Fabricating a drainage unit having a quilted exterior surface
View Patent ↗A substantially cylindrical drainage unit for use when buried in soil as part of a wastewater leach field comprises a first plastic bead aggregate mass, optionally with a central perforated pipe, surrounded by a segmented-quilt exterior surface. Quilts are captured around the drainage unit by straps, a circumscribing netting sleeve, or by being themselves in the form of tubular sleeves. Preferred rectangular quilt segments contain a second pebble aggregate that is smaller than the first aggregate. Quilts are fabricated by mating two layers of geotextile and inserting the second aggregate into channels or cavities that are defined by seams that join the layers to each other.
1. A method of making a drainage unit for receiving and collecting water when buried in soil or other particulate material, the drainage unit having a length, a diameter, a nominally cylindrical exterior and opposing ends, the drainage unit comprising a generally cylindrical mass of first aggregate, and a quilt made of water permeable geotextile running around all or part of the circumference of said first aggregate mass, the quilt comprised of a multiplicity of interconnected segments, each segment having an internal cavity containing a second aggregate, which method comprises:
(i) fabricating a quilt by
(a) running a base layer of geotextile vertically downwardly through space;
(b) contouring a cap layer of geotextile by means of a forming a roller so the cap layer has alternating lengthwise-running peaks and valleys;
(c) running the cap layer downwardly so the cap layer mates with and runs downwardly with the base layer so the valleys of the cap layer contact the base layer;
(d) forming a geotextile assembly by welding the cap layer to the base layer at vertically running weld seams where the valleys of the cap layer contact the base layer, the seams defining one or more vertical channels within the geotextile assembly;
(e) depositing a predetermined amount of the second aggregate into the upper end of the one or more vertical channels; and,
(f) welding the cap layer to the base layer at spaced-apart horizontal seams, to thereby create a plurality of rectangular quilt segments containing the second aggregate; and
(ii) mating the quilt with a first aggregate mass having a generally cylindrical shape, so the first aggregate is contained within a tubular shape quilt structure.
2. The method of claim 1 wherein during step (ii) the cap layer of the quilt is placed in contact with the first aggregate mass when the quilt is mated with the first aggregate mass.
3. The method of claim 2 further comprising: (iii) placing a sleeve of netting around the quilt after it is mated with the first aggregate mass.
4. The method of claim wherein during step (i)(e) the predetermined amount of the second aggregate is first accumulated within the vertical cavity of a shuttle assembly and deposited into the upper end of said one or more channels by means of a tube connected to said vertical cavity.