The invention relates to housings used to protect, and provide access to, underground system devices, and more particularly, to a housing that provides openings formed on the housing by the removal of knockouts for conduits to extend into the housing.
Valve boxes and other underground protective housings are used to protect pumps, valves, meters and other components of underground systems. These system components are typically connected to water pipes, wire conduits, and/or other types of conduits. The housings often have open bottoms so that they can be positioned over the underground component with the top of the housing being flush or slightly above or below the ground level. A lid covers the top of the housing thereby keeping out dirt and debris while permitting access to the system components for maintenance or replacement of the system component. The housings are typically made of plastic.
It is often desirable to have the system component placed on top of, or even spaced above, a sub-grade floor and within the valve box, rather than partially buried within the sub-grade floor, for convenient access to all sides of the system component. Since the sub-grade floor is often a dirt or gravel floor, it also is desirable to keep the system component as removed as possible from dirt, dust, or other harmful foreign matter or elements from the sub-grade floor that might reduce the useful life of the system component. Since many underground system components are attached along horizontal conduits of the underground system, the horizontal conduits also are typically disposed on top of, or spaced above, the sub-grade floor.
The bottom of the housing is usually placed flush on top of the sub-grade floor to prevent further dirt or other matter from entering the interior of the valve box. In this case, a conduit extending from the system component within the housing and above the sub-grade level will need clearance to extend through a sidewall of the valve box. Thus, for some plastic valve boxes, a conduit extends through an opening on the sidewall formed by removal of a knockout. Knockouts are thin or perforated sections of the valve box, or sections with a thin periphery connecting the knockout to the remainder of the valve box, so that the knockout is relatively easily removed from the sidewall of the housing by being punched out by hand or by a tool to cut the knockout away from the sidewall of the valve box.
Plastic valve boxes also typically have a continuous, thickened flange extending all the way around the bottom of the housing to provide a wide base for the housing to sit level upon. This is especially helpful on relatively uneven sub-grade floors made of gravel for example. The flange also increases rigidity and strength of the housing walls to better withstand both vertical and lateral forces from backfilled dirt placed against the valve box. Thus, the flange acts like a footing and helps to prevent tipping, bending or buckling of the housing sidewalls. When the sidewalls of the housing form a closed tubular shape, whether rectangular or circular, the continuous flange also helps to increase hoop strength, such that the flange alleviates direct lateral forces from backfill impacted on a first wall section by transferring some of those forces to other wall sections around the valve box. Finally, once backfill is placed on top of the flange, the flange acts as an anchor to prevent unintentional pull-out of the housing from the ground.
On conventional valve boxes, the knockouts are not continued onto the flange on the bottom of the housing because that would reduce the strength of the valve box. This is adequate when small diameter conduits extending from the system component are maintained at an elevation above the flange. Often times, however, this is not the case, and a section of the flange also must be cut out, in addition to the knockout on the sidewall, in order to provide clearance for the conduit to extend out of the valve box. Thus, on the known valve boxes, a cutting tool often is needed to cut the relatively thick flange to provide such clearance. Cutting the flange is typically strenuous and time consuming work depending on the tools available.
Once a conduit is placed through a hole created by the removal of a knockout, a gap often exists between the conduit and the opening in the box that allows dirt to fall into the interior of the housing when the area around the box is backfilled. Users have attempted to cover the gap with cardboard or duct tape before filling the dirt in around the valve box. However, this is often ineffective to adequately cover the gap.
On some known valve boxes, the knockout is a flat plate with a straight bottom edge that is removed from a sidewall of the valve box. In an attempt to cover at least some of the gaps on the opening, the removed knockout can be reattached to the housing to cover at least part of the opening. In this case, the flat bottom edge is placed on a typically cylindrical conduit extending through the opening so that significant gaps still exist between the straight edge and around the conduit that permit dirt to enter the interior of the valve box. Thus, there is a desire for a housing that addresses all of these shortcomings.
Referring to
The flange 22 may be integrally formed with the wall 14 and provides a relatively wide base for the housing 10 for level and stable placement of the housing 10 on a sub-grade floor 200 (shown in
The housing 10, in the illustrated form, is generally a rectangular cylinder or rectangular frustum with two opposite short sides 34 and 36 and two opposite long sides 38 and 40. Optionally, the main body 12 may be generally annular or other closed arcuate shape where a single wall extends continuously around the entire valve box. Even further, the main body 12 may be polygonal with three or more distinct sides where the sides may or may not be the same size, or may include any other combination of curved and/or flat sides with an open top and an open bottom.
As shown in
Referring to
While in the present case, the knockouts 26 are shown to be placed on all sides of the housing 10 for versatility, and a number of knockouts are provided with different sizes to accommodate conduits of different sizes, this need not always be a combination, and at least one side of the housing 10 may have at least one knockout. It will be understood that the number and placement of the knockouts may be different depending on what is desired for a given system component to be covered and the conduits that attach to it. Features common to all of the knockouts are numbered similarly and may only be indicated on one of the knockouts 26.
Each illustrated knockout 26 has the wall section 28 forming part of the wall 14 of the main body 12, and the flange section 30 extending outward at the flange 22 and generally transverse from the wall section 28. The wall section 28 is detachable from the wall 14, while the flange section 30 is detachable from the flange 22. Once detached, a conduit 206 can extend through the resulting opening 32 and into the interior space 16, as shown on
Referring to
The thinned sections 42 and 44 should be sufficiently thick to limit unintentional detachment of the knockouts 26 from the housing 10 due to external forces common when in use, such as backfill being placed against the housing 10 and, once the backfill is set, forces due to lateral earth pressure or hydraulic pressure from groundwater. Also, the knockouts 26 and the thinned sections 42 and 44 should be sufficiently thick so that when the knockout 26 remains integrally attached to the housing 10, the flange section 30 assists to make flange 22 continuous around the main body 12 such that the forces described above and impacted by the wall 14 and/or flange 22 are transferred throughout the flange 22 to absorb and dissipate the forces. In the illustrated form, the thinned sections 42 and 44 are approximately 0.02 to 0.04 inches thick while the knockouts 26 and the surrounding wall 14 and flange 22 are generally about 0.10 inches thick or greater.
The thinned sections 42 and 44 are located at the peripheries 46 and 48 of the wall section 28 and the flange section 30, respectively. To strengthen the housing 10 and limit unintentional detachment of the knockouts 26 from the housing 10, the length of the thinned sections 42 and 44 are maximized. Thus, in one example, the thinned sections 42 and 44 extend substantially continuously along peripheries 46 and 48. In other words, the wall section 28 is connected to the wall 14 by the thinned section 42 wherever the periphery 46 of the wall section 28 faces or opposes the wall 14. Likewise, the flange section 30 is connected to the flange 22 wherever the periphery 48 of the flange section 30 faces or opposes the flange 22. Thus, the thinned section 42, and in turn the periphery 46, extends along an inverted, generally U-shape with two generally parallel left and right segments 50 and 52 connected by an inverted semi-circular segment 54 (although other shapes are possible).
With this configuration, once the knockout 26 is removed, the opening 32 has a corresponding shape (as shown on
Similarly, the thinned section 44, and in turn the periphery 48, of the flange section 30 has two generally outwardly extending, opposite left and right segments 62 and 64 that are generally parallel to each other and that extend outwardly from the wall 14 to a distal rim 66 of the flange 22. The thinned section 44 also includes jog segments 68 and 70 extending along wall 14 and respectively interconnecting the thinned flange segments 62 and 64 to the thinned wall segments 50 and 52 of the thinned section 42.
In one form, the flange section 30 has a contoured portion 72 shaped to receive a conduit 204 or 206, and two flat left and right flange or wing portions 74 and 76 extending transversely from opposite sides of the contoured portion 72. The periphery 48 of the flange section 30, and in turn the thinned section 44, is formed on the wing portions 74 and 76 for connecting the flange section 30 to adjacent portions 78 and 80 of the flange 22. Alternatively, the separable thinned section 44 could be provided along seams 82 that transition the contoured portion 72 to the wing portions 74 and 76. It also will be understood that the wing portions 74 and 76 could be eliminated and the contoured portion 72 could directly attach to the adjacent portions 78 and 80 of the flange 22. It will be appreciated that, alternatively, the thinned sections 42 and 44 may extend on less than the full length of the peripheries 46 and 48 such as spaced at uniform or non-uniform locations on the peripheries 46 and 48.
Referring to
The flange section 30 has a transverse profile 92 that aligns with the profile 86 of the lower surface 84 and conforms to the shape of the conduit 204 to provide clearance for the conduit 204 through the flange 22, or more specifically, under the flange section 30. In more detail, a lower surface 94 of the flange section 30 forms transverse profile 92 and extends flush from the lower surface 84 of the wall section 28. In one example, the profiles 84 and 92 are contoured to receive pipes or conduits with outer diameters of about 1 to 2 inches. The profiles of different knockouts may be dimensioned to align with, and provide clearance for, conduits of different sizes while the knockout 26 is still integrally attached to the housing 10. Optionally, some of the knockouts 26 may not provide such clearance.
In one form, the flange section 30 is semi-cylindrical or barrel vault shaped such that the lower surface 94 of the flange section 30 has a constant radius generally from a proximal end portion 96 of the flange section 30 and near the wall section 28 to a distal end portion 98 of the flange section 30 as shown for the knockouts 26a to 26c on the long side 38 of the main body 12. Alternatively, the flange section 30 may taper in as it extends away from the wall 14 so that the distal end portion 98 may be just slightly larger than a conduit of a certain size while maintaining a uniform width of the wall section 28 on the wall 14 from knockout to knockout. As shown on
In the illustrated examples, the flange sections 30 of knockouts 26d to 26h taper inward as they extend outward from the wall 14 so that the distal end portion 98 of each flange section 30 has a profile with a smaller diameter than the diameter of the profile at the proximal end portion 96 at the wall section 28. This tapered configuration also provides clearance for flanged parts of a conduit with a larger outer diameter than the adjacent conduit, such as at the junction of two pipe pieces. The flanged part may be placed under the wall section by the larger diameter profile while a smaller diameter section of conduit may be placed at the distal end portion 98 of the flange section 30.
It will be appreciated that the flange section 30 may have many other shapes to accommodate conduits of unusual shapes, such as three dimensional shapes including a gable roof. The flange section 30 may have a transverse profile 92 on lower surface 94 that is linear, chevron, stepped, sloped, or grooved or any other shape to conform to the outer profile of a conduit received by the flange section 30. It will also be appreciated that the longer the flange section 30, the greater the amount of foreign particles the flange section 30 can impede. Thus, the flange section 30 may even be set to extend beyond the distal rim 66 to impede more foreign particles from entering beneath it as explained herein.
Referring to
Referring to
Referring to
Whether tapered or not, the adjacent portions 78 and 80 on the flange 22 that face opposite sides 124 and 126 of the flange section 30 have sufficient height so that even when the knockout 26 is reattached to the housing 10 and placed over a conduit 206 depending on the size of the conduit, the flange section 30 still extends directly between the adjacent portions 78 and 80 to generally enclose the cavity 100 underneath the flange section 30 and between the adjacent portions 78 and 80. This generally impedes foreign particles from entering the cavity 100 along the left and right sides 124 and 126 of the flange section 30.
Referring to
Similarly, corner portions 142 of the flange 22 have transverse sidewalls 144 similar in shape to the sidewall 140 of the ribs 130 and that extend both upward and downward from a flat, horizontally extending, interior portion 146. The sidewalls 144 also extend along an exterior edge portion 148 of the corner portions 142 to form the corners of the distal rim 66. An upper edge 150 of the sidewalls 140 and 144 slants upward as the sidewalls extend toward the wall 14. Sidewalls 140 and 144 form the adjacent portions 78 and 80 that are connected to the wing portions 74 and 76 on the left and right sides 124 and 126 of the flange section 30 by the thinned section 44. Thus, the flange sections 30 are disposed either between two ribs 130 (at knockouts 26b, 26g, and 26h), between a rib 130 and a corner portion 142 (at knockouts 26a, 26c, 26f, and 26i), or between two corner portions 142 (at knockouts 26d and 26e).
The interior portions 132 and 146 also are set at the same height on the flange 22 as the wing portions 74 and 76 of the flange sections 30 so that the interior portions 132 and 146 and wing portions 74 and 76 of a flange section 30 remaining attached to the flange 22 generally form a continuous horizontal plate for the flange 22 (albeit bent at contoured portions 72 of the flange sections 30) for transferring, absorbing, and/or dissipating forces.
Referring to
Referring again to
While the invention has been described with respect to specific examples including presently preferred modes of carrying out the invention, those skilled in the art will appreciate that there are numerous variations and permutations of the above described systems and techniques that fall within the scope of the invention as set forth in the appended claims.