Inlet Filter Mat

Abstract

An above grate inlet filter system for erosion and sediment control includes a filter base substrate having an upper and lower surface, a pair of sides and a front and a rear end with plurality of drain holes therethrough from the upper surface to the lower surface; grate coupling elements attached to the filter base substrate configured to attach the system to a filter grate; a plurality of fiber filter components attached to the upper surface of the filter base substrate and aligned with the drain holes, whereby fluid can flow through a fiber filter component and through an aligned drain hole in the filter base substrate, and wherein the plurality of fiber filter components form a meandering flow channel extending along the upper surface of filter base substrate between the sides of the filter base substrate wherein fluid can flow from the sides along the flow channel.

Description

RELATED APPLICATIONS

[0001] This application claims the benefit of provisional patent application Ser. No. 63 / 744,143 filed Jan. 10, 2025, which application is incorporated herein by reference. This application relates to improvement over an earlier design set forth in U.S. patent application Ser. No. 15 / 449,576, which published as U.S. Publication 2017-0254063 and issued as U.S. Pat. No. 10,167,620 which is incorporated herein by reference.BACKGROUND INFORMATION1. Field of the Invention

[0002] The present invention relates to erosion and sediment control for inlet grates, and more particularly to above grate inlet filter mats.2. Background Information

[0003] The present invention represents the next generation inlet filter mat based generally upon design sold under the trademark BLACKHAWK™ by MKB Company and described in in U.S. patent application Ser. No. 15 / 449,576, which published as U.S. Publication 2017-0254063 and issued as U.S. Pat. No. 10,167,620 which is incorporated herein by reference. The present inventor, Mr. Zock, was a co-inventor of this earlier inlet filter mat, and as of the time of the filing of this application, asserts that this still represents one of the best performing technologies in this field, yet there is room for improvement.

[0004] The background of the '620 patent is relevant for the present invention which also relates to erosion and sediment control filtration systems reducing the amount of silt, sedimentation and debris in water entering storm drains via the grate inlets.

[0005] In response to tighter guidelines imposed by the federal Environmental Protection Agency (EPA) under the Clean Water Act, additional regulatory attention is being focused on controlling silt and sediment found in storm, construction site and other sources of water runoff. Various federal and state agencies have issued mandates and developed guidelines regarding the prevention of non-point source pollution. These mandates affect water runoff from storms, construction sites, and other sources. Such laws and regulations have a significant impact on not only how runoff water may be channeled and diverted, but also on, for example, the ways that contractors can dispose of excess or unwanted water from constructions sites. With respect to construction sites, the EPA has a goal of having developers prevent eighty percent of general contaminants, such as unwanted, site-generated sediment, from entering inlet drains.

[0006] One conventional type of inlet drain protection is referenced as a filter bag or “silt sack”, which is generally shown in the Pennsylvania Department of Environmental Protection (Pa-DEP) manual. Representative examples of the these known drain filter bags, silt sacks or drain inserts is found in U.S. Pat. Nos. 5,575,925, 6,086,758, 6,093,314, 6,059,964, 6,045,691, 7,201,843, and 8,017,005. The deficiencies of below grate filters is detailed further in the '620 patent.

[0007] The '620 patent notes that others have developed other above grate filter systems, (also may be references as above grade—but above grate is more accurate) such as disclosed in U.S. Pat. No. 7,481,921 and U.S. Patent Publication 2008-0296211, which are incorporated herein by reference. The '921 patent and '211 publication each teach the use of a randomly aligned coir fiber filter member formed preferably of two generally inch high filtering segments secured to the grate via a plurality of zip-tie or cable-tie members.

[0008] U.S. Pat. No. 8,043,498, which is incorporated herein by reference, discloses an inlet filter mat having: a first, top layer comprising a generally horizontal surface having a plurality of holes formed therein, and a plurality of substantially vertical projections emanating from said horizontal surface, wherein said holes allow passage of water vertically through said first layer, and wherein said vertical projections extend a height sufficient to prevent passage of debris across said top layer while permitting passage of water over said horizontal surface, thereby preventing the drain inlet from being clogged; a center layer composed of a screen or mesh having apertures of approximately one-eighth inch or greater in diameter; and a third layer composed of a felt material having hydrophobic properties; wherein said first, second and third layers are fastened together and act as a single barrier that is coextensively laid over said grate.

[0009] U.S. Pat. Nos. 8,051,568 and 8,216,453 disclose an inlet filter mat which includes an expanded metal screen sized to fit over the storm water grate; a U-shaped edge trim having a plurality of barbs thereon; a high flow monofilament fabric filter sized to fit over the expanded metal screen and being attached to said expanded metal screen; and a plurality of bolts attaching the expanded metal screen and monofilament fabric filter to said storm water grate.

[0010] The '620 patent co-invented by the inventor of the present application also discloses several above grate filter mats, the most commercially viable one is sold under the trademark BLACKHAWK by MKB Company.

[0011] Despite the advantages of the BLACKHAWK inlet filter mat there exists a need for better devices, systems and methods for filtering sediment from water entering storm drains, specifically those which provide ease of installation; can be easily cleaned or changed, even during periodic flooding; prevent unwanted back-up of excess water; filter nearly all or all of the water that comes through the inlet; and are cost effective.SUMMARY OF THE INVENTION

[0012] The present invention provides an inlet filter mat for filtering sediment from water entering storm drains with ease of installation; and which can be easily cleaned or changed, even during periodic flooding; and which prevents unwanted back-up of excess water; and which filters nearly all of the water that comes through the inlet (e.g., except for high flow events operating in bypass); and which is cost effective.

[0013] One aspect of the present invention provides an above grate inlet filter system for erosion and sediment control includes a filter base substrate having an upper and lower surface, a pair of sides and a front and a rear end with plurality of drain holes therethrough from the upper surface to the lower surface; grate coupling elements attached to the filter base substrate configured to attach the system to a filter grate; a plurality of fiber filter components attached to the upper surface of the filter base substrate and aligned with the drain holes, whereby fluid can flow through a fiber filter component and through an aligned drain hole in the filter base substrate, and wherein the plurality of fiber filter components form a meandering flow channel extending along the upper surface of filter base substrate between the sides of the filter base substrate wherein fluid can flow from the sides along the flow channel.

[0014] These and other advantages of the present invention are described below in connection with the attached drawings in which like reference numbers represent like elements throughout.BRIEF DESCRIPTION OF THE FIGURES

[0015] FIG. 1 is a schematic top plan view of an above grate inlet filter system for erosion and sediment control according to one embodiment of the present invention.

[0016] FIG. 2 is a schematic bottom plan view of the above grate inlet filter system for erosion and sediment control according to FIG. 1.

[0017] FIGS. 3A and 3B schematically show the installation of the above grate inlet filter system for erosion and sediment control according to FIG. 1 on a Type C inlet (sidewall).

[0018] FIGS. 3C and 3D schematically show the installation of the above grate inlet filter system for erosion and sediment control according to FIG. 1 on a Type M inlet.

[0019] FIG. 4 schematically shows the folding and shipping of the above grate inlet filter system for erosion and sediment control according to FIG. 1.

[0020] FIG. 5 schematically shows the modular nature and sizes available in the above grate inlet filter system for erosion and sediment control according to FIG. 1.

[0021] FIG. 6 is a schematic bottom plan view of a modified above grate inlet filter system for erosion and sediment control according to FIG. 1.

[0022] FIG. 7 is a schematic top plan view of an above grate inlet filter system for erosion and sediment control according to FIG. 1 further including a channel plug member.DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] This invention is directed to an above grate, or above grade, based inlet filter system 10 for erosion and sediment control also called an inlet filter mat 10. An above grate inlet filter system 10 for erosion and sediment control includes a filter base substrate 20 having an upper and lower surface, a pair of sides and a front and a rear end with plurality of openings 80 and 50 (or drain holes 80 and bypass 50) therethrough from the upper surface to the lower surface; grate coupling elements (magnets 60 and 70) attached to the filter base substrate 20 configured to attach the system 10 to a filter grate 5 or 7; a plurality of fiber filter components 30 attached to the upper surface of the filter base substrate 20 and aligned with the drain holes 80 (and bypass 50), whereby fluid can flow through a fiber filter component 30 and through an aligned drain hole (80) in the filter base substrate 20, and wherein the plurality of fiber filter components 30 form a meandering flow channel 40 extending along the upper surface of filter base substrate 20 between the sides of the filter base substrate 20 wherein fluid can flow from the sides along the flow channel 40.

[0024] The present invention is a composite inlet filter mat 10 including a filter base substrate 20 (or just substrate 20) that preferably is a 0.4″ thick air-laid polyester layer formed from recycled carpet fiber and plastic bottles. Alternative material for the substrate 20 is a natural fiber or combination of natural and synthetic. The substrate 20 is the base upon which the filter mat 10 is assembled.

[0025] On top of the substrate 20 is plurality of fiber filter components 30 such as coir fiber filter elements 30 formed of 5.75 OSF random fiber orientation coir matting about 2″ high and held together with a water-resistant latex binder. All coir components 30 are designed to be made out of 8-inch-wide coir “raw material” strips that improves manufacturing and allows for a modular design. Further this leads to a smaller inventory at all assembly factories for an infinite variety of mat designs such as shown in FIG. 5.

[0026] A key aspect of the invention is that the coir fiber elements form a meander flow channel 40 thru center of mat 10. The channel 40 is considered to “meander” herein because it is intentionally non-linear creating increased surface area of the elements 30 facing the channel 40 and the fluid therein. The meander flow channel 40 allows much more filter material 30 to contact dirty water under low- to-moderate flow conditions than relying upon the mat perimeter (like 3× more before top breach).

[0027] The mat 10 has a central overflow or bypass opening 50 for high flow conditions with the bypass opening 50 being through both a central coir element 30 and the substrate 20.

[0028] The substrate 20 is held to the grate 5 or 7 through a magnetic system comprised of three neodymium magnets 60 coupled to the substrate 20 and lower strength flexible strip magnets 70 coupled to the substrate 20 about the perimeter of the mat 10. Each of the three neodymium magnets 60 is a permanent magnet made from an alloy of neodymium, iron, and boron and are the most widely used type of rare-earth magnet. The magnets 60 include a mesh support on the substrate to accommodate the strength of the magnets 60 (to avoid ripping the mat 10 apart when removing or adjusting the mat 10).

[0029] The substrate 20 includes openings 80 or drain holes 80 (and bypass opening or drain hole 50) aligned with the coir elements 30. In low flow operation the flow is filtered through coir elements 30 to a drain hole opening 80. In high flow operation the flow is still filtered through coir elements 30 to an opening 80 but excess fluid flows in bypass mode through drain hole opening 50. The high flow condition occurs when water pools over the height of the central coir element 30

[0030] The substrate 20 includes an extension or flap 22 which can be bent vertically for placement against a type-C inlet 5 as shown in FIGS. 3A-B with no field modification of the mat. Openings (not shown) may be made in the substrate in the flap 22 to provide an unobstructed bypass side flow path, if desired but that is only for the type C inlet 5. As shown in FIGS. 3C-D the same design works equally well with the type M inlet 7.

[0031] The mat 10 has two “designed in” fold zones 90 that allows for efficient folding and shipping of just one mat in a relatively small box 100 as shown in FIG. 4.

[0032] The modular aspects of the current design can be shown in the various sized embodiments illustrated in FIG. 5. It each of the designs shown in FIG. 5 the substrate 20 may for formed or die cut for the outer perimeter and drain holes 80 and bypass opening 50 as shown in FIG. 2 or 6 and strips of coir elements 30 added to complete the filtering elements of the mat 10. The magnets 60 and 70 are attached to complete the assembly. The modular design allows for a multitude of sizes to be constructed. As shown in some embodiments two central overflows or bypass openings 50 are used and the overflow may align with a larger opening 80 in the substrate 20.

[0033] A further modification is that the meander path 40 may be easily plugged at one side opening with a matching (beveled) coir element 110, where the flow is to be stopped within the mat 20 and / or it flows from only one side. The plug coir element 110 is set in place and can be on either side.

[0034] The mat 10 of the invention is 40% lighter when dry than the closest commercial product of the same size (namely the current 2024 BLACKHAWK inlet filter mat) and is 20% physically stronger (because of substrate 20). The matt 10 of the invention is 20% stronger magnetic holding system because of 2 types of magnets 60 and 70. Further the mat 10 of the invention is 20% heavier when wet than the closest commercial product of the same size as the substrate 20 acts as water-soaked wicking sponge which seals mat 10 to inlet perimeter and keeps the whole mat 10 in place on the metal grate. The mat 10 of the invention exhibits at least 20% overall higher flow and >3× higher flow before top breaching (bypass mode) than the closest commercial product of the same size. The mat 10 of the invention has a 20% higher blinding resistance (based on comparing geometries) than the closest commercial product of the same size. As noted above, the modular design dramatically reduces raw materials inventory or the need for dye cutting.

[0035] While the invention has been shown in several particular embodiments it should be clear that various modifications may be made to the present invention without departing from the spirit and scope thereof. For example, the mat 10 may further include material for hydrocarbon capture in substrate 20. The scope of the present invention is defined by the appended claims and equivalents thereto.

Examples

Embodiment Construction

[0023]This invention is directed to an above grate, or above grade, based inlet filter system 10 for erosion and sediment control also called an inlet filter mat 10. An above grate inlet filter system 10 for erosion and sediment control includes a filter base substrate 20 having an upper and lower surface, a pair of sides and a front and a rear end with plurality of openings 80 and 50 (or drain holes 80 and bypass 50) therethrough from the upper surface to the lower surface; grate coupling elements (magnets 60 and 70) attached to the filter base substrate 20 configured to attach the system 10 to a filter grate 5 or 7; a plurality of fiber filter components 30 attached to the upper surface of the filter base substrate 20 and aligned with the drain holes 80 (and bypass 50), whereby fluid can flow through a fiber filter component 30 and through an aligned drain hole (80) in the filter base substrate 20, and wherein the plurality of fiber filter components 30 form a meandering flow chan...

RELATED APPLICATIONS

[0001] This application claims the benefit of provisional patent application Ser. No. 63 / 744,143 filed Jan. 10, 2025, which application is incorporated herein by reference. This application relates to improvement over an earlier design set forth in U.S. patent application Ser. No. 15 / 449,576, which published as U.S. Publication 2017-0254063 and issued as U.S. Pat. No. 10,167,620 which is incorporated herein by reference.BACKGROUND INFORMATION1. Field of the Invention

[0002] The present invention relates to erosion and sediment control for inlet grates, and more particularly to above grate inlet filter mats.2. Background Information

[0003] The present invention represents the next generation inlet filter mat based generally upon design sold under the trademark BLACKHAWK™ by MKB Company and described in in U.S. patent application Ser. No. 15 / 449,576, which published as U.S. Publication 2017-0254063 and issued as U.S. Pat. No. 10,167,620 which is incorporated herein by reference. The present inventor, Mr. Zock, was a co-inventor of this earlier inlet filter mat, and as of the time of the filing of this application, asserts that this still represents one of the best performing technologies in this field, yet there is room for improvement.

[0004] The background of the '620 patent is relevant for the present invention which also relates to erosion and sediment control filtration systems reducing the amount of silt, sedimentation and debris in water entering storm drains via the grate inlets.

[0005] In response to tighter guidelines imposed by the federal Environmental Protection Agency (EPA) under the Clean Water Act, additional regulatory attention is being focused on controlling silt and sediment found in storm, construction site and other sources of water runoff. Various federal and state agencies have issued mandates and developed guidelines regarding the prevention of non-point source pollution. These mandates affect water runoff from storms, construction sites, and other sources. Such laws and regulations have a significant impact on not only how runoff water may be channeled and diverted, but also on, for example, the ways that contractors can dispose of excess or unwanted water from constructions sites. With respect to construction sites, the EPA has a goal of having developers prevent eighty percent of general contaminants, such as unwanted, site-generated sediment, from entering inlet drains.

[0006] One conventional type of inlet drain protection is referenced as a filter bag or “silt sack”, which is generally shown in the Pennsylvania Department of Environmental Protection (Pa-DEP) manual. Representative examples of the these known drain filter bags, silt sacks or drain inserts is found in U.S. Pat. Nos. 5,575,925, 6,086,758, 6,093,314, 6,059,964, 6,045,691, 7,201,843, and 8,017,005. The deficiencies of below grate filters is detailed further in the '620 patent.

[0007] The '620 patent notes that others have developed other above grate filter systems, (also may be references as above grade—but above grate is more accurate) such as disclosed in U.S. Pat. No. 7,481,921 and U.S. Patent Publication 2008-0296211, which are incorporated herein by reference. The '921 patent and '211 publication each teach the use of a randomly aligned coir fiber filter member formed preferably of two generally inch high filtering segments secured to the grate via a plurality of zip-tie or cable-tie members.

[0008] U.S. Pat. No. 8,043,498, which is incorporated herein by reference, discloses an inlet filter mat having: a first, top layer comprising a generally horizontal surface having a plurality of holes formed therein, and a plurality of substantially vertical projections emanating from said horizontal surface, wherein said holes allow passage of water vertically through said first layer, and wherein said vertical projections extend a height sufficient to prevent passage of debris across said top layer while permitting passage of water over said horizontal surface, thereby preventing the drain inlet from being clogged; a center layer composed of a screen or mesh having apertures of approximately one-eighth inch or greater in diameter; and a third layer composed of a felt material having hydrophobic properties; wherein said first, second and third layers are fastened together and act as a single barrier that is coextensively laid over said grate.

[0009] U.S. Pat. Nos. 8,051,568 and 8,216,453 disclose an inlet filter mat which includes an expanded metal screen sized to fit over the storm water grate; a U-shaped edge trim having a plurality of barbs thereon; a high flow monofilament fabric filter sized to fit over the expanded metal screen and being attached to said expanded metal screen; and a plurality of bolts attaching the expanded metal screen and monofilament fabric filter to said storm water grate.

[0010] The '620 patent co-invented by the inventor of the present application also discloses several above grate filter mats, the most commercially viable one is sold under the trademark BLACKHAWK by MKB Company.

[0011] Despite the advantages of the BLACKHAWK inlet filter mat there exists a need for better devices, systems and methods for filtering sediment from water entering storm drains, specifically those which provide ease of installation; can be easily cleaned or changed, even during periodic flooding; prevent unwanted back-up of excess water; filter nearly all or all of the water that comes through the inlet; and are cost effective.SUMMARY OF THE INVENTION

[0012] The present invention provides an inlet filter mat for filtering sediment from water entering storm drains with ease of installation; and which can be easily cleaned or changed, even during periodic flooding; and which prevents unwanted back-up of excess water; and which filters nearly all of the water that comes through the inlet (e.g., except for high flow events operating in bypass); and which is cost effective.

[0013] One aspect of the present invention provides an above grate inlet filter system for erosion and sediment control includes a filter base substrate having an upper and lower surface, a pair of sides and a front and a rear end with plurality of drain holes therethrough from the upper surface to the lower surface; grate coupling elements attached to the filter base substrate configured to attach the system to a filter grate; a plurality of fiber filter components attached to the upper surface of the filter base substrate and aligned with the drain holes, whereby fluid can flow through a fiber filter component and through an aligned drain hole in the filter base substrate, and wherein the plurality of fiber filter components form a meandering flow channel extending along the upper surface of filter base substrate between the sides of the filter base substrate wherein fluid can flow from the sides along the flow channel.

[0014] These and other advantages of the present invention are described below in connection with the attached drawings in which like reference numbers represent like elements throughout.BRIEF DESCRIPTION OF THE FIGURES

[0015] FIG. 1 is a schematic top plan view of an above grate inlet filter system for erosion and sediment control according to one embodiment of the present invention.

[0016] FIG. 2 is a schematic bottom plan view of the above grate inlet filter system for erosion and sediment control according to FIG. 1.

[0017] FIGS. 3A and 3B schematically show the installation of the above grate inlet filter system for erosion and sediment control according to FIG. 1 on a Type C inlet (sidewall).

[0018] FIGS. 3C and 3D schematically show the installation of the above grate inlet filter system for erosion and sediment control according to FIG. 1 on a Type M inlet.

[0019] FIG. 4 schematically shows the folding and shipping of the above grate inlet filter system for erosion and sediment control according to FIG. 1.

[0020] FIG. 5 schematically shows the modular nature and sizes available in the above grate inlet filter system for erosion and sediment control according to FIG. 1.

[0021] FIG. 6 is a schematic bottom plan view of a modified above grate inlet filter system for erosion and sediment control according to FIG. 1.

[0022] FIG. 7 is a schematic top plan view of an above grate inlet filter system for erosion and sediment control according to FIG. 1 further including a channel plug member.DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] This invention is directed to an above grate, or above grade, based inlet filter system 10 for erosion and sediment control also called an inlet filter mat 10. An above grate inlet filter system 10 for erosion and sediment control includes a filter base substrate 20 having an upper and lower surface, a pair of sides and a front and a rear end with plurality of openings 80 and 50 (or drain holes 80 and bypass 50) therethrough from the upper surface to the lower surface; grate coupling elements (magnets 60 and 70) attached to the filter base substrate 20 configured to attach the system 10 to a filter grate 5 or 7; a plurality of fiber filter components 30 attached to the upper surface of the filter base substrate 20 and aligned with the drain holes 80 (and bypass 50), whereby fluid can flow through a fiber filter component 30 and through an aligned drain hole (80) in the filter base substrate 20, and wherein the plurality of fiber filter components 30 form a meandering flow channel 40 extending along the upper surface of filter base substrate 20 between the sides of the filter base substrate 20 wherein fluid can flow from the sides along the flow channel 40.

[0024] The present invention is a composite inlet filter mat 10 including a filter base substrate 20 (or just substrate 20) that preferably is a 0.4″ thick air-laid polyester layer formed from recycled carpet fiber and plastic bottles. Alternative material for the substrate 20 is a natural fiber or combination of natural and synthetic. The substrate 20 is the base upon which the filter mat 10 is assembled.

[0025] On top of the substrate 20 is plurality of fiber filter components 30 such as coir fiber filter elements 30 formed of 5.75 OSF random fiber orientation coir matting about 2″ high and held together with a water-resistant latex binder. All coir components 30 are designed to be made out of 8-inch-wide coir “raw material” strips that improves manufacturing and allows for a modular design. Further this leads to a smaller inventory at all assembly factories for an infinite variety of mat designs such as shown in FIG. 5.

[0026] A key aspect of the invention is that the coir fiber elements form a meander flow channel 40 thru center of mat 10. The channel 40 is considered to “meander” herein because it is intentionally non-linear creating increased surface area of the elements 30 facing the channel 40 and the fluid therein. The meander flow channel 40 allows much more filter material 30 to contact dirty water under low- to-moderate flow conditions than relying upon the mat perimeter (like 3× more before top breach).

[0027] The mat 10 has a central overflow or bypass opening 50 for high flow conditions with the bypass opening 50 being through both a central coir element 30 and the substrate 20.

[0028] The substrate 20 is held to the grate 5 or 7 through a magnetic system comprised of three neodymium magnets 60 coupled to the substrate 20 and lower strength flexible strip magnets 70 coupled to the substrate 20 about the perimeter of the mat 10. Each of the three neodymium magnets 60 is a permanent magnet made from an alloy of neodymium, iron, and boron and are the most widely used type of rare-earth magnet. The magnets 60 include a mesh support on the substrate to accommodate the strength of the magnets 60 (to avoid ripping the mat 10 apart when removing or adjusting the mat 10).

[0029] The substrate 20 includes openings 80 or drain holes 80 (and bypass opening or drain hole 50) aligned with the coir elements 30. In low flow operation the flow is filtered through coir elements 30 to a drain hole opening 80. In high flow operation the flow is still filtered through coir elements 30 to an opening 80 but excess fluid flows in bypass mode through drain hole opening 50. The high flow condition occurs when water pools over the height of the central coir element 30

[0030] The substrate 20 includes an extension or flap 22 which can be bent vertically for placement against a type-C inlet 5 as shown in FIGS. 3A-B with no field modification of the mat. Openings (not shown) may be made in the substrate in the flap 22 to provide an unobstructed bypass side flow path, if desired but that is only for the type C inlet 5. As shown in FIGS. 3C-D the same design works equally well with the type M inlet 7.

[0031] The mat 10 has two “designed in” fold zones 90 that allows for efficient folding and shipping of just one mat in a relatively small box 100 as shown in FIG. 4.

[0032] The modular aspects of the current design can be shown in the various sized embodiments illustrated in FIG. 5. It each of the designs shown in FIG. 5 the substrate 20 may for formed or die cut for the outer perimeter and drain holes 80 and bypass opening 50 as shown in FIG. 2 or 6 and strips of coir elements 30 added to complete the filtering elements of the mat 10. The magnets 60 and 70 are attached to complete the assembly. The modular design allows for a multitude of sizes to be constructed. As shown in some embodiments two central overflows or bypass openings 50 are used and the overflow may align with a larger opening 80 in the substrate 20.

[0033] A further modification is that the meander path 40 may be easily plugged at one side opening with a matching (beveled) coir element 110, where the flow is to be stopped within the mat 20 and / or it flows from only one side. The plug coir element 110 is set in place and can be on either side.

[0034] The mat 10 of the invention is 40% lighter when dry than the closest commercial product of the same size (namely the current 2024 BLACKHAWK inlet filter mat) and is 20% physically stronger (because of substrate 20). The matt 10 of the invention is 20% stronger magnetic holding system because of 2 types of magnets 60 and 70. Further the mat 10 of the invention is 20% heavier when wet than the closest commercial product of the same size as the substrate 20 acts as water-soaked wicking sponge which seals mat 10 to inlet perimeter and keeps the whole mat 10 in place on the metal grate. The mat 10 of the invention exhibits at least 20% overall higher flow and >3× higher flow before top breaching (bypass mode) than the closest commercial product of the same size. The mat 10 of the invention has a 20% higher blinding resistance (based on comparing geometries) than the closest commercial product of the same size. As noted above, the modular design dramatically reduces raw materials inventory or the need for dye cutting.

[0035] While the invention has been shown in several particular embodiments it should be clear that various modifications may be made to the present invention without departing from the spirit and scope thereof. For example, the mat 10 may further include material for hydrocarbon capture in substrate 20. The scope of the present invention is defined by the appended claims and equivalents thereto.

Examples

Embodiment Construction

[0023]This invention is directed to an above grate, or above grade, based inlet filter system 10 for erosion and sediment control also called an inlet filter mat 10. An above grate inlet filter system 10 for erosion and sediment control includes a filter base substrate 20 having an upper and lower surface, a pair of sides and a front and a rear end with plurality of openings 80 and 50 (or drain holes 80 and bypass 50) therethrough from the upper surface to the lower surface; grate coupling elements (magnets 60 and 70) attached to the filter base substrate 20 configured to attach the system 10 to a filter grate 5 or 7; a plurality of fiber filter components 30 attached to the upper surface of the filter base substrate 20 and aligned with the drain holes 80 (and bypass 50), whereby fluid can flow through a fiber filter component 30 and through an aligned drain hole (80) in the filter base substrate 20, and wherein the plurality of fiber filter components 30 form a meandering flow chan...

Claims

1. An above grate inlet filter system for erosion and sediment control comprising:a filter base substrate having a plurality of drain holes therethrough;grate coupling elements attached to the filter base substrate configured to attach the system to a filter grate;a plurality of fiber filter components attached to an upper surface of the filter base substrate and aligned with the drain holes, whereby fluid can flow through a fiber filter component and through an aligned drain hole in the filter base substrate, and wherein the plurality of fiber filter components form a flow channel extending along the upper surface of filter base substrate.

2. The above grate inlet filter system according to claim 1, wherein at least one of the plurality of fiber filter components includes a bypass opening aligned with a drain hole in the filter base forming a bypass path for high flow conditions with through the fiber filter component and the filter base substrate.

3. The above grate inlet filter system according to claim 2, wherein at least one bypass path is in a central area of the filter base substrate.

4. The above grate inlet filter system according to claim 1, wherein the filter base substrate includes an extension configured to be bent vertically for placement against a type-C inlet with no field modification.

5. The above grate inlet filter system according to claim 1, wherein filter base substrate is a 0.4 inch thick polyester layer.

6. The above grate inlet filter system according to claim 1, wherein plurality of fiber filter components are formed of coir fiber elements.

7. The above grate inlet filter system according to claim 6, wherein the coir fiber elements are 5.75 osf Random Fiber Orientation coir matting about 2″ high and held together with a water resistant latex binder.

8. The above grate inlet filter system according to claim 6, wherein the coir fiber elements are designed to be made out of 8-inch wide coir strips.

9. The above grate inlet filter system according to claim 1, wherein the grate coupling elements includes three neodymium magnets.

10. The above grate inlet filter system according to claim 1, wherein the grate coupling elements includes flexible strip magnets about a perimeter of the filter base substrate.

11. An above grate inlet filter system for erosion and sediment control comprising:a filter base substrate having an upper and lower surface, a pair of sides and a front end and a rear end with plurality of drain holes therethrough from the upper surface to the lower surface;grate coupling elements attached to the filter base substrate configured to attach the system to a filter grate;a plurality of fiber filter components attached to the upper surface of the filter base substrate and aligned with the drain holes, whereby fluid can flow through a fiber filter component and through an aligned drain hole in the filter base substrate, and wherein the plurality of fiber filter components form a meandering flow channel extending along the upper surface of filter base substrate between the sides of the filter base substrate wherein fluid can flow from the sides along the flow channel.

12. The above grate inlet filter system according to claim 11, wherein at least one of the plurality of fiber filter components includes a bypass opening aligned with a drain hole in the filter base forming a bypass path for high flow conditions with through the fiber filter component and the filter base substrate.

13. The above grate inlet filter system according to claim 12, wherein at least one bypass path is in a central area of the filter base substrate.

14. The above grate inlet filter system according to claim 11, wherein the filter base substrate includes an extension configured to be bent vertically for placement against a type-C inlet with no field modification.

15. The above grate inlet filter system according to claim 11, wherein filter base substrate is a 0.4 inch thick polyester layer.

16. The above grate inlet filter system according to claim 11, wherein plurality of fiber filter components are formed of coir fiber elements.

17. The above grate inlet filter system according to claim 16, wherein the coir fiber elements are 5.75 osf Random Fiber Orientation coir matting about 2″ high and held together with a water resistant latex binder.

18. The above grate inlet filter system according to claim 16, wherein the coir fiber elements are designed to be made out of 8-inch wide coir strips.

19. The above grate inlet filter system according to claim 11, wherein the grate coupling elements includes three neodymium magnets.

20. The above grate inlet filter system according to claim 11, wherein the grate coupling elements includes flexible strip magnets about a perimeter of the filter base substrate.

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