IP Library Granted Patent US 10,774,516
Granted Patent B2
US 10,774,516 · App. 16/390,144 · Granted Sep 15, 2020

Modular tessellation assembly for storage of water underground

Inventors: Zachariha J. Kent (Fair Oaks Ranch, TX); John Scott (Fallbrook, CA)
Assignee: Bio Clean Environmental Services, Inc.
E03F1/003B65G5/00E02B11/00E03F1/002E03F1/005
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Quick Facts
Patent No.
US 10,774,516
App. No.
16/390,144
Granted
Sep 15, 2020
Kind
B2
Abstract

Individual hexagonal shaped modules used in an assembly for underground storage of storm water and other fluid storage needs. Modules are assembled into a resultant honeycomb shape for maximized structural strength and material use efficiency. Adjacent modules are in direct fluid communications with one another via openings or windows in module side walls. Assemblies include various top and side pieces along with access ports for entry into said assembly.

Claims (41)

1. A honeycomb shaped assembly system for storing water underground, wherein the honeycomb shaped assembly system is comprised of a plurality of individual adjoining hexagonal modules,

wherein each hexagonal module is comprised of a hexagonally shaped module with six sides,

said sides are all connected together by hexagonally shaped top, making a singular monolithic piece,

wherein each hexagonal module is comprised of a hexagonally shaped top, a hexagonally shaped bottom wherein the top and bottom are connected to side walls on opposite ends,

said side walls are all of equal length and width,

wherein said side walls contain windows based upon their position within the assembly,

wherein said windows are equal to or shorter than the height of the side wall,

said hexagonal modules assembled in such a manner that all modules are in fluid connection with one another via windows,

wherein said honeycomb shaped assembly containing modules along the assembly's external perimeter, with walls not in contact with walls of other modules are without windows or filled windows such that the overall assembly is generally impervious around its external perimeter thus allowing the overall system to hold water or other fluids internally within its entirety,

wherein said modules of honeycomb shaped assembly are arranged as a hexagonal tiling in which three hexagons meet at each vertex such that all walls of all modules are of the same width and are assembled such that walls of adjacent modules are lined up symmetrically with walls of all other modules resulting in only 120 degree angles at each vertex of all adjoined hexagonal modules so three hexagonal modules at a point make a full 360 degrees,

wherein at least one said module has an access hole in its top for access into said honeycomb shaped assembly system after installation underground.

2. A honeycomb shaped assembly system of claim 1 , wherein the module is composed of a top module with more than one perpendicularly downward extending walls and an open bottom, a bottom module with more than one perpendicularly upward extending walls and an open top, said top module is stacked directly over the bottom module and secured in place utilizing a pair of male and female shiplap joints or similarly placed at the bottom edge of the side walls of the hexagonal top module and the top edge of the side walls of the hexagonal bottom module, respectively.

3. A honeycomb shaped assembly system of claim 1 , containing drainage notches in said windows that extend from the bottom of the window to the module bottom to allow water to drain fully down and while providing more wall area to increase overall strength of module.

4. A honeycomb shaped assembly system of claim 1 , containing drainage holes in the bottom of said module to allow water to exit the system and percolate into underlying gravel layer or soils.

5. A honeycomb shaped assembly system of claim 1 , in which up to 30% of internal hexagonally-shaped modules are removed without reducing the overall assembly strength and resultant internal void areas are covered by hexagonally-shaped top slab larger than the resultant void area of the removed module(s), said hexagonally-shaped top slab having a notch down on its bottom side that is smaller than the void area to lock it in place within the assembly.

6. A honeycomb shaped assembly system of claim 1 , in which vertically extending side panels are added to the external perimeter of the assembly.

7. A honeycomb shaped assembly system of claim 6 , where the top module, bottom module, top slab, and side panel are all comprised of concrete reinforced with rebar.

8. A honeycomb shaped assembly system of claim 1 , where a top access hole is covered by an access frame and cover and includes access risers to extend the access frame and cover to finish surface from the top access hole located underground.

9. A honeycomb shaped assembly system of claim 1 , made water tight using an impervious liner, sealant or other means to prevent leakage.

10. A honeycomb shaped assembly system of claim 1 , wherein the modules are selected and comprised of materials including concrete, plastic, metal, composite, and/or fiberglass.

11. A honeycomb shaped assembly system for storing water underground, wherein the honeycomb shaped assembly system is comprised of a plurality of individual adjoining hexagonal modules,

said side walls containing one or more windows based upon their position within the assembly,

wherein said windows are equal to or shorter than the height of the side wall, said hexagonal modules assembled in such a manner that all modules are in fluid connection with one another via windows,

wherein said honeycomb shaped assembly containing modules along the assembly perimeter, with walls not in contact with walls of other modules are without windows or windows filled such that the overall assembly is generally impervious around its external perimeter, top thus allowing the overall system to hold water or other fluids internally within its entirety,

wherein said modules of honeycomb shaped assembly are arranged as a regular hexagonal tiling in which three hexagons meet at each vertex such that all walls of all modules are of the same width and are assembled such that walls of adjacent modules are lined up symmetrically with walls of all other modules, resulting in only 120 degree angles at each vertex of all adjoined hexagonal modules so three modules at a point make a full 360 degrees.

12. A honeycomb shaped assembly system of claim 11 , wherein the module is composed of a top module with more than one perpendicularly downward extending walls and an open bottom, said module is placed on a dirt, a gravel based or a concrete slab.

13. A honeycomb shaped assembly system of claim 11 , in which up to 30% of internal hexagonally-shaped modules are removed without reducing the overall assembly strength and resultant internal void areas are covered by a hexagonally-shaped top slab larger than the resultant void area of the removed module(s), said top slab having a notch down on its bottom side that is smaller than the void area to lock it in place within the assembly.

14. A honeycomb shaped assembly system of claim 11 , in which vertically extending side panels are added to the external perimeter sides of the assembly.

15. A honeycomb shaped assembly system of claim 14 , where the hexagonal top module, where the top access hole is covered with an access frame and cover and optionally includes access risers to extend the access frame and cover to finish surface from the top access hole located underground slab, and side panel are all comprised of concrete reinforced with rebar.

16. A honeycomb shaped assembly system of claim 11 , where the top access hole is with a top access hole covered with an access frame by an access frame and cover and optionally includes access risers to extend the access frame and cover to finish surface from the top access hole located underground.

17. A honeycomb shaped assembly system of claim 11 set on a concrete slab and made water tight using an impervious liner, sealant or other means to prevent leakage.

18. A honeycomb shaped assembly system of claim 11 , wherein the modules are selected and comprised of materials including concrete, plastic, metal, composite, and/or fiberglass.

19. A method of assembling a hexagonal honeycomb shaped module assembly system using stacked hexagonal top modules comprised of the steps of identifying the shape of the hexagonal module assembly desired, selecting and assembling the needed number of hexagonal modules possessing side walls with windows, hexagonal modules without windows, hexagonal modules with top access holes, and hexagonal modules with inflow pipes,

excavating the site for assembly of the hexagonal top module assembly,

placing dirt, concrete or rock on the floor of said excavated site,

placing one or more of the hexagonal top modules together, open end down such that their side walls press directly against each other,

arranging said hexagonal top modules such that the exterior modules define the perimeter of the overall assembly have no side windows, that the hexagonal top modules, each have one or more side windows facing each other's side windows, wherein said modules of honeycomb shaped assembly are arranged as a regular hexagonal tiling in which three hexagons meet at each vertex such that all walls of all modules are of the same width and are assembled such that walls of adjacent modules are lined up symmetrically with walls of all other modules, resulting in only 120 degree angles at each vertex of all adjoined hexagonal modules so three hexagonal modules at a point make a full 360 degrees,

arranging that at least one hexagonal top module possesses a top access hole and that at least one exterior hexagonal top module possesses an inflow pipe,

wherein side panels and cover panels are added to the hexagonal module assembly system,

filling in the surrounding area of said excavation with rock and gravel, covering over the hexagonal module assembly system with dirt or other coverings.

20. The method according to claim 19 of assembling a hexagonal top module assembly system with internal void areas comprised of the additional steps of identifying the location of the void area(s) in the hexagonal module assembly, covering the internal void with a plurality of hexagonal top slabs and adding a plurality of side panels to the gaps left by the walls left by the exterior hexagonal bottom modules.

Assignments (11)
PATENT SECURITY AGREEMENT Recorded Feb 10, 2025
From: BEST BLOCK, LLC; CONTECH ENGINEERED SOLUTIONS LLC; CUSTOM BUILDING PRODUCTS, LLC; FORTERRA CONCRETE PRODUCTS, LLC; FORTERRA PIPE & PRECAST, LLC; KEYSTONE RETAINING WALL SYSTEMS LLC; PAVESTONE, LLC; THE QUIKRETE COMPANIES, LLC; UNITED STATES PIPE AND FOUNDRY COMPANY, LLC; USP HOLDINGS, LLC
To: U.S. BANK TRUST COMPANY, NATIONAL ASSOCIATION
Reel/Frame 070170/0919 →
MERGER Recorded Jan 28, 2025
From: BIO CLEAN ENVIRONMENTAL SERVICES, LLC
To: CONTECH ENGINEERED SOLUTIONS LLC
Reel/Frame 070031/0163 →
ARTICLES OF CONVERSION Recorded Sep 4, 2024
From: BIO CLEAN ENVIRONMENTAL SERVICES, INC.
To: BIO CLEAN ENVIRONMENTAL SERVICES, LLC
Reel/Frame 068836/0331 →
PATENT SECURITY AGREEMENT (ABL) Recorded Mar 23, 2022
From: UNITED STATES PIPE AND FOUNDRY COMPANY, LLC; GRIFFIN PIPE PRODUCTS CO., LLC; CUSTOM FAB, INC.; BIO CLEAN ENVIRONMENTAL SERVICES, INC.; MODULAR WETLAND SYSTEMS, INC.; FORTERRA PIPE & PRECAST, LLC; FORTERRA CONCRETE PRODUCTS, INC.; FORTERRA PRECAST CONCEPTS, LLC; BEST BLOCK, LLC; PAVESTONE, LLC; CONTECH ENGINEERED SOLUTIONS LLC; KEYSTONE RETAINING WALL SYSTEMS LLC
To: WELLS FARGO BANK, NATIONAL ASSOCIATION, AS AGENT
Reel/Frame 059479/0336 →
PATENT SECURITY AGREEMENT (ABL) Recorded Mar 23, 2022
From: UNITED STATES PIPE AND FOUNDRY COMPANY, LLC; GRIFFIN PIPE PRODUCTS CO., LLC; CUSTOM FAB, INC.; BIO CLEAN ENVIRONMENTAL SERVICES, INC.; MODULAR WETLAND SYSTEMS, INC.; FORTERRA PIPE & PRECAST, LLC; FORTERRA CONCRETE PRODUCTS, INC.; FORTERRA PRECAST CONCEPTS, LLC; BEST BLOCK, LLC; PAVESTONE, LLC; CONTECH ENGINEERED SOLUTIONS LLC; KEYSTONE RETAINING WALL SYSTEMS LLC
To: WELLS FARGO BANK, NATIONAL ASSOCIATION, AS AGENT
Reel/Frame 059479/0437 →
RELEASE OF ABL SECURITY INTEREST IN INTELLECTUAL PROPERTY RECORDED AT REEL 053228/FRAME 0967 Recorded Mar 21, 2022
From: BANK OF AMERICA, N.A.
To: FORTERRA PIPE & PRECAST, LLC; BIO CLEAN ENVIRONMENTAL SERVICES, INC.; FORTERRA CONCRETE PRODUCTS, INC.; UNITED STATES PIPE AND FOUNDRY COMPANY, LLC; FORTERRA PRECAST CONCEPTS, LLC; MODULAR WETLAND SYSTEMS, INC.
Reel/Frame 059718/0621 →
RELEASE OF SECURITY INTEREST Recorded Mar 21, 2022
From: DEUTSCHE BANK TRUST COMPANY AMERICAS, AS COLLATERAL AGENT
To: FORTERRA PIPE & PRECAST, LLC; UNITED STATES PIPE AND FOUNDRY COMPANY, LLC; GRIFFIN PIPE PRODUCTS CO., LLC; CUSTOM FAB, INC.; BIO CLEAN ENVIRONMENTAL SERVICES, INC.; FORTERRA PRECAST CONCEPTS, LLC; MODULAR WETLAND SYSTEMS, INC.; FORTERRA CONCRETE PRODUCTS, INC.
Reel/Frame 060199/0286 →
SECURITY INTEREST Recorded Mar 18, 2022
From: BIO CLEAN ENVIRONMENTAL SERVICES, INC.
To: WELLS FARGO BANK, N.A., AS AGENT
Reel/Frame 059313/0570 →
CORRECTIVE ASSIGNMENT TO CORRECT THE APP 62905899 WHICH WAS ENTERED IN ERROR AND IS TO BE REMOVED FROM THOSE PATENTS PREVIOUSLY RECORDED ON REEL 053228 FRAME 0967. ASSIGNOR(S) HEREBY CONFIRMS THE SECURITY INTEREST.. Recorded Jul 17, 2020
From: FORTERRA, INC. (A DELAWARE CORPORATION); FORTERRA PIPE & PRECAST, LLC (A DELAWARE LIMITED LIABILITY COMPANY); BIO CLEAN ENVIRONMENTAL SERVICES, INC. (A CALIFORNIA CORPORATION); FORTERRA CONCRETE PRODUCTS, INC. (AN IOWA CORPORATION); MODULAR WETLAND SYSTEMS, INC. (A CALIFORNIA CORPORATION); UNITED STATES PIPE AND FOUNDRY COMPANY, LLC (AN ALABAMA LIMITED LIABILITY COMPANY); FORTERRA PRECAST CONCEPTS, LLC (A DELAWARE LIMITED LIABILITY COMPANY)
To: BANK OF AMERICA, N.A. (A NATIONAL BANKING INSTITUTION)
Reel/Frame 053246/0963 →
SECURITY INTEREST Recorded Jul 16, 2020
From: FORTERRA, INC. (A DELAWARE CORPORATION); FORTERRA PIPE & PRECAST, LLC (A DELAWARE LIMITED LIABILITY COMPANY); BIO CLEAN ENVIRONMENTAL SERVICES, INC. (A CALIFORNIA CORPORATION); FORTERRA CONCRETE PRODUCTS, INC. (AN IOWA CORPORATION); MODULAR WETLAND SYSTEMS, INC. (A CALIFORNIA CORPORATION); UNITED STATES PIPE AND FOUNDRY COMPANY, LLC (AN ALABAMA LIMITED LIABILITY COMPANY); FORTERRA PRECAST CONCEPTS, LLC (A DELAWARE LIMITED LIABILITY COMPANY)
To: BANK OF AMERICA, N.A. (A NATIONAL BANKING INSTITUTION)
Reel/Frame 053228/0967 →
SECURITY AGREEMENT (NOTES) Recorded Jul 16, 2020
From: BIO CLEAN ENVIRONMENTAL SERVICES, INC.; FORTERRA CONCRETE PRODUCTS, INC.; GRIFFIN PIPE PRODUCTS COMPANY, LLC; MODULAR WETLAND SYSTEMS, INC.; UNITED STATES PIPE AND FOUNDRY COMPANY, LLC
To: DEUTSCHE BANK TRUST COMPANY AMERICAS, AS NOTES COLLATERAL AGENT
Reel/Frame 053229/0924 →