U.S. patent application number 15/453220 was filed with the patent office on 2017-09-14 for self-adhering compressible containment berm devices.
The applicant listed for this patent is New Pig Corporation. Invention is credited to Anthony Scott Diminick, Dane R. Jackson, Daniel A. Silver, Justin L. Stroup.
Application Number | 20170260709 15/453220 |
Document ID | / |
Family ID | 58402137 |
Filed Date | 2017-09-14 |
United States Patent
Application |
20170260709 |
Kind Code |
A1 |
Stroup; Justin L. ; et
al. |
September 14, 2017 |
SELF-ADHERING COMPRESSIBLE CONTAINMENT BERM DEVICES
Abstract
Compressible fluid-impermeable berm devices that self-adhere to
surfaces such as ground, pavement and floors are disclosed. The
compressible containment berm devices include one or more
compressible containment wall sections formed from a flexible shell
and a compressible filler material. A pre-applied adhesive layer at
least partially covers the underside of each compressible
containment wall, and is used to adhere and seal the containment
wall to the containment surface. Corner joints may be used to
connect the compressible containment wall sections together to
thereby form the berm devices with a closed perimeter that contains
leaks and spills. The compressible fluid-permeable berm devices can
be easily removed or repositioned after use leaving little or no
adhesive residue.
Inventors: |
Stroup; Justin L.; (Altoona,
PA) ; Diminick; Anthony Scott; (Hollidaysburg,
PA) ; Jackson; Dane R.; (Port Matilda, PA) ;
Silver; Daniel A.; (State College, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
New Pig Corporation |
Tipton |
PA |
US |
|
|
Family ID: |
58402137 |
Appl. No.: |
15/453220 |
Filed: |
March 8, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62305668 |
Mar 9, 2016 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F16N 31/006 20130101;
B65D 90/24 20130101; E02D 31/002 20130101; E02B 7/00 20130101; E02B
7/005 20130101 |
International
Class: |
E02B 7/00 20060101
E02B007/00; B65D 90/24 20060101 B65D090/24 |
Claims
1. A self-adhering compressible containment berm device comprising
at least one compressible liquid impermeable containment wall
forming a liquid containment perimeter adhered to a containment
surface, wherein the compressible liquid impermeable containment
wall comprises: a flexible liquid impermeable shell comprising at
least one sidewall and a bottom shell layer; a compressible fill
material at least partially contained in the flexible liquid
impermeable shell; and a pre-applied adhesive layer covering at
least a portion of the bottom shell layer and contacting the
containment surface to thereby adhere and seal the compressible
containment wall to the containment surface.
2. The self-adhering compressible containment berm device of claim
1, wherein the pre-applied adhesive layer comprises a pressure
sensitive adhesive that is releasably adhered to the containment
surface.
3. The self-adhering compressible containment berm device of claim
2, wherein the pressure sensitive adhesive has a peel resistance of
from 5 to 800 ounces force.
4. The self-adhering compressible containment berm device of claim
1, wherein the pre-applied adhesive layer comprises a rubber-based
or acrylic-based polymer.
5. The self-adhering compressible containment berm device of claim
1, wherein the pre-applied adhesive layer has a thickness of from
0.0005 to 0.25 inch.
6. The self-adhering compressible containment berm device of claim
1, wherein the pre-applied adhesive layer comprises a pliable,
tacky material.
7. The self-adhering compressible containment berm device of claim
6, wherein the pliable, tacky material has a shore 00 durometer of
from 5 to 40.
8. The self-adhering compressible containment berm device of claim
6, wherein the pliable, tacky material comprise polyurethane.
9. The self-adhering compressible containment berm device of claim
6, wherein the pliable, tacky layer has a thickness of from 0.005
to 1 inch.
10. The self-adhering compressible containment berm device of claim
6, further comprising a low-density bonding layer between the
pliable, tacky pre-applied adhesive layer and the bottom shell
layer.
11. The self-adhering compressible containment berm device of claim
10, wherein the low-density bonding layer comprises a portion of
the pliable, tacky material impregnated therein.
12. The self-adhering compressible containment berm device of claim
11, wherein the pliable, tacky material is impregnated into the
low-density bonding layer a distance of from 1 to 50 percent of a
thickness of the low-density bonding layer.
13. The self-adhering compressible containment berm device of claim
10, wherein the low-density bonding layer comprises polyester.
14. The self-adhering compressible containment berm device of claim
10, wherein the low-density bonding layer has a thickness of from
0.01 to 0.25 inch.
15. The self-adhering compressible containment berm device of claim
1, further comprising at least one extended bottom strip extending
laterally from the bottom shell layer.
16. The self-adhering compressible containment berm device of claim
15, wherein the at least a portion of the adhesive layer is applied
to a bottom surface of the at least one extended bottom strip.
17. The self-adhering compressible containment berm device of claim
1, wherein the flexible liquid impermeable shell comprises fabric
reinforced polyvinyl chloride.
18. The self-adhering compressible containment berm device of claim
1, wherein the flexible liquid impermeable shell has a thickness of
from 0.001 to 0.5 inch.
19. The self-adhering compressible containment berm device of claim
1, wherein the compressible fill material comprises open-cell
polyurethane foam.
20. The self-adhering compressible containment berm device of claim
1, wherein the compressible fill material has an expanded height of
from 0.5 to 16 inches, and a compressed height of from 0.1 to 10
inches.
21. The self-adhering compressible containment berm device of claim
1, wherein the compressible containment wall has an expanded height
of from 1 to 15 inches, and a compressed height of from 0.15 to 10
inches.
22. The self-adhering compressible containment berm device of claim
1, wherein the compressible containment wall has an expanded height
and a compressed height, and the compressed height is from 10 to 70
percent of the expanded height.
23. The self-adhering compressible containment berm device of claim
1, wherein the pre-applied adhesive layer is covered by a release
film layer that is removable prior to contacting the pre-applied
adhesive layer with the contact surface.
24. The self-adhering compressible containment berm device of claim
1, wherein the berm device comprises a plurality of the
compressible containment walls connected together to form the
liquid containment perimeter.
25. The self-adhering compressible containment berm device of claim
1, wherein the contact surface comprises ground, pavement or a
floor.
26. A compressible liquid impermeable containment wall for use in
assembling a containment berm device on a containment surface, the
compressible liquid impermeable containment wall comprising: a
flexible liquid impermeable shell comprising at least one sidewall
and a bottom shell layer; a compressible fill material at least
partially contained in the flexible liquid impermeable shell; and a
pre-applied adhesive layer covering at least a portion of the
bottom shell layer structured and arranged to contact the
containment surface to thereby adhere and seal the compressible
containment wall to the containment surface.
27. The compressible liquid impermeable containment wall of claim
26, wherein the pre-applied adhesive layer comprises a pressure
sensitive adhesive.
28. The compressible liquid impermeable containment wall of claim
27, further comprising a release film layer covering the
pre-applied adhesive layer.
29. The compressible liquid impermeable containment wall of claim
26, wherein the pre-applied adhesive layer comprises a pliable,
tacky material having a Shore 00 durometer of from 5 to 40.
30. The compressible liquid impermeable containment wall of claim
29, further comprising a low-density bonding layer between the
pliable, tacky pre-applied adhesive layer and the bottom shell
layer.
31. A method of assembling a containment berm device on a
containment surface comprising connecting multiple compressible
liquid impermeable containment walls together to form a liquid
containment perimeter adhered to the containment surface, wherein
each compressible liquid impermeable containment wall comprises: a
flexible liquid impermeable shell comprising at least one sidewall
and a bottom shell layer; a compressible fill material at least
partially contained in the flexible liquid impermeable shell; and a
pre-applied adhesive layer covering at least a portion of the
bottom shell layer that contacts the containment surface to thereby
adhere and seal the compressible containment wall to the
containment surface.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 62/305,668 filed Mar. 9, 2016, which is
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to compressible containment
berm devices, and more particularly relates to drive-over berm
devices for containing leaks and spills that are self-adhering to
ground, pavement and floor surfaces, and which can be removed and
placed in other locations for reuse.
BACKGROUND INFORMATION
[0003] Berm devices have conventionally been used to contain leaks,
spills and other liquids. An example of a buildable berm system is
disclosed in U.S. Pat. No. 5,820,297, which is incorporated herein
by reference.
SUMMARY OF THE INVENTION
[0004] The present invention provides compressible
fluid-impermeable berm devices that self-adhere to surfaces such as
ground, pavement and floors, and which can be easily removed or
repositioned after use leaving little or no adhesive residue. The
compressible containment berm devices include one or more
compressible containment wall sections formed from a flexible shell
and a compressible filler material. A pre-applied adhesive layer at
least partially covers the underside of each compressible
containment wall, and is used to adhere and seal the containment
wall to the containment surface. Corner joints may be used to
connect the compressible containment wall sections together to
thereby form the berm devices with a closed perimeter that contains
leaks and spills.
[0005] An aspect of the present invention is to provide a
self-adhering compressible containment berm device comprising at
least one compressible liquid impermeable containment wall forming
a liquid containment perimeter adhered to a containment surface.
Each compressible liquid impermeable containment wall comprises a
flexible liquid impermeable shell comprising at least one sidewall
and a bottom shell layer, a compressible fill material at least
partially contained in the flexible liquid impermeable shell, and a
pre-applied adhesive layer covering at least a portion of the
bottom shell layer and contacting the containment surface to
thereby adhere and seal the compressible containment wall to the
containment surface.
[0006] Another aspect of the present invention is to provide a
compressible liquid impermeable containment wall for use in
assembling a containment berm device or a containment surface. The
compressible liquid impermeable containment wall comprises a
flexible liquid impermeable shell comprising at least one sidewall
and a bottom shell layer, a compressible fill material at least
partially contained in the flexible liquid impermeable shell, and a
pre-applied adhesive layer covering at least a portion of the
bottom shell layer structured and arranged to contact the
containment surface to thereby adhere and seal the compressible
containment wall to the containment surface.
[0007] A further aspect of the present invention is to provide a
method of assembling a containment berm device on a containment
surface. The method comprises connecting multiple compressible
liquid impermeable containment walls together to form a liquid
containment perimeter adhered to the containment surface, wherein
each compressible liquid impermeable containment wall comprises a
flexible liquid impermeable shell comprising at least one sidewall
and a bottom shell layer, a compressible fill material at least
partially contained in the flexible liquid impermeable shell, and a
pre-applied adhesive layer covering at least a portion of the
bottom shell layer that contacts the containment surface to thereby
adhere and seal the compressible containment wall to the
containment surface.
[0008] These and other aspects of the present invention will be
more apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is an isometric view of a self-adhering compressible
containment berm device installed on a containment surface in
accordance with an embodiment of the present invention.
[0010] FIG. 2 is a partially schematic cross-sectional view of a
self-adhering compressible containment wall for use in a berm
device in accordance with an embodiment of the present
invention.
[0011] FIG. 3 is a partially schematic cross-sectional view of the
self-adhering compressible containment wall of FIG. 2 prior to
installation, including a release film layer covering a pre-applied
adhesive layer on the bottom of the containment wall in accordance
with an embodiment of the present invention.
[0012] FIG. 4 is a partially schematic cross-sectional view of a
self-adhering compressible containment wall for use in a berm
device in accordance with another embodiment of the present
invention.
[0013] FIG. 5 is a partially schematic cross-sectional view of a
self-adhering compressible containment wall for use in a berm
device in accordance with a further embodiment of the present
invention.
[0014] FIG. 6 is a partially schematic cross-sectional view of a
self-adhering compressible containment wall for use in a berm
device in accordance with another embodiment of the present
invention.
DETAILED DESCRIPTION
[0015] FIG. 1 shows a berm device 10 in accordance with an
embodiment of the present invention. The berm device 10 includes
multiple compressible liquid impermeable containment walls 16
connected together to form a liquid containment area in which a
spill 14, leak, or other liquid is prevented from escaping. The
compressible containment walls 16 are connected by corner joints 18
to thereby form a closed perimeter of the berm device 10. The
compressible containment walls 16 and corner joints 18 are directly
mounted on a containment surface 20 such as the ground, pavement,
floor or the like. Connecting straps 22 may be used to connect the
compressible containment walls 16 and the corner joints 18.
[0016] As shown in FIG. 1, the berm device 10 can be formed in the
shape of a rectangle surrounding the spill 14. In this arrangement,
the berm device 10 includes four sections of compressible
containment walls 16 which define the four sides of the rectangular
berm device 10. The corner joints 18 may be provided in right-angle
configurations as shown. Alternatively, the corner joints 18 can be
provided in other configurations to provide a triangular-shaped
berm, a pentagonal-shaped berm, or other multiple-sided berm. The
corner joints 18 can also be configured to provide a berm device 10
in the shape of a parallelogram, octagon or other geometric
configuration.
[0017] The berm device 10 has a liquid containment height
corresponding to the expanded height of the compressible
containment walls 16. In certain embodiments, the compressible
containment walls have a typical expanded height of from 0.5 to 18
inches, for example, from 1 to 15 inches, or from 2 to 12 inches.
When the compressible containment walls 16 are compressed, e.g.,
when a vehicle passes over the containment wall(s), the compressed
height of the compressible containment walls 16 may typically range
from 0.1 to 12 inches, for example, from 0.15 to 10 inches, or from
0.2 to 8 inches. In certain embodiments, the compressed height is
from 5 or 10 to 70 percent of the expanded height of the
compressible containment wall 16, for example, from 15 or 20 to 60
percent, or from 22 or 25 to 50 percent.
[0018] FIGS. 2-6 are cross-sectional views of compressible
containment walls 16 in accordance with embodiments of the present
invention. In the embodiment shown in FIGS. 2 and 3, the
compressible containment wall 16 includes a flexible shell 30
having a bottom shell layer 32, sidewalls 33 and a top shell layer
34. A compressible filling material 36 is provided inside the
flexible shell 30. The flexible shell 30 is made of at least one
layer of a liquid impermeable, durable material. Although the
flexible shell 30 is shown as a continuous layer of material in
FIGS. 2 and 3, it has to be understood that the flexible shell 30
may be made from multiple panels of flexible, liquid impermeable
material that are connected together by any suitable means
including adhesives, welding, sewing, and the like.
[0019] As further shown in FIGS. 2 and 3, a pre-applied adhesive
layer 40 is located on the exterior surface of the bottom shell
layer 32. As used herein, the term "pre-applied adhesive" means an
adhesive layer that is applied to the bottom shell layer 32 during
an initial manufacturing or assembly process, rather than being
applied separately at an installation site. As more fully described
below, the pre-applied adhesive layer 40 helps to secure and seal
the bottom shell layer 32 to the containment surface 20 to thereby
reduce or eliminate the flow of spills, leaks or other liquids
underneath the compressible containment walls 16.
[0020] As shown in FIG. 3, during manufacture of the compressible
containment walls 16, a release liner or film 44 may be applied to
the bottom surface of the adhesive layer 40 in order to cover the
adhesive layer until the compressible containment walls 16 is
installed at a containment site. The release liner 44 may comprise
a thin flexible sheet of material including polymers such as
polypropylene, polyethylene and/or polyester, wax and/or silicone
coated paper, or the like.
[0021] In certain embodiments, the thickness of the bottom shell
layer 32, sidewalls 33 and top shell layer 34 of the flexible shell
30 may typically range from 0.001 to 0.5 inch, for example, from
0.005 to 0.2 inch, or from 0.01 to 0.1 inch. In a particular
embodiment, the thickness may be about 0.025 inch.
[0022] The flexible shell 30 may be made from any suitable liquid
impermeable material such as vinyl, polyurethane, polyols, extruded
plastic materials and the like. If made from vinyl or other similar
polymeric materials, the flexible shell 30 may typically have a
basis weight of from 10 to 50 oz/yd.sup.2, for example, from 15 to
30 oz/yd.sup.2, or about 18 oz/yd.sup.2. In certain embodiments,
the flexible polymeric sheet material of the flexible shell 30 may
be reinforced with at least one layer of reinforcing material, such
as scrim cloth, woven fabric, non-woven fabric, fibers, or the
like.
[0023] The compressible fill material 36 may comprise a resilient
highly compressible material such as an open-cell foam or
closed-cell foam, for example, synthetic rubber, polyolefin or
polyurethane open cell foam. The compressible material allows the
berm to temporarily collapse as equipment is wheeled into the
containment area and to return to its original height once the
compression force is removed. Open-celled foam is advantages over
closed-cell foam since it is easier to collapse. Alternately, other
resilient compressible materials can be used, such as polymer or
metal springs, synthetic fibers or an air bladder. However, any
suitable flexible, pliable material can be used as the filler
including cellulose, and synthetic or mineral materials. The
compressible fill material 36 may have a shape retention property
such that, when compression is released, the compressible fill
material returns to generally its original shape. In certain
embodiments, the compressible fill material 36 may have an expanded
height of from 0.5 to 16 inches, and a compressed height of from
0.1 to 8 or 10 inches.
[0024] FIG. 4 illustrates a compressible containment wall 116 in
accordance with another embodiment of the present invention. This
embodiment is similar to that shown in FIGS. 2 and 3, with the
exception that the adhesive layer does not form a continuous sheet
across the entire bottom surface of the bottom shell layer 32, but
rather comprises a central adhesive strip 40a, and two separate
side adhesive strips 40b and 40c.
[0025] FIG. 5 illustrates a compressible containment wall 216 in
accordance another embodiment of the present invention. In this
embodiment, the bottom shell layer 32 is extended laterally to form
extended bottom strips 32a and 32b on either side of the
compressible containment wall 216. In this embodiment, an extended
adhesive layer 40d is provided across the entire bottom surface
area of the bottom shell layer 32, including the extended bottom
strips 32a in and 32b. Alternatively, the adhesive layer may be
provided as discontinuous strips, similar to those shown in the
embodiment of FIG. 4.
[0026] In certain embodiments the pre-applied adhesive layer 40 may
be a pressure sensitive adhesive (PSA). The adhesive, for example,
may be natural rubber-based, synthetic rubber-based, acrylic-based,
or the like. The pre-applied adhesive layer 40 may comprise a
cross-linked type PSA that has good chemical resistance. The PSA
may be applied directly onto the bottom surface of the bottom shell
layer 32, or may be applied to a carrier film (not shown) that is
then attached to the bottom shell layer 32. Suitable carrier films
may be made of polypropylene, polyethylene, polyester, nylon, or
the like.
[0027] The PSA may have a peel value of from 5 to 800 ounces force,
for example from 40 to 225 ounces, wherein the peel value is
measured per the Pressure Sensitive Tape Council test method #PSTC
101. Alternatively the PSA can be a permanent type with a peel
force of greater than 225 ounces for applications that do not
require relocation of the berm.
[0028] In certain embodiments, the thickness of the pre-applied
adhesive layer 40 may typically range from 0.0005 to 0.25 inch, for
example, from 0.0008 to 0.15 inch, or from 0.001 to 0.1 inch. In a
particular embodiment, the thickness may be about 0.0015 inch.
[0029] FIG. 6 illustrates a compressible containment wall 316 in
accordance with another embodiment of the present invention. In
this embodiment, the lower most layer of the compressible
containment wall 316 comprises an adhesive sealing layer 50 made of
a pliable, tacky material, as more fully described below. A
low-density bonding layer 60 is provided between the bottom shell
layer 32 and the pliable, tacky adhesive sealing layer 50. As used
herein, the term "low-density bonding layer" means a deep pile or
lofty material having at least one surface comprising entanglement
fibers that extend from the layer to provide additional surface
area and attachment sites for the adjacent bottom shell layer 32
and/or adhesive sealing layer 50. In certain embodiments, a portion
of the adhesive sealing layer 50 may be at least partially
impregnated into the low-density, bonding layer 60. For example,
the pliable, tacky material of the adhesive sealing layer 50 may be
embedded into the low-density bonding layers a distance of from 1
to 50 or 75 percent of the thickness of the low-density bonding
layer 60, for example, from 3 or 5 to 30 or 40 percent. As more
fully described below, the low-density bonding layer 60 helps to
secure the adhesive sealing layer 50 to the bottom shell layer 32
during removal and repositioning of the compressible containment
walls 16.
[0030] In certain embodiments, the thickness of the pliable, tacky
adhesive sealing layer 50 may typically range from 0.01 to 2 inch,
for example, from 0.05 to 0.5 inch, or from 0.1 to 0.25 inch. In a
particular embodiment, the thickness may be about 0.125 inch.
[0031] In certain embodiments, the thickness of the low-density
bonding layer 60 may typically range from 0.01 to 0.1 inch, for
example, from 0.015 to 0.08 inch, or from 0.03 to 0.06 inch. In a
particular embodiment, the thickness may be about 0.04 inch.
[0032] The adhesive sealing layer 50 is a pliable, tacky layer that
is flexible and tacky in order to conform to irregularities or
roughness in the containment surface 20 and adheres to the surface
to thereby provide a seal which reduces or eliminates the flow of
spilled liquids. The adhesive sealing layer 50 may comprise
materials such as urethane, polyurethane, polyvinyl chloride and/or
silicone. The adhesive sealing layer 50 may have a hardness, as
measured by a durometer, at least 10 percent less than the hardness
of the bottom shell layer 32. In one embodiment, the adhesive
sealing layer 50 serves to keep the berm device 10 in its desired
location due to its tacky surface. The adhesive sealing layer 50
can comprise an inherently tacky material or can have a standard
tackifier applied to any exposed surface. The adhesive sealing
layer 50 has a tackiness such that it adheres to the containment
surface 20. In one embodiment, the adhesive sealing layer 50 has
sufficient tackiness such that the sealing layer adheres when
pressed against a vertical wall. The tackiness of the adhesive
sealing layer 50 may also be measured by other test methods known
to those skilled in the art, such as rolling ball, peel and probe
tests.
[0033] In certain embodiments, the adhesive layer 50 may consist of
a tacky soft polyurethane with maximum durometer of 40 (Shore 00
scale), for example, from 5 to 40, or from 10 to 20, and may have a
minimum coating thickness of 0.005 inches up to 1 inch, for
example, from 0.01 to 0.75 inch, or from 0.05 or 0.1 to 0.5 inch.
The low durometer of the soft tacky polyurethane allows it to flow
into and fill the cracks and crevices of the surface it is applied
to. This is particularly important on rough surfaces, such as
macadam, for forming a fluid tight seal between the berm device and
the rough containment surface. Thicker coating levels and lower
durometer polyurethanes may be preferred since thicker coatings
have more polyurethane available to flow into the cracks and
crevices while lower durometer polyurethanes flow easily into the
voids.
[0034] Since tacky soft urethanes may not adhere strongly to
polymer materials used for the bottom shell layer shell 32, the
low-density bonding layer 60 may be used to achieve a satisfactory
bond. Examples of such low-density bonding layers are described in
U.S. Pat. No. 8,117,686, which is incorporated herein by
reference.
[0035] In one embodiment, a mixture of various polyurethanes can be
used to make the adhesive sealing layer 50. A typical polyurethane
mixture comprises from about 50 to about 90 weight percent polyol,
and from about 10 to about 50 weight percent isocyanate prepolymer.
The liquid polyurethane is mixed and cured in a manner which gives
it a moderate degree of inherent tackiness to all exposed surfaces
of the polyurethane material. The molding and curing process
creates a substantially smooth exposed surface, which may contain
minor undulations. The polyurethane material is soft, yet
resilient, and thus may be easily severed by a user with a knife.
Surfaces of the polyurethane material which are exposed when a
portion of it is severed can also be inherently tacky. While a
process is described above for manufacturing polyurethane having an
inherent tackiness, one skilled in the art will appreciate that
other materials, such as, for example, vinyls, silicones and
rubbers, may also be modified to have an inherent tackiness.
[0036] The low-density bonding layer 60 is provided between the
bottom shell layer 32 and the adhesive sealing layer 50. The
low-density bonding layer 60 has a density that is typically less
than 0.26 ounces per cubic inch, preferably from 0.02 to 0.1 ounces
per cubic inch. The low-density bonding layer 60 typically has a
weight per area of less than 20 ounces per square yard, for
example, from 1 to 10 ounces per square yard. The low-density
bonding layer 20 provides secure and permanent attachment between
the bottom shell layer 32 and the adhesive sealing layer 50, while
maintaining separation between the materials of the adjacent layers
32 and 50. In contrast with an open mesh or permeable screen
material that would allow the layers 32 and 50 to contact each
other, the low-density bonding layer 60 maintains separation
between the layers 32 and 50.
[0037] The low-density bonding layer 60 may be non-woven and may
comprise entanglement fibers made of polyester, polypropylene,
poly(ethylene propylene), polyvinylchloride, fiberglass, nylon,
cotton, urethane and the like. In one embodiment, the low-density
bonding layer 60 comprises a base or backing layer from which the
entanglement fibers extend on one or both sides of the backing
layer. For example, the low-density bonding layer 60 may comprise
fleece made of polyester and having a thickness of about 0.04 inch.
The fleece assists in the adhesion of the bottom shell layer 32 and
the adhesive sealing layer 50. The low-density bonding layer 60 may
also provide puncture resistance.
[0038] The low-density bonding layer 60 may be adhered to the
underside of the bottom shell layer 32 by any suitable means such
as adhesives, co-extrusion, thermal welding, sonic welding, RF
welding, or the like. For example, an adhesive such as a pressure
sensitive adhesive may be applied directly to the bottom shell
layer 32 without the need for an intermediate layer. However, the
pressure sensitive adhesive may be the pre-applied to a carrier
film (not shown), which is bonded to the bottom shell layer 32,
i.e., the carrier film may be used as an intermediate layer. The
carrier film may be polyethylene, polypropylene, nylon, polyester
or the like, for example, polyethylene having a thickness of from
0.00075 to 0.003 inches (0.75 to 3 mils). The carrier layer may be
bonded to the bottom shell layer 32 with a polyolefin-based hot
melt adhesive, by thermal, sonic or RF welding, or the like.
[0039] While the compressible containment walls 16, 116, 216 and
316 are illustrated as having rectangular cross-sections in the
figures, any other suitable cross-sectional shape may be used, such
as square, triangular, trapezoidal, semi-circular or the like.
[0040] The berm device 10 may come in various lengths and shapes,
such as straight sections, curved sections, 45.degree. and
90.degree. corner sections, termination ends and freely formable
sections, all of which can be fitted and sealed together to form
any size or shape fluid containment area that is required. The
freely formable sections are laterally flexible enough to permit
forming curvilinear shapes as the berm is installed.
[0041] The self-adhering capability of the berm device 10
eliminates the need to apply sealing adhesive to the berm before
installation and eliminates the need for mechanical fasteners. This
results in time savings during installation and a savings on labor
to install.
[0042] Because of the pliability of the compressible containment
walls, the berm device of the present invention can be provided in
a kit that includes at least one coil of compressible containment
walls, at least four right-angled corner joints, and a sheet of
vinyl strapping. In use, the coils of compressible containment
walls can be cut with a sharp object such as scissors or a utility
knife to a desired length. The corner joints may be set against the
cut compressible containment walls to allow for a custom fit of a
specific containment area. Once the proper configuration of berm
device is achieved, the compressible containment wall sections and
corner joints are pressed into place to make proper contact. The
strapping material can be cut into desired length to cover any
areas that were exposed during cutting of the ends of the
compressible containment walls. The strapping material may be
applied to the compressible containment walls and corner joints by
means of standard strapping glue. The strapping material may also
be integrally formed on the end of the compressible containment
wall sections, for example, as an overhanging length or flap of the
flexible sidewall material and/or top shell layer of the flexible
shell. The flap can overlay adjacent compressible containment wall
sections and be joined by an appropriate adhesive.
[0043] One of the advantages of the present berm device is that the
compressible containment wall sections can be cut from a longer
strip of material at the work site in order to construct a berm
having the desired dimensions. The ability to cut the compressible
containment wall sections to size affords an added degree of
flexibility, which allows the berm devices of the present invention
to be used for any number of configurations.
[0044] Whereas particular embodiments of this invention have been
described above for purposes of illustration, it will be evident to
those skilled in the art that numerous variations of the details of
the present invention may be made without departing from the
invention as defined in the appended claims.
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