Method and apparatus for coupling drainage units
Drainage apparatuses and methods for their assembly, the drainage apparatuses comprising inter-related connectors and couplings to improve standardized assembly, and improve installation and system performance.
This invention relates generally to liquid drainage systems. More specifically, the invention relates to aggregate-based liquid drainage systems, such as those used for foundation drainage, landscape drainage, athletic fields, open trenches, French drains, or fields, such as nitrification fields used as discharge points for septic tanks, etc. More particularly, the present invention relates to apparatuses and methods for facilitating the pre-selected and secure connectivity of drainage units to other drainage components and to each other. Such interconnectivity represents an improvement over the flexible preassembled drainage line units that are the subject of commonly owned U.S. Pat. Nos. 5,015,123; 6,173,483; 6,705,800, 6,854,924, and 4,247,136 the contents of which, cumulatively, are herein incorporated by reference in their entirety, as if made a part of the present application.
BACKGROUNDKnown preassembled drainage line units constitute loose aggregate in the form of lightweight materials, such as polystyrene beads provided in surrounding relationship to a preferably perforated conduit and bound thereto by a perforated sleeve member, such as plastic netting. Known units may or may not comprise the perforated conduit, or pipe, to be completely effective in a selected use, as explained more fully in commonly owned U.S. Pat. No. 6,854,924.
While known preassembled drainage line units have enjoyed commercial success, certain potential performance limitations persist with respect to manufacture, application and, in particular, installation. For example, depending upon the end use drainage configuration, multiple units may be desired. In such instances it may be desirable for such units to be physically linked, joined or coupled together or to other structures. Known installation methods include the use of additional physical, or otherwise imprecise couplers to join available drainage units to other structures, such as, for example a drainage manifold or drainage distribution box, etc. Such methods necessitate severing a section from the end of an annular structure, such as, for example a polyvinyl chloride (PVC) pipe, followed by physically inserting the PVC pipe, such as, by friction fit, into an end of a drainage unit. In such known methods, an additional sealing mechanism, or sealing step is required to join the two parts, most often requiring an additional gluing step. In still other known methods, discrete joining appliances are used to join the drainage unit to another drainage structure requiring stabilizing features such as joining, or “self-tapping” screws, etc. Such screws must penetrate the overlapping ends of the two drainage structures, as well as the joining coupler. Such joining methods are cumbersome, expensive, require multiple parts, are time-intensive, and further often fail to insure proper long-term stabilization. As a result, such known joining methods are not reliable in terms of preventing leakage, as such methods employ joining parts to “force” coupling of components that are not ordinarily designed to “mate” with one another. Further, such known methods and apparatuses lack the convenience afforded by a more standardized approach.
The improved products of the present invention, as described below, have been developed to overcome the problems associated with the units described in the known prior art, and to better fulfill market needs.
SUMMARY OF THE INVENTIONThe present invention relates to improved drainage devices having features to assist in drainage unit installation and connection to drainage components, such as, for example, drainage pipes and other drainage components and units.
According to one embodiment, the present invention provides a method for adapting a drainage component for attachment. A drainage unit is provided comprising a preferably substantially annular conduit that is optionally surrounded by an amount of aggregate, such that the aggregate and conduit are contained within a permeable sleeve material, with said conduit extending a predetermined distance from the sleeve material and aggregate. The conduit has a internal diameter and an external diameter. A preferably substantially annular connector is provided having a first and second end. The connector comprises an external diameter substantially equivalent to the internal diameter of the conduit, with the connector further comprising an integral means for retaining the connector within the conduit. A coupling is provided having first and second ends, and further comprises a plurality of staged internal diameters. One of the coupling's internal diameters is dimensioned to be substantially equivalent to the external diameter of said connector. The connector's first end is then introduced into the conduit and engages the connector retaining means within the conduit. The connector's second end is introduced into the coupling first end, with the connector's retaining means engaging the coupling.
In another preferred embodiment, a substantially annular drainage component is provided having an external diameter at a first end, with the external diameter being substantially equivalent to an internal diameter of the second end of the coupling. The component first end is then inserted into the coupling second end. A sealing compound or other sealing means may be provided to surfaces of the components to effect enhanced sealing. The sealant may preferably react chemically with any of the coupling, connector and/or drainage component surfaces as required.
According to a further embodiment, the present invention is directed to an apparatus for adapting drainage components for attachment comprising a substantially annular connector having a first and second end. The connector comprises an external diameter substantially equivalent to the internal diameter of the conduit, and an integral means for retaining the connector within the conduit. The apparatus further comprises a coupling having first and second ends, and comprising a plurality of staged internal diameters; one of the internal diameters being substantially equivalent to the external diameter of said connector.
In a still further embodiment, the present invention is directed to a drainage assembly comprising a drainage unit comprising a substantially annular conduit surrounded by an amount of aggregate and contained within a permeable sleeve material, with said conduit extending a predetermined distance from the sleeve material and aggregate. The conduit has an internal diameter and an external diameter. The system further comprises a substantially annular connector having a first and second end, and an external diameter substantially equivalent to the internal diameter of the conduit. The connector further comprises integral means for retaining the connector within the conduit, said connector engaged within said conduit. A substantially annular coupling having first and second ends, and a plurality of staged internal diameters is provided to engage with the connector. The first end of the coupling, therefore, has an internal diameter substantially equivalent to the external diameter of the connector.
In yet another embodiment, the drainage assembly of the present invention further comprises a substantially annular drainage component having an external diameter at a first end that is substantially equivalent to the internal diameter of the second end of the coupling, such that the drainage component may intimately contact with the second end of the coupling.
Further objects, advantages and embodiments of the invention will become evident from the reading of the following detailed description of the invention wherein reference is made to the accompanying drawings.
As disclosed in the aforementioned U.S. Patents, the production and use of drainage units for installation in a drainage field, such as, for example, in a nitrification field employed in a ground absorption sewage treatment and disposal system, etc. require ease of installation on-site at an end use, uniformity, etc. Since such drainage units must often connect to other drainage components, it is important for drainage units to conveniently and predictably interconnect with other drainage components, as well as themselves. As explained above, known systems in the field do not lend themselves to convenient, substantially uniform and/or predictable connectivity.
According to preferred embodiments of the present invention, the coupling may be made from any moldable thermoplastic or thermoset material able to withstand environmental degradation, and moldable to any suitable dimension desired to facilitate coupling a drainage unit to another connector that is in intimate contact with, or is itself integral to another drainage component or drainage component line. More preferably the coupling is made from a material selected from the group consisting of polyvinyl chloride (PVC) and acrylonitrile butadiene styrene (ABS). Most preferably, the coupling of the present invention is made from a PVC.
According to embodiments of the present invention, the connectors may be made from any moldable thermoplastic or thermoset material able to withstand environmental degradation and moldable to any suitable dimension desired to facilitate coupling a drainage unit to another connector that is in intimate contact with, or is itself integral to another drainage component or drainage component line. More preferably the coupling is made from a material selected from the group consisting of polyethylene, polypropylene, PVC, and ABS. Most preferably, the connectors used in connection with the present invention are made from a high density polyethylene (HDPE).
Still further, it is understood that the connectors and couplings of the present invention are dimensioned to receive an annular drainage component such as a pipe or tubing that is itself integral with a drainage component, or that is connected to another drainage component. In this way, the coupling acts to securely, conveniently and predictably join, in uniform fashion, the drainage apparatuses that are the subject of commonly assigned U.S. Pat. Nos. 5,015,123; 6,854,924 and 6,705,800 (the contents of which are incorporated by reference herein, as if made a part of this specification) to a second drainage component having an annular connector. The present application contemplates that such annular connectors are made from any suitable moldable thermoplastic or thermoset material able to withstand environmental degradation and moldable to any suitable dimension desired to facilitate coupling a drainage unit to another connector that is in intimate contact or is itself integral to another drainage component or drainage component line. More preferably the annular elements or connectors extending from the drainage units are made from a material selected from the group consisting of HDPE, polypropylene, PVC or Most preferably, the annular elements or connectors used in connection with the present invention are made from HDPE.
According to present industry standards in the drainage art, four inch corrugated pipe or tubing is used in concert with the drainage units that are the subject of the aforementioned commonly assigned US Patents. Therefore, the present invention solves the existing problem of how best to connect the drainage units comprising the internally disposed pipe to other drainage components that are in intimate contact with connectors such as polyethylene (PE) pipe. Such PE pipe typically connects to drainage components including drainage manifolds or drainage distribution boxes.
In one embodiment, the present invention comprises the use of specialized, uniform parts that quickly and predictably standardize the process of joining and coupling drainage components together, by providing a uniform connector that is sized to securely engage the aggregate-filled drainage units. The connector is designed to intimately engage a specially designed, uniform coupling ring having a plurality of sections, each with varying inner diameter suited to mate with annular components of varying dimensions common to the pipe and drainage industry. In this way, the annular component having a certain outer diameter mates with the coupling ring having a matching inner diameter to provide a secure, predictable intimate connection, with or without the separate application of securing compounds or securing agents such as, for example, adhesives, bonding agents, glues, screws, fasteners, clamps, etc. Such systems and apparatuses of the present invention thus afford much economy to the otherwise tedious and imprecise methodology presently used, whereby pipes (e.g. PVC or PE, etc.) require use of a pipe coupler, or otherwise cut ends off from the pipe to create an ad hoc securing means to be glued or otherwise secured onto the end of a PVC fitting.
In one preferred embodiment, the present invention comprises a specially molded and dimensioned coupling ring with a plurality of inner diameter specifically designed to mate with both standardized outer diameters of approved pipe commonly used in the drainage industry, such as, Sch 40 and Sch 35 pipe. Thus, the innovative couplings and systems of the present invention allow either commonly sized pipe to be connected to the aggregate-filled drainage components via the versatile coupling ring.
It is understood that the connectors, coupling and drainage components will most often be annular, as the accepted drainage component conveyance for fluids is most often a pipe, and the interconnected appliances must “mate, or otherwise engage with such pipe, which is ordinarily presented with a substantially annular configuration. Such annular components will therefore have an inner and outer diameter and radius. However, it is also understood that the components, couplings and connectors presented in the embodiments of the present invention are not limited in any way to any such annular orientation. Therefore, the present invention contemplates improved drainage systems having components, couplings and connectors that may not be annular, either along their length, or at their ends. In these instances of non-annularinity, the components, couplings and connectors of the present invention will have internal and external dimensions, rather than diameters. The only shape requirement in such cases, is that the components, couplings and connectors are suitably, cooperatively dimensioned for predetermined engagement with one another as disclosed herein, and as would be readily apparent to one skilled in the drainage fitting industry in light of the teachings herein.
Such standardization afforded by the systems and apparatuses of the present invention is especially important for use within regulated industries, such as transportation, home and other construction industries, etc. where materials and their proper installation are commonly regulated by various codes and ordinances to insure public safety.
The aggregate used in the drainage units requiring coupling to other drainage components is preferably made from lightweight plastic pieces (e.g. plastic puffballs, chips, cubes, etc.), and is preferably crush-resistant, blown polystyrene pieces of any desired shape selected to predictably facilitate the liquid throughflow drainage features of the resulting drainage units. Such aggregate is preferably held in a tubular sleeved orientation by netting as disclosed in the aforementioned commonly assigned U.S. Patents.
The sleeve netting is preferably a seamless plastic mesh tube of construction netting with an expandable diameter of variable size, for example, of from about 12 inches up to about 36 inches or more. However, it is understood that a plastic or other useful material can be selected to stretch or shrink to any conceivable desired unit diameter, dependent only on the requirements of the end use of the drainage unit in the field. The sleeve material may be provided to the manufacturing methods and apparatuses of the present invention substantially continuously as, for example, a roll, or may be supplied in individual, pre-dimensioned segments, as desired.
The drainage units contemplated for use with respect to the coupling of the present invention comprise a perforated conduit, or other pipe component, depending on the end use field requirements of the drainage units.
As described in the '924 patent, the drainage units may comprise a liquid permeable barrier sheet that may be constructed of any suitable pliable water permeable sheet material such as paper or cloth, but is preferably a geo-textile material such as nylon having a fine weave to block the passage of solids such as sand or dirt, but remain sufficiently permeable to allow the passage of water and fluids therethrough, preferably at a predictable and pre-selected rate. The barrier sheet may be of any desired thickness. The barrier sheet may be very thin to readily conform to the shape of the unit, which is preferably cylindrical, or the barrier sheet may be of a thickness as desired to provide rigidity to the unit for desired applications. The non-permeable barriers sheets are made from any suitable material that is impervious to liquids. Preferred non-permeable barrier sheets are made from plastics as would be readily understood by one skilled in the field of liquid impervious materials.
It is to be understood that, according to contemplated embodiments of the present invention, the novel connector and coupling arrangement with conduits may be useful in the drainage and other fields of use without the presence of aggregate surrounding the conduit. In other words, according to the present invention, a drainage or other conduit (such as, for example, a pipe) may engage one end of the connector and coupling, and another conduit or component (such as, for example, a second pipe) may engage the other end of the connector and coupling. In this way, a first conduit generally “fits” over the connector and is retained in position due to frictional fit with the aid of the retaining means. The first conduit then engages the outside of the first end of the coupling ring to a predetermined distance, and can be secured in position by means of supplied adhesive applied to the external surface of the coupling ring. Further, a second conduit can then be introduced to the interior of the second end of the coupling ring, and may preferably be “sandwiched” between the interior of the coupling ring and the exterior of the connector.
The present invention, therefore, generally contemplates the use of a versatile 2-piece connector and reinforcing coupling ring to universally join conduits of varying sizes. The conduits may fit within or outside of the connector and coupling ring as need to effect the desired union of conduits in a drainage or other line for the purpose of transporting fluids. In addition, depending upon the dimensions of the conduits being joined, and in certain circumstances, the present application also contemplates and embraces arrangements where the connector may engage a second coupling ring such that the connection unit comprises three pieces; two coupling rings engaged with the connector. In this orientation, one or both of the conduits being joined via the connector and coupling rings could be “sandwiched” between the exterior of the connector and the interior of the coupling ring.
The present invention may be embodied in still other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be construed in all respects as illustrative and not restrictive, the scope of the invention being indicated by the claims set forth below rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
Claims
1. A method for attaching drainage components comprising the steps of:
- providing a drainage unit comprising a conduit, said conduit having an internal dimension and an external dimension;
- providing a connector having a first and second end, at least one of said first or second ends comprising an external dimension substantially equivalent to the internal dimension of the conduit, said connector further comprising integral means for engaging the connector within the conduit;
- providing a coupling having first and second ends, said coupling comprising a plurality of staged internal dimensions, at least one of said internal dimensions being substantially equivalent to the external dimension of an end of said connector;
- introducing the connector first end into the coupling first end, said coupling engaging the connector retaining means within the coupling; and
- introducing the conduit into the coupling second end, and engaging the connector retaining means to position the coupling in a predetermined position.
2. The method of claim 1, further comprising the steps of:
- providing a drainage component having an external dimension at a first end, said external dimension substantially equivalent to an internal dimension of the coupling and said component having an internal dimension substantially equivalent to the external dimension of the connector; and
- introducing the component first end into the space between said coupling and said connector.
3. The method of claim 1, further comprising the steps of:
- providing a drainage component having an internal dimension at a first end, said internal dimension substantially equivalent to an external dimension of the coupling; and
- introducing the coupling into first end into the drainage component.
4. The method of claim 1, further comprising the steps of:
- providing a drainage component having an internal dimension at a first end, said internal dimension substantially equivalent to the external dimension of the connector second end; and
- introducing the drainage component first end onto the connector second end, said connector retaining means engaging the internal dimension of the component.
5. The method of claim 1 wherein the coupling has at least three staged internal dimensions.
6. The method of claim 5, wherein the internal dimensions have different values.
7. The method of claim 1, wherein the connector retaining means comprise locking tabs.
8. The method of claim 1, wherein the connector first and second ends have varying external dimensions.
9. The method of claim 1, wherein the connector has a wall diameter dimensioned to allow insertion into the coupling to a predetermined distance within the coupling, such that the end of the connector intimately contacts a first flange within the coupling.
10. The method of claim 1, wherein the connector has a wall diameter dimensioned to allow insertion into the coupling to a predetermined distance within the coupling, such that the end of the connector intimately contacts a second flange within the coupling.
11. The method of claim 2, further comprising the steps of:
- providing a compound to facilitate sealing;
- applying the compound about the external dimension or internal dimension of the component to effect a seal at the interface of the internal dimension of the second end of the coupling with the external dimension of the first end of the component, or to effect a seal at the interface of the external dimension of the connector and the internal dimension of the component.
12. The method of claim 11, wherein the compound is a sealant;
13. The method of claim 11, wherein the compound reacts chemically with the component and a surface selected from the group consisting of a coupling surface and a connector surface.
14. The method of claim 11, wherein the compound is selected from the group consisting of: epoxies, acrylonitirles, polyvinyl chloride cement, and combinations thereof.
15. The method of claim 1, wherein the coupling comprises a material selected from the group consisting of: high density polyethylene, polypropylene, acrylonitrile butadiene styrene, polyvinyl chloride, and combinations thereof.
16. The method of claim 2, wherein the coupling, the connector, and the drainage component are substantially annular.
17. The method of claim 1, wherein the conduit is substantially longitudinally surrounded by an amount of aggregate, said aggregate and conduit oriented within a permeable sleeve material.
18. A method for adapting a drainage component for attachment comprising the steps of:
- providing a drainage unit comprising a conduit, said conduit having an internal dimension and an external dimension;
- providing a connector having a first and second end, at least one of said first or second connector ends comprising an external dimension substantially equivalent to the internal dimension of the conduit, said connector further comprising integral means for retaining the connector within the conduit;
- providing a coupling having first and second ends, said coupling comprising a plurality of staged internal dimensions, at least one of said internal dimensions being substantially equivalent to the external dimension of said connector;
- introducing the connector first end into the conduit and engaging the connector retaining means within the conduit;
- introducing the connector second end into the coupling first end, and engaging the connector retaining means within the coupling.
- providing a drainage component having an external dimension at a first end, said external dimension substantially equivalent to an internal dimension of the coupling, and having an internal dimension substantially equivalent to the external dimension of the connector; and
- introducing the component first end into the coupling, such that the drainage component extends into the coupling to a distance sufficient to overlap a portion of the connector within the coupling.
19. The method of claim 18, wherein the coupling, the connector, and the drainage component are substantially annular.
20. The method of claim 18, wherein the conduit is substantially longitudinally surrounded by an amount of aggregate, said aggregate and conduit oriented within a permeable sleeve material.
21. An apparatus for adapting drainage components for attachment comprising:
- a connector having a first and second end, said connector comprising an external dimension substantially equivalent to the internal dimension of the conduit, said connector further comprising integral means for retaining the connector within the conduit; and
- a coupling having first and second ends, said coupling comprising a plurality of staged internal dimensions, one of said internal dimensions being substantially equivalent to the external dimension of said connector.
22. The apparatus of claim 21 wherein the coupling has at least three staged internal dimensions.
23. The apparatus of claim 21, wherein the internal dimensions have different values.
24. The apparatus of claim 21, wherein the connector retaining means comprise locking tabs.
25. The apparatus of claim 21, wherein the connector first and second ends have varying external dimensions.
26. The apparatus of claim 21 further comprising:
- a component having an internal dimension substantially similar to the external dimension of the connector, and said component having an external dimension substantially similar to an internal dimension of the coupling.
27. The apparatus of claim 21, wherein the value of the external dimension of the connector substantially near a connector end is less than the value of the internal dimension of the coupling internal dimension, such that a gap having a predetermined value exists between the coupling and the connector.
28. The apparatus of claim 21, wherein the connector, and the coupling are substantially annular.
29. The apparatus of claim 26, wherein at least an end of the component is annular.
30. The apparatus of claim 21, further comprising a compound to facilitate sealing applied to the external dimension of the component to effect a seal at the interface of the internal dimension of an end of the coupling with the external dimension of an end of the component.
31. The apparatus of claim 30, wherein the compound is a sealant.
32. The apparatus of claim 30, wherein the compound reacts chemically with the component and the coupling.
33. The apparatus of claim 30, wherein the compound is selected from the group consisting of: epoxies, acrylonitirles, polyvinyl chloride cement, and combinations thereof.
34. The apparatus of claim 21, wherein the coupling comprises a material selected from the group consisting of: high density polyethylene, polypropylene, acrylonitrile butadiene styrene, polyvinyl chloride, and combinations thereof.
35. The apparatus of claim 21, wherein the component is substantially longitudinally surrounded by an amount of aggregate, said aggregate and conduit oriented within a permeable sleeve material.
36. A drainage assembly comprising:
- a drainage unit comprising a conduit, said conduit having a internal dimension and an external dimension;
- a connector having a first and second end, said connector ends comprising an external dimension substantially equivalent to the internal dimension of the conduit, said connector further comprising integral means for retaining the connector within the conduit, said connector retaining means engaged within said conduit; and
- a coupling having first and second ends, said coupling comprising a plurality of staged internal dimensions.
37. The drainage assembly of claim 36, wherein the coupling further comprises:
- a first end of having an internal dimension substantially equivalent to the external dimension of said connector, with said first end of said coupling in intimate contact with said connector.
38. The drainage assembly of claim 36, further comprising:
- a drainage component having an external dimension at a first end, said external dimension substantially equivalent to the internal diameter of an end of said coupling, the external dimension of the first end of the component in intimate contact with an internal dimension of the coupling.
39. The drainage assembly of claim 36, further comprising:
- a drainage component having an internal dimension at a first end, said internal dimension substantially equivalent to an external dimension of the coupling, such that the component internal dimension at the first end engages an external dimension of the coupling.
40. The drainage assembly of claim 36, wherein the coupling, the connector, and the conduit are substantially annular.
41. The drainage assembly of claim 38, wherein the component comprises at least an end that is annular.
42. The drainage assembly of claim 39, wherein the component comprises at least an end that is annular.
43. The drainage assembly of claim 36, wherein the conduit comprises drainage piping.
44. The drainage assembly of claim 36, wherein the conduit is substantially longitudinally surrounded by an amount of aggregate, said aggregate and conduit oriented within a permeable sleeve material.
45. A drainage system comprising the apparatus of claim 21.
46. A drainage system comprising the drainage assembly of claim 36.
47. A drainage system comprising the drainage assembly of claim 38.
48. A drainage system comprising the drainage assembly of claim 39.
Type: Application
Filed: Apr 25, 2007
Publication Date: Oct 30, 2008
Inventor: Theophilus B. Terry (Somerville, TN)
Application Number: 11/789,655
International Classification: E02B 11/00 (20060101);