. In further embodiments,
the aperture is positioned adjacent the sidewall. In some
embodiments, the sidewall includes a sigmoidal curvature along the
periphery of the body. In other embodiments, the aperture follows a
contour of the curvature.
[0010] The inventive subject matter further contemplates a system
for covering a surface of a body of liquid, including a plurality
of disks configured to float on the surface of the body of liquid.
The plurality of disks unite when floating on the surface of the
body of liquid to form an arrangement of floating disks. Each of
the plurality of disks includes an interlocking element configured
to interact with a complementary interlocking element at an
adjacent disk to assist in keeping the arrangement of floating
disks together.
[0011] The interlocking elements may include a portion of the
sidewall, a curvature of the sidewall, and/or a sigmoidal curvature
of the sidewall extending from the bottom surface of the body and
an inverse curvature extending from the top surface at a
corresponding location of the body.
[0012] In further embodiments, a system for covering a surface of a
body of liquid includes a plurality of disks configured to float on
the surface of the body of liquid, each disk including a body
having a substantial polygonal shape in the horizontal floating
plane, the body including a top surface and a bottom surface, a
plurality of ribs projecting from the top surface and the bottom
surface of the body, each rib having a height above the body that
decreases from the center of the body towards the periphery of the
body, a sidewall protruding from the top surface and from the
bottom surface at the periphery of the body and coupled to at least
some of the plurality of ribs.
[0013] A portion of the body, a portion of the plurality of ribs,
and a portion of the sidewall define a cavity allowing a volume of
a gas to be trapped in the cavity when the disk is deployed on the
surface of the body of liquid. The plurality of disks unite when
floating on the surface of the body of liquid to form an
arrangement of floating disks. Each of the plurality of disks
includes an interlocking element configured to interact with a
complementary interlocking element at an adjacent disk to assist in
keeping the arrangement of floating disks together.
[0014] The foregoing embodiment may further include a plurality of
apertures at the periphery of the body, the aperture allowing a
liquid to pass through the top surface and the bottom surface. In
some embodiments, the plurality of ribs are arranged in a pattern
that is substantially identical at the top surface and at the
bottom surface of the body. In other embodiments, the body includes
a cross-sectional profile that that decreases from a center of the
body towards the periphery of the body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a perspective view of an arrangement of liquid
covering disks.
[0016] FIG. 2 is a perspective view of a liquid covering disk.
[0017] FIG. 3 is an exploded perspective view of a portion of the
liquid covering disk shown in FIG. 2.
[0018] FIG. 4 is a close up view of the texture of the material
forming the liquid covering disk shown in FIG. 1.
[0019] FIG. 5 is a top plan view of the liquid covering disk of
FIG. 2.
[0020] FIG. 6 is a cross-sectional view of the liquid covering disk
of FIG. 2 along line 6-6 in FIG. 5.
[0021] FIG. 7 is a cross-sectional view of the liquid covering disk
of FIG. 2 along line 7-7 in FIG. 5.
[0022] FIG. 8 is a side elevation view of the liquid covering disk
of FIG. 2.
[0023] FIG. 9 is a cross-sectional perspective view of the
arrangement of liquid covering disks of FIG. 1, illustrating
interlocking features between disks.
[0024] FIG. 10 is an exploded cross-sectional view of interlocking
features of liquid covering disks of FIG. 9.
[0025] FIG. 11 is top plan view of a second embodiment of a liquid
covering disk.
[0026] FIG. 12 is a side view of the liquid covering disk of FIG.
11.
[0027] FIG. 13 is a top plan view of a third embodiment of a liquid
covering disk.
[0028] FIG. 14 is a side view of the liquid covering disk of FIG.
13.
[0029] FIG. 15 is a top plan view of a fourth embodiment of a
liquid covering disk, which includes spherical chambers.
[0030] FIG. 16 is a side view of the liquid covering disk of FIG.
15.
[0031] FIG. 17 is a top plan view of a fifth embodiment of a liquid
covering disk.
[0032] FIG. 18 is a side view of the liquid covering disk of FIG.
17.
[0033] FIG. 19 cross-sectional view the embodiment of a liquid
covering disk shown in FIG. 17 along line 19-19.
[0034] FIG. 20 is a perspective view of a sixth embodiment of a
liquid covering disk, which includes cylindrical chambers.
DETAILED DESCRIPTION
[0035] The disclosed liquid covering disks and systems will become
better understood through review of the following detailed
description in conjunction with the figures. The detailed
description and figures provide merely examples of the various
inventions described herein. Those skilled in the art will
understand that the disclosed examples may be varied, modified, and
altered without departing from the scope of the inventions
described herein. Many variations are contemplated for different
applications and design considerations; however, for the sake of
brevity, each and every contemplated variation is not individually
described in the following detailed description.
[0036] Throughout the following detailed description, examples of
various liquid covering disks are provided. Related features in the
examples may be identical, similar, or dissimilar in different
examples. For the sake of brevity, related features will not be
redundantly explained in each example. Instead, the use of related
feature names will cue the reader that the feature with a related
feature name may be similar to the related feature in an example
explained previously. Features specific to a given example will be
described in that particular example. The reader should understand
that a given feature need not be the same or similar to the
specific portrayal of a related feature in any given figure or
example.
[0037] The inventive subject matter provides systems and liquid
covering disks that reduce evaporation, heat loss, reduce foam
formation and emission of noxious or toxic fumes from an open
liquid surface by forming a floating arrangement of liquid covering
disks. The liquid covering disks include a body, a plurality of
ribs projecting from the body, and a sidewall protruding at the
periphery of the body. A portion of the body, a portion of the
plurality of ribs, and a portion of the sidewall define a
cavity.
[0038] A liquid covering disk including a number of such open
cavities allows a volume of a gas to be trapped in the cavity when
the disk is deployed on the surface of the body of liquid thereby
providing buoyancy to the disk. Additionally, cavities with an open
side facing the surface of the body of liquid provide the disks
with a tendency to stick to the surface of the body of liquid.
Furthermore, disks that are generally similar in shape tend to
unite edge to edge when floating on the surface of the body of
liquid to form an arrangement of floating disks that covers a major
portion of an open liquid body. Complementary interlocking elements
assist in keeping the arrangement of floating disks together.
[0039] The liquid covering disk has a polygonal shape in the
horizontal floating plane, for example a triangular, quadrangular
or hexagonal shape. The liquid covering disks may be hollow or
solid. Some embodiments are made using a plastic having a gravity
which is approximately one half the specific gravity of the liquid
to provide the disk with the desired buoyancy.
[0040] With reference to FIGS. 1-10, a first example of a system
for covering a surface of a body of liquid and liquid covering disk
will now be described. Liquid covering disk 100 includes a body 120
having a top surface 112, a bottom surface 114, and apertures 132
at a periphery 122 of body 120. Apertures 132 are configured to
allow a liquid and debris to pass through. Disk 100 further has a
sidewall 116 protruding vertically at periphery 122 of body 120 and
a plurality of ribs 124 projecting vertically from body 120.
[0041] A plurality of channels 126 are formed by portions of body
120, portions of ribs 124, and portions of sidewall 116. The
channels are formed by ribs 124, protuberance 148, sidewall 116,
and top surface 112. Each rib 24 has two surfaces which define
faces of channels 126.
[0042] On each major side of disk 100, channels 126 slope downwards
towards apertures 132 proximate sidewall 116. Channels 126 serve to
direct water and other debris towards apertures 132 to allow the
water and debris to exit channels 126 through apertures 132 on
whatever side of disk 100 is oriented upwards. Of course, the
channels on the side of disk 100 oriented downwards will be wholly
or partially submerged in the liquid body.
[0043] As can be seen in FIGS. 2, 5 and 6, disk 100 includes a set
of cavities 118 and cavities 144. Cavities 118 are disposed along
the periphery of disk 100 whereas cavities 144 are located at the
center of disk 100. Cavities 118 are defined by a portion 136 of
body 120, portions 138 and 140 of ribs 124, and portion 141 of
sidewall 116. Cavity 144 is defined by a substantially cylindrical
protuberance 148 that projects from body 120 at the center of the
hexagonal shaped body 120.
[0044] When floating on the surface of a body of liquid a volume of
a gas, such as air, may be trapped in cavities 118 and 144 between
the surface 128 of the body of liquid 130 and the surfaces of the
cavities. The trapped volume of gas imparts increased stability and
buoyancy to disk 100. Trapping air below the bottom surface of the
disk in the cavities increases the buoyancy of the disk.
[0045] Cavities 118 and 144 increase the stability of liquid
covering disk through pressure equilibrium principles. When a
pocket of air is trapped in cavities 118 and 144 by the surface of
a liquid, the pressure of that pocket of air will be in equilibrium
with the local atmospheric pressure. Attempts to separate the disk
from the surface of the liquid will have the effect of increasing
the volume of the chamber of air sealed in the cavities. Increasing
the volume of the sealed chamber will decrease the air pressure
within the sealed chamber and create a pressure imbalance with the
ambient air pressure. The net result is that disk 100 will resist
separating from the surface of the liquid in response to wind or
other forces because the ambient air will act on the liquid and the
disk to maintain the pressure of air sealed in cavities 118 and 144
in equilibrium with the ambient air pressure.
[0046] When an arrangement of liquid covering disks is used, wind
may push upon the rib faces and push the liquid covering disks more
closely together and reduce gaps in the coverage between them. The
liquid covering disks may unite as an arrangement 142 of floating
disks disposed in edge to edge relationship with generally like
disks to cover at least a major portion of a body of liquid. For
example, a system 190 for covering a surface of a body of liquid
including a plurality of disks 100 is shown in FIG. 1.
[0047] Liquid covering disk 100, or a collection thereof, function
to reduce heat loss and evaporation, suppress waves, reduce foam
formation, and prevent the emission of noxious or toxic fumes from
a body of liquid on which liquid covering disk 100 is deployed. In
operation, liquid covering disk 100 floats with top surface 112
approximately above surface 128 of a body of liquid 130 and bottom
surface 114 approximately below surface 128 of body of liquid 130.
Of course, the disk may flip over from time to time, reversing the
orientation of the top and bottom surfaces.
[0048] Body 120 of disk 100 has a substantially hexagonal shape in
a horizontal plane. Top surface 112 includes a substantially
cylindrical protuberance 148 that projects from body 120 at the
center of the hexagonal shaped body 120. Although protuberance 148
is substantially cylindrical in shape with a substantially flat
top, this disclosure also contemplates protuberances that implement
different designs as well.
[0049] A plurality of ribs 124 radiate from protuberance 148
extending from body 120. In particular, twelve trapezoidal ribs 124
on each side of disk 100 radiate out from protuberance 148 towards
periphery 122 of body 120 where they merge with sidewall 116. As
one can see in FIG. 2, the height of ribs 124 gradually descends as
they approach sidewall 116 and merges with the sidewall at equal
height. The outer edges of the ribs, i.e., the end of the ribs away
from the top/bottom surface, defines the contours of the disk, for
example contour 134 of disk 100.
[0050] Liquid covering disk 100 further includes a sidewall 116,
formed by a projection of the hexagonal periphery of top surface
112 and bottom surface 114. In some embodiments, sidewall 116, top
surface 112, and bottom surface 114 are coupled such that they form
a unified body.
[0051] Sidewall 116 generally follows periphery 122 of hexagonal
shaped body 120. However, at each side of the hexagonal shape,
sidewall 116 includes a curvature, for example sigmoidal curvature
152. Curvature 152 includes a concave portion 154, where the
sidewall deviates slightly inward, relative to the side of the
hexagonal shape, towards the center of the body, and a convex
portion 156, where the sidewall deviates slightly outward, relative
to the side of the hexagonal shape, towards the center of the
body.
[0052] Apertures 132 serve as a port that allows an amount of
liquid to pass through freely. For example, apertures 132 are
formed in body 120 proximate sidewall 116 and allow water and
debris to flow through back into the main liquid body.
Additionally, apertures 132 along the periphery reduce or prevent
water from being trapped on the top surface of the disk.
[0053] Aperture 132 allows for a gap in body 120 and sidewall 116
so that when a collection of liquid covering disks are used in
concert and are nested in a closed, packed pattern, liquid is
allowed to easily pass through aperture 132, whereas other liquid
covering disks in the tightly packed pattern may otherwise
substantially restrict such flow. In some embodiments, disks may be
provided with additional apertures or ports.
[0054] Bottom surface 114 is substantially similar to top surface
112, including a similar shape, size, and topography, except for a
shift in the curvature along the sides of the hexagonal shape,
i.e., concave portions at the top surface align with convex
portions at the bottom surface, and vice versa.
[0055] For the sake of brevity, the elements of bottom surface 114
will not be described in detail. However, bottom surface 114, like
top surface 112, includes a central protuberance and ribs that are
substantially the same shape and size as the corresponding parts on
top surface 112. Sidewall 116, however, along the sides of the
polygonal shaped body includes a portion wherein the curvatures are
the opposite of the curvatures at the top surface. In particular,
at top surface 112 sidewall 116 includes sigmoidal curvature 152
whereas at bottom surface 114, sidewall 116 includes sigmoidal
curvature 158, which is positioned as the inverse to sigmoidal
curvature 152.
[0056] For example, FIG. 1 shows a split in sidewall 116 where a
concave portion 160 curves inward below convex portion 156 of
curvature 152 and a convex portion 162 curves outward below concave
portion 154 of curvature 152. Although the patterns formed by the
ribs 124 of top surface 112 and bottom surface 114 are
substantially similar, this is not specifically required, and
liquid covering disks with different top surfaces and bottom
surfaces are equally within this disclosure.
[0057] Additional openings 164 and 166 are provided in the portions
of body 120 where sidewall 116 curves outward, i.e., in top surface
112 and bottom surface 114 at the convex portions 156 and 162,
respectively, of side wall 116. Openings 164 and 166 assist the
disk in settling into a substantially flat position on the surface
of the body of liquid and to communicate fluid between channels 126
and the body of liquid on which disk 100 floats. In some
embodiments, the body, ribs, and sidewall may include additional
openings.
[0058] Body 120 has a cross-sectional thickness that decrease from
the center to edge 146 to facilitate dispersion of rain water and
to avoid standing water. For example, the center of top surface 112
is at a higher elevation relative to its lateral periphery 122.
However, in some embodiments liquid covering disks may include a
substantially flat top surface and/or bottom surface. In other
embodiments, either the top surface, bottom surface, or both, may
include a depression, or lowers in elevation as one approaches the
center, for example in combination with an opening.
[0059] The outer contours of the ribs follow a similar profile.
Ribs 116 create channels which guide rain to the edges of the
disks. Ribs 116 provide structural support to the disk and provide
resistance to wind. The contour of the disk is determined by the
height of the ribs and the sidewall.
[0060] The dimension of the cavities may depend on the application
and wind resistance that is desired. The cavities can be sized to
provide additional stability and buoyancy. In some embodiments, the
size of the cavities is selected to allow the disks to float at a
predetermined depth below the surface of the body of liquid.
[0061] In one example, a body has a diameter of about 8 inches and
a height of at least about 0.5 inches. In another example, three
liquid covering disks may cover about 1 square foot of surface of
body of liquid. In some embodiments, the sidewall may have a height
between 40% and 60% of the overall height of the disk.
[0062] FIG. 5 illustrates the position of the channels 126 created
by the body, ribs, and sidewall. Disk 100 has a total of 48
channels, 24 channels at the top surface side of the body and 24
channels at the bottom surface side. Each side has a middle cavity
at the center of the polygonal shape and 6 cavities at the
peripheral edges.
[0063] Cavities 118 and 144 may capture a given amount of a gas
when a liquid covering disk is placed in water or other liquid. The
size and volume of the cavities may be selected to create desired
buoyancy and surface adhesion characteristics. For example, the
size and volume of the cavities may be selected to cause the
buoyant force of the gas enclosed in cavities 118 and 144, combined
with any buoyant force created by the density of the disk's
construction material, to be sufficient to maintain the disk afloat
on the body of liquid with its lower contours at a predetermined
depth below the surface of the body of liquid.
[0064] In some embodiments, the disk may have cavities that are
enclosed. In other embodiments, the disk may have cavities that are
enclosed and filled with foam and other solids that are generally
understood to include pockets of trapped gas. Further example
embodiments may include cavities that are enclosed and partially
filled with a fluid. In some examples, dense substances may be
added to the body to provide more stability to the disk while
positioned in a liquid body.
[0065] Liquid covering disks may hold differing quantities of gas
into the cavities. By adjusting the shape of the body and the
pattern of the ribs and sidewall, the size of the cavities is
modified and the liquid covering disks may be designed to float at
different depths, for example from about 10% to about 60% submerged
when deployed on a body of liquid. These modifications may also be
useful in adapting liquid covering disks for use in liquids of
varying densities.
[0066] FIGS. 9 and 10 illustrate details of an interlocking
mechanism 172 as used in an arrangement 142 of floating disks
disposed in edge to edge relationship. Interlocking mechanism 172
includes portions of substantially identical disks 100 with
curvatures on the sides of adjacent disks complementing and
overlapping each other.
[0067] FIGS. 9 and 10 show disks 100, here referred to as a first
disk 174 and a second disk 176, having interlocking elements 168
and 170, respectively. Interlocking element 168 is formed, for
example, by the concave portions 54, 60 and convex portions 56, 62
of sidewall 116, as described above, on disk 168. Complementary
interlocking element 170 is formed of similar concave portions 54,
60 and convex portions 56, 62 of a sidewall 116 of adjacent disk
176 which is oriented such that curvatures of each respective disk
complements the other.
[0068] The interlocking elements are symmetrically positioned over
the polygonal body and include protruding and recessing portions
formed by alternating concave and convex portions. The concave and
convex portions are designed to overlap with similar but inverse
interlocking elements of adjacent disks.
[0069] Liquid disk covering 100 is shown in FIGS. 1-10 with a
specific rib pattern and a hexagonal shape, but this shape is not
explicitly required in every embodiment of liquid disk coverings.
For example, the disk may take a wide variety of shapes, including,
but not limited to, polygonal, elliptical, or non-polygonal shapes.
Certain shape examples include interlocking elements, such as
complimentarily configured projections and recesses positioned
around the liquid covering disk's perimeter when viewed from
above.
[0070] Turning attention to FIGS. 11-19, additional examples of a
liquid covering disks are described. The liquid covering disks
described hereafter includes many similar or identical features to
liquid covering disk 100. Thus, for the sake of brevity, each
feature of liquid covering disks 200, 300, 400, and 500 will not be
redundantly explained. Rather, key distinctions between liquid
covering disks 200, 300, 400, 500 and liquid covering disk 100 will
be described in detail and the reader should reference the
discussion above for features substantially similar between the
liquid covering disks.
[0071] FIGS. 11 and 12 illustrate a second example of a liquid
covering disk. Liquid covering disk 200 has a body 220, a sidewall
216, a plurality of channels 226, and plurality of ribs 224. Body
220 is substantially triangular shaped. Sidewall 216 projects
around periphery 222 of body 220 similar to sidewall 116, described
above, and including interlocking mechanism 272 having sigmoidal
curvatures 252 and 258 along the sides of the substantially
triangular shaped body 220. Ribs 224 radiate from a center cavity
244.
[0072] FIGS. 13 and 14 illustrate a third example of a liquid
covering disk. Disk 300 has a body 320, a sidewall 316, a plurality
of cavities 318, a plurality of channels 326, and plurality of ribs
324. Body 320 is substantially rectangular shaped. Sidewall 316
projects around periphery 322 of body 320, similar to sidewall 116
described above.
[0073] Disk 300 includes interlocking mechanism 372 having
sigmoidal curvatures 352 and 358 along the sides of the
substantially rectangular shaped body 320. Ribs 324 radiate from a
center of disk 300. A central cavity may be formed at the center of
the disk in addition or alternatively to the periphery cavities
318.
[0074] FIGS. 15 and 16 illustrate a fourth example of a liquid
covering disk. Disk 400 has a body 420, a sidewall 416, a plurality
of channels 426, and a plurality of ribs 424. Sidewall 416 projects
around periphery 422 of body 420, similar to sidewall 116 described
above, including interlocking mechanism 472 having sigmoidal
curvatures 452 and 458 along the sides of the substantially
hexagonal shaped body 420. Ribs 424 radiate from a center of disk
400. The pattern of the ribs 424 of disk 400 is similar to the
pattern of ribs of disk 100 described above with reference to FIGS.
1-10.
[0075] A key difference between liquid covering disk 400 and liquid
covering disk 100 lies in the placement of six spherical chambers
492, 493, 494, 495, 496, 497 at the vertices of the hexagonal
shaped disk 400. Spherical chambers 492, 493, 494, 495, 496, 497
are positioned on, or form part of body 420, with symmetrical
halves being part of top surface 412 and bottom surface 414. In
some embodiments, spherical chambers may be filled with a gas or
any suitable material that assists with buoyancy of disk 400. In
further embodiments, spherical chamber may be filled with a dense
material and contribute to the stability of the disk on the surface
of the body of liquid.
[0076] FIGS. 17-19 show a fifth example of a liquid covering disk.
Disk 500 has a body 520, a sidewall 516, a plurality of periphery
vertices 518, a pair of central cavities 544, and a plurality of
ribs 524. Ribs 524 radiate from central cavities 544. The pattern
of ribs 524 is similar to the pattern of ribs of disk 100,
described above with reference to FIGS. 1-10.
[0077] A key difference between liquid covering disk 500 and liquid
covering disks described above is that vertices 518 are solid as
opposed to hollow cavities or chambers. In the present example,
vertices 518 are made from the same material as the other
components of disk 500. However, the material forming vertices may
be selected to impart desired buoyancy characteristics, such as a
variety of structural foams.
[0078] The profile of disk 500 is conducive to stacking disks on
top of each other during manufacturing and installation. Further,
the profile of disk 500 is conducive to the disks sliding past each
other when deploying the disks into a body of liquid.
[0079] Interlocking mechanism 572, having sigmoidal curvatures 552
and 558 along the sides of the substantially hexagonal shaped body
520, is substantially identical to interlocking mechanism 172
described above.
[0080] FIG. 20 shows a sixth example of a liquid covering disk,
namely, liquid covering disk 600. Liquid covering disk 600 is
substantially similar to liquid covering disks described above,
including to liquid covering disk 400, and includes a plurality of
channels 626. As the reader can see in FIG. 20, however, liquid
covering disk 600 cylindrical chambers or cavities 696 instead of
the spherical chambers included in liquid covering disk 400.
Cylindrical chambers 696 may be open or unplugged, as shown in FIG.
20, or closed off or plugged to trap a volume of air within the
cylindrical chamber. Plugging or unplugging the chambers will
change the buoyancy of the liquid covering disk, with disks having
plugged chambers being more buoyant.
[0081] The disks may be made of a material which resists chemicals,
UV, and abrasion from friction between adjacent disks. FIG. 4 shows
an example of a suitable material, an engineered micro-structure
180, which may be used for the body of the liquid covering
disk.
[0082] In some embodiments, liquid covering disk 100 and all of its
components are made of an ultraviolet stabilized material, such as
ultraviolet stabilized high density polyethylene (HDPE). The use of
ultraviolet stabilized high density polyethylene helps maintaining
the disk's material integrity during outdoor use over an extended
period of time. In liquid covering disk 100, for example, adding
carbon black to the polyethylene, for example a ratio of about 2%,
provides ultraviolet light protection and stabilization. In other
embodiments, ultraviolet light protection or stabilization may be
achieved by adding carbon black to the main constituent of the
disk, such as high density polyethylene or polypropylene, for
example in a ratio of about 2% to about 10%.
[0083] Examples of suitable constructions materials for disks
include expanded polypropylene, high density polyethylene, and an
expanded polypropylene using a blowing agent with UV stabilization.
An expanded HDPE using a blowing agent with UV stabilization may
also be used.
[0084] In some examples, an expanded polypropylene is used that was
created using a process that expands plastics while in the solid
state as opposed to conventional foaming techniques. Conventional
foaming techniques can inadequately control bubble size in the
plastic piece and require the use of potentially harmful foaming
agents. One suitable solid state plastic expansion process is the
Ad-air.RTM. process utilized by MicroGREEN Polymers, Inc.
[0085] Other suitable materials include an expanded polypropylene
using a glass bubble or an expanded HDPE using a glass bubble.
[0086] In some embodiments, the disk may be formed in one piece but
using a different materials and/or different color for the main
body and ribs. Other embodiments may be formed as an assembly of
parts, for example, a body provided with distinct ribs and a
sidewall. Further example embodiments may be made by joining a top
portion and a bottom portion to form disks as described above. In
many examples, many features at the top surface and the bottom
surface of the disks are identical, which simplifies
manufacturing.
[0087] Some example embodiments of liquid covering disks may be
made by injection molding techniques. For example, each half of a
liquid covering disk may be made by an injection molding technique.
The molded halves are then fused together using a hot plate, which
allows for a "perfect weld" when working with high-density
polyethylene. Other joining techniques can also be used, such as
ultrasonic welding, high frequency welding, friction welding, spin
welding, laser welding, hot gas welding, free-hand welding, and the
like.
[0088] Other embodiments of liquid covering disks may be made by
blow molding techniques. Blow molding may be desirable where high
speed fabrication is required. Using blow molding techniques, disks
can be made in one simple operation, removing the need for welding
two halves.
[0089] Other example embodiments of liquid covering disks may be
made by a combination of injection molding with air injection
technologies which reduce the original polymer density and improve
insulation properties.
[0090] Blow molding agents and glass spheres may be added to reduce
density and improve physical properties. Some rib patterns may
increase the disk's rigidity and thereby offset the increased
elasticity and softness resulting from the use of the blowing
agent. Because the ribs can be added separately from the body, a
different material can be used where no blowing additive has been
introduced. Adding the ribs separately can be done, for example, in
one step by using a two material injection molding method where two
types of thermoplastic resin are successively injected into the
mold by respectively different injection cylinders, thereby
producing a product with two types of resins and colors.
[0091] Liquid covering disks in this disclosure are often recited
using terms such as "top" and "bottom" to better illustrate disks'
relative vertical orientation. However, many liquid covering disks
according to this disclosure, specifically including liquid
covering disks 100, 200, 300, 400, and 500 may be turned over 180
degrees and be capable of substantially the same functionality.
This may be particularly useful in windy conditions, in which a
liquid covering disk may be flipped unintentionally.
[0092] The disclosure above encompasses multiple distinct
inventions with independent utility. While each of these inventions
has been disclosed in a particular form, the specific embodiments
disclosed and illustrated above are not to be considered in a
limiting sense as numerous variations are possible. The subject
matter of the inventions includes all novel and non-obvious
combinations and subcombinations of the various elements, features,
functions and/or properties disclosed above and inherent to those
skilled in the art pertaining to such inventions. Where the
disclosure or subsequently filed claims recite "a" element, "a
first" element, or any such equivalent term, the disclosure or
claims should be understood to incorporate one or more such
elements, neither requiring nor excluding two or more such
elements.
[0093] Applicant(s) reserves the right to submit claims directed to
combinations and subcombinations of the disclosed inventions that
are believed to be novel and non-obvious. Inventions embodied in
other combinations and subcombinations of features, functions,
elements and/or properties may be claimed through amendment of
those claims or presentation of new claims in the present
application or in a related application. Such amended or new
claims, whether they are directed to the same invention or a
different invention and whether they are different, broader,
narrower or equal in scope to the original claims, are to be
considered within the subject matter of the inventions described
herein.
* * * * *