DRAINAGE SYSTEM

Abstract

A drainage system for draining a fluid from a hardenable material as the fluid flows through an aperture formed in the hardenable material includes a conduit and a catch. The conduit has an outer surface defining an inner chamber. The catch is supported by the outer surface of the conduit for directing the fluid from the aperture into the inner chamber. The catch includes a first tab and a second tab that extend along a portion of the length of the conduit, and the second tab is spaced from the first tab. Both the first tab and the second tab are inserted into the hardenable material about opposing sides of the aperture to prevent a collapsing of the conduit and to maintain a flow of the fluid from the aperture into the inner chamber.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of application Ser. No. 60/756,156 filed Jan. 4, 2006, which is hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The subject invention relates to system and method for draining a fluid from a hardenable material as the fluid flows through an aperture formed in the hardenable material.

2. Description of the Prior Art

Drainage systems are important when working with concrete surfaces. Specifically, drainage systems may be used to move a fluid from an expansion joint between two concrete surfaces. As the fluid flows into the expansion joint, changes in temperature cause the fluid to expand and contract, which can crack the concrete surfaces. Therefore, it is necessary to move the fluid away from the concrete surface to reduce the fluid in the expansion joint.

Various drainage systems are known in the art. One such drainage system is disclosed in U.S. Pat. No. 5,908,266 to Miller (the '266 patent). The '266 patent discloses a drainage system for draining a fluid from a hardenable material as the fluid flows through an aperture formed in the hardenable material. The drainage systems of the prior art include a conduit that has an outer surface that defines an inner chamber. The conduit has a length that extends between distal ends of the conduit and an axis that extends along the length. The drainage systems of the prior art also include a catch disposed on the outer surface of the conduit for directing the fluid from the aperture into the inner chamber.

Although the drainage systems of the prior art move the fluid away from the hardenable material, there remains an opportunity to improve upon the prior art drainage systems to prevent the conduit from collapsing and to maintain a flow of the fluid from the aperture into the inner chamber.

SUMMARY OF THE INVENTION AND ADVANTAGES

The invention provides for a drainage system for draining a fluid from a hardenable material as the fluid flows through an aperture formed in the hardenable material. The system includes a conduit having an outer surface defining an inner chamber and a length extending between distal ends with an axis extending along the length. A catch is supported by the outer surface of the conduit for directing the fluid from the aperture into the inner chamber. The catch includes a first tab extending along a portion of the length of the conduit and a second tab extending along a portion of the length of the conduit with the second tab radially spaced from the first tab about the axis for insertion into the hardenable material about opposing sides of the aperture to prevent collapsing of the conduit and to maintain a flow of the fluid from the aperture into the inner chamber.

The invention further provides for a method of making a drainage system. The system includes a hardenable material for forming a hardened layer, a conduit having an outer surface defining an inner chamber, and a catch having a first tab and a second tab. The method includes the steps of disposing the catch on the outer surface of the conduit, applying the hardenable material over the conduit and the catch, curing the hardenable material to form the hardened layer for embedding the first tab and the second tab within the hardened layer, and cutting the hardened layer to form an aperture. The method further includes the step of cutting the outer surface of the conduit between the first tab and the second tab to form a drainage opening simultaneously with the forming of the aperture and with the drainage opening in fluid communication with the aperture.

The invention further provides for a catch for a conduit for draining a fluid from a hardenable material. The catch includes a base defining a length with the base being adapted for mounting to the conduit. The catch further includes a first tab extending from the base along the length and defining a first plane. In addition, the catch includes a second tab extending from the base along the length spaced from the first tab and the second tab defining a second plane angled relative to the first plane for inserting the first tab and the second tab into the hardenable material to prevent collapsing of the conduit and to maintain a flow of the fluid into the conduit.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIG. 1 is a perspective view of a first environment utilizing a drainage system in accordance with the subject invention;

FIG. 2 is a perspective view of a second environment utilizing the drainage system in accordance with the subject invention;

FIG. 3 is a perspective view of a conduit and a catch used with the drainage system in accordance with the subject invention;

FIG. 4 is a cross-sectional view of the conduit and the catch used with the drainage system of FIG. 3 in accordance with the subject invention;

FIG. 5 is a perspective view of an end cap used with the drainage system in accordance with the subject invention;

FIG. 6 is a perspective view of the conduit, the catch, an the end cap as shown in FIG. 5 assembled in accordance with the subject invention;

FIG. 7 is a side view of the drainage system disposed below a hardened layer in accordance with the subject invention;

FIG. 8 is a perspective view of the drainage system disposed below the hardened layer and having an aperture, a fluid passage, and a drainage opening in accordance with the subject invention;

FIG. 9 is a side view of one embodiment of the drainage system as shown in FIG. 8 in accordance with the subject invention;

FIG. 10 is a side view of another embodiment of the drainage system as shown in FIG. 8 in accordance with the subject invention;

FIG. 11 is a side view of the drainage system disposed below the hardened layer in accordance with the subject invention;

FIG. 12 is a perspective view of the drainage system having at least one drain hole formed in the hardened layer in accordance with the subject invention;

FIG. 13 is a perspective view of the drainage system having at least one slot formed in the hardened layer in accordance with the subject invention; and

FIG. 14 is a perspective view of the drainage system having a combination of the at least one drain hole and the at least one slot formed in the hardened layer in accordance with the subject invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the Figures, wherein like numerals indicate corresponding parts throughout the several views, a drainage system 20 is disclosed generally at reference numeral. As shown in FIGS. 1 and 2, the drainage system 20 is used below a hardenable material 22, such as a concrete driveway or sidewalk. Referring to FIGS. 3 and 4, the drainage system 20 includes a conduit 24 having an outer surface 26 defining an inner chamber 28. A length extends between distal ends of the conduit 24 with an axis A extending along the length. A catch 30 is disposed on the outer surface 26 of the conduit 24 and extends along at least a portion of the length of the conduit 24. The catch 30 includes a first tab 32 having a first tab length that extends along the catch 30. In one embodiment, the first tab 32 defines a first plane P1 that extends through the first tab 32 and through the axis A. The catch 30 also includes a second tab 34 having a second tab length equal to that of the first tab length. Like the first tab 32, the second tab 34 defines a second plane P2 that extends through the second tab 34 and through the axis A. It is within the scope of the subject invention that the second plane P2 extends from the length angled relative to the first plane P1, causing the first plane P1 and the second plane P2 to intersect, and the axis A may be defined by where the first plane P1 and the second plane P2 intersect.

A base (not shown) may be located on the outer surface conduit 24, generally opposite the catch 30. The base may have a shape similar to the catch 30, and the first and second tabs 32, 34, but is not limited so such shape. The base acts to increase the stability of the drainage system 10.

In addition, at least one of the first tab 32 and the second tab 34 may extend from the outer surface 26 of the conduit 24 perpendicularly to the outer surface 26. Alternatively, at least one of the first tab 32 and the second tab 34 may extend from the outer surface 26 of the conduit 24 obliquely. Since it is within the scope of the subject invention that the first plane P1 and the second plane P2 not intersect, the axis A is then defined by conduit 24. In addition, the first tab 32 may extend continuously along the portion of the length of the conduit 24 parallel to the second tab 34. In yet another alternative, the catch 30 may include a base 36 that is disposed on the outer surface 26 of the conduit 24 that extends along the portion of the length of the conduit 24 to interconnect the first tab 32 and the second tab 34. The length of the base 36 may be greater than or equal to the first tab length and the second tab length. It should be understood that the first tab 32 and the second tab 34 may have different shapes or be arranged differently with respect to one another. For instance, the first tab 32 and the second tab 34 may be curved.

Furthermore, the base 36 is shaped or adapted to mount onto the outer surface 26 of the conduit 24. For example, if the conduit 24 is a pipe having a cylindrical cross-section, the outer surface 26 is rounded, and therefore, the base 36 of the catch 30 has an arcuate cross-section to fit onto the conduit 24. It should be understood that the conduit 24 may have alternative cross-sections as is known in the art.

The second tab 34 extends along the portion of the length of the base 36 and is radially spaced from the first tab 32 about the axis at an angle θ relative to the first tab 32. The angle θ is less than 90 degrees, however, it should be understood that the angle θ may be any angle. Additionally, as shown in FIGS. 5 and 6, end caps 38 may be disposed on the conduit 24 that are transverse relative to and extend between the first tab 32 and the second tab 34 and parallel to one another. With the end caps 38, the first tab 32 and the second tab 34 enclose the portion of the length of the conduit 24.

The catch 30, which includes the first tab 32, the second tab 34, the end caps 38, and alternatively, the base 36, may be disposed on the conduit 24 in various ways. For example, the base 36 may be adhered to the conduit 24 with an adhesive 40 or a fastener. Alternatively, the catch 30 may be integrally formed with the conduit 24 so that the conduit 24 and the catch 30 are formed from a single piece of material. In yet another alternative, the catch 30 may simply rest on the conduit 24. It should be understood that these and other alternatives for disposing the catch 30 on the conduit 24 are within the scope of the subject invention.

Referring to FIG. 7, after the catch 30 has been disposed on the outer surface 26 of the conduit 24, the conduit 24 and the catch 30 are partially buried in a ground layer 42. It should be understood that the conduit 24 may be partially placed in the ground layer 42 before disposing the catch 30 on the outer surface 26 of the conduit 24. Once the catch 30 and the conduit 24 are placed in the ground layer 42, the hardenable material 22 is applied over the entire catch 30 and over the portion of the length of the conduit 24 such that the first tab 32 and the second tab 34 extend into the hardenable material 22. The hardenable material 22 may be sloped toward the catch 30 and the conduit 24. After the hardenable material 22 is applied to the conduit 24 and the catch 30, the hardenable material 22 is cured to a sufficient hardness. Once cured, a hardened layer 44 is formed and the first tab 32 and second tab 34 are embedded in the hardened layer 44.

Next, referring to FIGS. 8-10, the hardened layer 44 is cut to form an aperture 46. Simultaneously, the conduit 24 is cut to form a drainage opening 48. If the catch 30 includes the base 36 as previously described, then the base 36 is simultaneously cut with the conduit 24 and the hardened layer 44 to form a fluid passage 50. The aperture 46, the fluid passage 50, and the drainage opening 48 may be cut to form at least one slot 52, such as an expansion joint. An expansion joint filler 54 may be placed in the at least one slot 52 as is known in the art. Alternatively, at least one drain hole 56 may be drilled through the hardened layer 44, the catch 30, and the conduit 24 to form the aperture 46, the fluid passage 50, and the drainage opening 48, respectively. A drain cap 58 may be placed over the at least one drain hole 56. Furthermore, as shown in FIG. 7, the drainage opening 48 in the conduit 24 is defined by the outer surface 26 between the first tab 32 and the second tab 34 of the catch 30, and the drainage opening 48 is in fluid 60 communication with the aperture 46. The base 36 of the catch 30 defines the fluid passage 50, which is in fluid 60 communication with the aperture 46 and the drainage opening 48.

Referring specifically to FIG. 9, the fluid passage 50 and the drainage opening 48 may be cut or drilled to an equal width as the aperture 46. In an alternative embodiment, as shown in FIG. 10, the aperture 46 has a first width while the fluid passage 50 and the drainage opening 48 have a second width that is smaller than the first width. It should be understood that the width of the aperture 46, the fluid passage 50, and the drainage opening 48 may be a diameter if the aperture 46, fluid passage 50, and the drainage opening 48 are circular in shape, such as the at least one drain hole 56.

As previously shown in FIG. 4, cutting the conduit 24 may cause the conduit 24 to collapse and close the drainage opening 48. However, by inserting the first tab 32 and the second tab 34 into the hardenable material 22 and embedding the first tab 32 and the second tab 34 into the hardened layer 44, the catch 30 can prevent the conduit 24 from collapsing. Although the hardenable material 22 need not be completely cured before cutting through the hardened layer 44 to form the aperture 46, when the drainage opening 48 is cut in the conduit 24, the first tab 32 and the second tab 34 must be embedded in the hardened layer 44 and the hardened layer 44 must be strong enough to hold the drainage opening 48 open. If the hardened layer 44 has not cured enough to hold the drainage opening 48 open, the conduit 24 may collapse and close the drainage opening 48.

Referring now to FIG. 11, the aperture 46 is formed in the hardened layer 44, the drainage opening 48 is formed in the conduit 24 in fluid 60 communication with the aperture 46, and the fluid passage 50 is formed in the base 36 of the catch 30 in fluid 60 communication with the aperture 46 and the drainage opening 48. Now, a fluid 60 can flow from the hardened layer 44 and through the aperture 46, the fluid passage 50, and the drainage opening 48 into the inner chamber 28 of the conduit 24. The first tab 32 and the second tab 34 embedded in the hardened layer 44 hold the drainage opening 48 open and help reduce the fluid 60 from flowing between the hardened layer 44 and the conduit 24 through capillary action. The conduit 24 then carries the fluid 60 away from the hardenable material 22. It should be understood that the conduit 24 may be any fluid-carrying device known in the art such as, but not limited to, a pipe or tube. In addition, the conduit 24 may be made of any material known in the art capable of carrying the fluid. Such materials include polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), or Acrylonitrile Butadiene Styrene (ABS). It should be understood that conduits 24 made of other materials are within the scope of the subject invention.

Referring to FIGS. 12-14, the aperture 46, the fluid passage 50, and the drainage opening 48 may be various shapes. In FIG. 12, the aperture 46, the fluid passage 50, and the drainage opening 48 are the at least one drain hole 56. As shown in FIG. 13, the aperture 46, the fluid passage 50, and the drainage opening 48 are the at least one slot 52. As shown in FIG. 14, the aperture 46, the fluid passage 50, and the drainage opening 48 are a combination of the at least one drain hole 56 and the at least one slot 52.

Obviously, many modifications and variations of the present invention are possible in light of the above teachings, and the invention may be practiced otherwise than as specifically described within the scope of the appended claims.

Claims

1. A drainage system for draining a fluid from a hardenable material as the fluid flows through an aperture formed in the hardenable material, said system comprising:

a conduit having an outer surface defining an inner chamber and a length extending between distal ends with an axis extending along said length; and

a catch supported by said outer surface of said conduit and having a first tab and a second tab, said first tab extending along a portion of said length of said conduit and said second tab extending along a portion of said length of said conduit with said second tab radially spaced from said first tab about said axis for insertion into the hardenable material about opposing sides of the aperture.

2. A drainage system as set forth in claim 1 wherein said first tab and said second tab extend from said outer surface of said conduit in a direction perpendicular to said outer surface of said conduit.

3. A drainage system as set forth in claim 1 wherein said second tab is radially spaced from said first tab at an angle less than 90 degrees relative to said first tab.

4. A drainage system as set forth in claim 1 wherein said catch further includes a base disposed on said outer surface of said conduit interconnecting said first tab and said second tab.

5. A drainage system as set forth in claim 4 wherein said catch is adhered to said outer surface of said conduit through said base.

6. A drainage system as set forth in claim 4 wherein said conduit has a circular cross-section and said base has an arcuate cross-section for fitting onto said conduit.

7. A drainage system as set forth in claim 1 wherein said outer surface of said conduit defines a drainage opening between said first tab and said second tab and in fluid communication with said aperture.

8. A drainage system as set forth in claim 7 wherein said catch further includes a base disposed on said outer surface of said conduit interconnecting said first tab and said second tab.

9. A drainage system as set forth in claim 8 wherein said base defines a fluid passage in fluid communication with said drainage opening and between said first tab and said second tab for directing fluid from the aperture into said inner chamber.

10. A drainage system as set forth in claim 1 further including a pair of end caps disposed on said conduit and extending between said first tab and said second tab.

11. A drainage system as set forth in claim 1 wherein said first tab and said second tab are continuous along a majority of the length of said conduit.

12. A method of making a drainage system, said system including a hardenable material for forming a hardened layer, a conduit having an outer surface defining an inner chamber, and a catch having a first tab and a second tab, said method comprising the steps of:

disposing the catch on the outer surface of the conduit;

applying the hardenable material over the conduit and the catch;

curing the hardenable material to form the hardened layer for embedding the first tab and the second tab within the hardened layer;

cutting the hardened layer to form an aperture; and

cutting the outer surface of the conduit between the first tab and the second tab to form a drainage opening simultaneously with the forming of the aperture and with the drainage opening in fluid communication with the aperture.

13. A method as set forth in claim 12 wherein said step of cutting the hardened layer is further defined as drilling the hardened layer to form the aperture.

14. A method as set forth in claim 12 wherein said step of cutting the outer surface of the conduit is further defined as drilling the outer surface of the conduit between the first tab and the second tab to form the drainage opening in fluid communication with the aperture.

15. A method as set forth in claim 12 wherein said step of cutting the outer surface of the conduit is further defined as cutting the outer surface of the conduit to form the drainage opening of a same width as the aperture.

16. A method as set forth in claim 12 wherein said step of cutting the outer surface of the conduit is further defined as cutting the outer surface of the conduit to form the drainage opening of a smaller width than the aperture.

17. A method as set forth in claim 12 wherein said step of disposing the catch is further defined as adhering the catch to the outer surface of the conduit.

18. A method as set forth in claim 12 wherein said step of applying the hardenable material is further defined as inserting the first tab and the second tab into the hardenable material such that the hardenable material extends over the entire catch.

19. A method as set forth in claim 12 further including a step of sloping the hardenable material toward the conduit.

20. A catch for a conduit for draining a fluid from a hardenable material comprising:

a base defining a length with said base being adapted for mounting to the conduit;

a first tab extending from said base along said length and defining a first plane; and

a second tab extending from said base along said length spaced from said first tab and said second tab defining a second plane angled relative to said first plane for inserting said first tab and said second tab into the hardenable material to prevent collapsing of the conduit and to maintain a flow of the fluid into the conduit.

21. A catch as set forth in claim 20 wherein said first plane intersects said second plane to define an axis below said base.

22. A catch as set forth in claim 21 wherein said first tab and said second tab are radially spaced about said axis.

23. A catch as set forth in claim 20 wherein said second tab extends along said length of said base parallel to said first tab.

24. A catch as set forth in claim 20 wherein said base has an arcuate cross-section.

25. A catch as set forth in claim 20 wherein said base defines a fluid passage for maintaining the flow of the fluid into the conduit.

26. A catch as set forth in claim 20 further including a pair of end caps disposed on said base transverse relative to said first tab and said second tab and extending between said first tab and said second tab.