This application claims benefit to provisional application Ser. No. 61/449,590 filed Mar. 4, 2011.
The present invention relates to tanks for containing liquids, in particular to tanks which are assembled from molded plastic half tanks, especially septic tanks.
Large oblong plastic tanks, such as those for containing water or wastewater have in the past been fabricated by molding two dish-shape halves and then mating the halves at a lengthwise planar joint. This kind of construction provides an advantage over one piece plastic tanks in that half tanks may be nested for shipment and storage, potentially reducing handling and transport costs. It also enables closer control of wall thickness and better definition of interior detail. This kind of construction provides an economic and ease-of-handling advantage over typical concrete septic tanks that are heavy and comprised of halves which do not nest for transport.
In the past, half tanks may be joined to each other by adhesives or mechanical means. Adhesives have the advantage of permanency of joint. Examples of tanks made by such means include those shown in Graham U.S. Pat. No. 4,325,823 and U.S. Patent Publication 2001/0019026 of Berg et al. Mechanical joining means provide the advantage of being independent of substrate material properties, joint preparation, environment, and cure time which often relate to bonding or fusing.
Large plastic tanks, including those suitable for septic tank application, have been previously made as injection molded halves which are clamped together for use. See for example, U.S. Pat. Nos. 7,572,372 and 5,878,907 of Graf. Injection molding produces good dimensional control and fidelity, compared to tanks made by fiberglass resin layup or to polyolefin tanks made in one or more pieces by blow molding or rotational molding as shown in Kruger U.S. Pat. No. 8,070,005.
When a septic tank is an assembly of mechanically mated halves, it is important that the seal of the joint between half tanks be sound, to prevent flow into or out of the tank through the joint region. In contrast to typical concrete septic half tanks which are typically mated at the point of installation in the soil, molded plastic septic tanks of the type described in the Graf patents and the present invention can be assembled at a work place remote from the factory and then transported a relatively short distance to the point of use, where they may be lifted from a truck and placed in a pit. Often an assembled tank is dragged across the surface of the earth to the point of installation. Occasionally, a tank may be dropped from a truck bed or other transporter. Thus, the means for holding the halves together must be sufficient to reasonably endure such kinds of mechanical forces.
An object of the invention if to provide a septic tank comprised of mechanically mated half tanks which is strong under conditions of transport and use and which is leak resistant and durable during use. A further object is to provide means for mechanically holding together mated half tanks that does not require special tools and that can reliably be carried out in the field, and is economical to manufacture on a mass production basis.
In accord with the invention, a tank is formed by joining together half tanks at mating flanges, and the flanges are held together with a multiplicity of clamps having a C-shape cross section. In an embodiment of the invention, each clamp has a groove-containing concavity and slides lengthwise to engage aligned pairs of nubs, which mating nubs pairs project from the surfaces of the mated flanges which surfaces are away from the surfaces which form the joint.
In different embodiments of the invention, the surface of one nub or an aligned nub pair may be either sloped or parallel relative to the surface of the other nub. The concavity of the clamp which engages the such aligned nub pairs have interior opposing side grooves. Lengthwise motion of the clamp causes the nubs, and thus the flanges, to be drawn together to form a tight joint, within which is typically a resilient seal.
In embodiments of the invention, an end of a clamp concavity comprises one or more flared portions. A flare portion running transverse to the claim length enables a clamp, when first being engaged with an aligned nub pair, to be angled about a vertical axis which is nominally perpendicular to the plane of the joint. This makes easy clamp installation, particularly when the clamps are close together. Other flare portions run from the bottoms of the grooves, to ease the engagement of the free surfaces of the nubs with the bottoms of the grooves, as the flanges are being forced toward each under, to compress a resilient gasket between the flanges.
When a clamp reaches its desired home position, a clamp may self-lock from further motion in one or both lengthwise directions by engagement of the clamp with a mating feature on the wall or flange of the tank. In one embodiment, there is a tooth on the wall of the tank which engages a notch in the side of the clamp, and contact portions of the mating locking parts are substantially perpendicular to the lengthwise direction of clamp motion.
Tanks of the present invention exist in kit form, that is, as components which can be easily and economically transported, with the half tanks nested with each other, so they can be assembled at the point of fabrication or of use. Alternately, tanks of the present invention exist in assembled form. The invention achieves the objects which are set forth above.
The foregoing and other objects, features and advantages of the present invention will become more apparent from the following description of preferred embodiments and accompanying drawings.
While the invention is described in terms of a septic tank embodiment, it will be appreciated that the features of the invention can be applied to tanks suited for other uses. Typical characteristics and functional aspects of septic tanks are described in commonly owned patent application Ser. No. 12/445,774 of K. Kruger et al. and Ser. No. 12/445,774 of R. Moore Jr. et al. both filed Jun. 5, 2009, where a one-piece rotationally molded tank is described. The disclosures of the foregoing applications are hereby incorporated by reference.
With reference to
Each exemplary half tank 22 has a multiplicity of cylindrical pockets 44 spaced apart along the length of the tank wall inboard of the flange. The pockets 44 receive dowels 38 that facilitate accurate mating of the halves when the top half is lowered onto the bottom half. The exterior end of a pocket 44 is shown in
In the
Clamps preferably have locking features. With reference to
Notch 56C and tooth 50C are shaped so that, when they become engaged and the clamp is locked in position, the vertical space between the flange mating surface is sufficiently close to obtain a good seal and a mechanically stable joint. The engagement of the notch and tooth prevents the clamp from sliding backwards, and from releasing the force which clamp applies to the flanges and joint. In this and some other embodiments, there are locking features at both of the mated half tanks. In the generality of the invention, a clamp may be locked to only one of the half tanks, since when half tanks are laterally fixed to each other, as here by means of dowels 38, such a clamp will be locked from motion relative to both half tanks. As shown in
With reference again
Grooves 54 which comprise portions of the C-shape concavity or interior 80 of the clamp, are illustrated in
As clamp 60 is first being engaged with a mated nub pair, vertical flare 78 allows the clamp to be angled and twisted about a vertical axis VL which is nominally perpendicular to the horizontal plane BP of the mating flange joint 32, as such features are illustrated seen in
To summarize the foregoing: In embodiments of the invention, a clamp has a body with a C-shape cross section, defining an interior length-wise concavity and internal grooves. The clamp engages at the groove location pairs of nubs, one nub on each of the mated flanges. The surfaces of aligned nubs may be parallel, or they may be angled relative to each other and relative to the plane of the joint. The internal grooves of a clamp may be parallel to each other or they may have an included angle between them. Clamps of either style may be used with nubs of either style, with potential differing degrees of force and restraint being applied to the mated flanges. Preferred nubs have lengths substantially greater than their nub heights, where height is distance between a flange second surface and the free end of the a nub. When a clamp is first engaged with the nub pair, the clamp is angled with respect to the nub length along the flange; and as the clamp is further engaged, the clamp is swiveled or twisted in the plane of the joint between the mated half tank flanges.
As pointed out in connection with
Clamp 60 preferably has two spaced apart lands 68, 70 which define the notch 55. As evident from
In an alternate embodiment, not shown, land 70, 70D is not present on exemplary clamps 60, 60D. In such instance, when clamp is sufficient driven, the home position point is reached where the tooth “falls off” the land 68, and reverse motion of the clamp will be prevented. In this configuration of locking means, consequential further forward motion of the clamp might be resisted due to interference of the nubs within the opposing side grooves of the clamp, i.e., when one or the other is tapered. The presences of features corresponding with both of the lands 68, 70 is useful in that locking in both-directions prevents a tank assembler from over-driving the clamp and possibly causing it to move beyond the desired home position, and off the nubs or possibly the clamp can be broken due to “over-wedging.”.
While nubs have been described thus far as unitary structures, in the generality of the invention nubs may be comprised of discrete sub-elements. For example,
The tooth and a mating notch may respectively have other cross sections and shapes than the rectangular shape shown. For example, the tooth may have a semi-round configuration or a triangle configuration, and the notch may correspondingly have a shape which is a reverse image of such configuration. However, such shapes provide lesser degree of positive locking than do preferred locking features, where engagement surfaces are substantially perpendicular to the direction of sliding engagement of the clamp with the nub pairs.
Still other means for locking a clamp may be used in addition to, or in substitution of, the embodiments thus far described. For example, there may be a protuberance on the nub surface which engages a pocket within the groove of a clamp; the trailing end of the clamp may have a tooth which engages a notch on the surface of the flange or nub; the flange may have a tooth which engages a notch in the clamp; or a pin may be slipped into an appropriately located hole in the flange or tank wall, so the pin projects into the clamp rearward path; or a small wedge may be jammed between the trailing end of the clamp and the flange surface. In carrying out the invention, a clamp may be locked in home position by more than one different means for locking. Alternately, in carrying out the invention involving the flaring, a clamp may have no means for locking.
The half tanks of the invention may be made of a thermoplastic such as polypropylene or high density polyethylene. In the generality of the invention, the half tanks may be made by means other than injection molding, and they may be made of a non-thermoplastic resin. A clamp of the present invention is preferably made of glass-filed polypropylene, or other reinforced or engineered plastic. Alternately, the clamp may be made of other materials, including metals and plastics. Some features of exemplary half tanks are described in somewhat more detail in a commonly owned related U.S. patent application of R. Moore, Jr. et al., filed on even date hereof, bearing Ser. No. 13/412,466, and entitled “Manipulating and Restraining a Plastic Septic Tank.” The disclosure of the foregoing application is hereby incorporated by reference.
In use of the tank kit, the half tanks and clamps are injection molded at a factory using known molding methods. The half tanks are nested, typically concave wall down, for storage or transport to an assembly point, which could be the point of installation of the tank in the soil. Tanks may be economically shipped as kits to a distant point, since the half tanks can be nested. At the assembly point, exemplary steps for forming a tank comprise:
The foregoing system of making tanks from half tanks has been found advantageous. The clamps may be installed without special fixtures and only a mallet. Yet they hold the flanges of the tanks together well and a leak proof joint can be created.
The invention may be used with tanks where the half tanks, or the mating flanges and associated features of half tanks, are not identical. The principles of the invention may be applied to half tanks joints which are not entirely planar, and a reference to the plane of the joint for such kinds of tanks is a reference to the nominal or mean plane of the joint. A tank may have more than one joint. For instance, a tank may have a bottom concave piece, a middle cylindrical piece, and an upper concave piece, so that there are two clamped joints in the assembled tank.
The invention, with explicit and implicit variations and advantages, has been described and illustrated with respect to one or more embodiments. Those embodiments should be considered illustrative and not restrictive. Any use of words such as “preferred” and variations suggest a feature or combination which is desirable but which is not necessarily mandatory. Thus embodiments lacking any such preferred feature or combination may be within the scope of the claims which follow. Persons skilled in the art may make various changes in form and detail without departing from the spirit and scope of the claimed invention.
Number | Name | Date | Kind |
---|---|---|---|
1549878 | Immel | Aug 1925 | A |
4040372 | Flanders | Aug 1977 | A |
4231482 | Bogan | Nov 1980 | A |
4325823 | Graham | Apr 1982 | A |
4333580 | Sweigart, Jr. | Jun 1982 | A |
5361930 | Perry | Nov 1994 | A |
5878907 | Graf | Mar 1999 | A |
6280614 | Berg et al. | Aug 2001 | B1 |
6558535 | Berg et al. | May 2003 | B2 |
7572372 | Graf | Aug 2009 | B2 |
7854338 | Graf | Dec 2010 | B2 |
8070005 | Kruger et al. | Dec 2011 | B1 |
20110293371 | Moore et al. | Dec 2011 | A1 |
Number | Date | Country | |
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61449590 | Mar 2011 | US |