TRENCH DRAIN

Abstract

Trench drains are installed in indoor or outdoor locations and provide drainage for water and/or other liquids. Trench drains are elongated, having a length that is generally longer than a width. A trench drain includes a channel, a frame, and a drain cover. The channel can receive and direct water and/or other liquids that have entered the drain via the drain cover. The drain cover is supported by the frame, which is mounted to the channel.

Description

TECHNICAL FIELD

The present application relates to drains, and in particular to trench drains.

BACKGROUND

Trench drains are installed in indoor or outdoor locations and provide drainage for water and/or other liquids. Trench drains are elongated, having a length that is generally longer than a width.

SUMMARY

In one independent aspect, a trench drain includes a channel including an upper edge, a base, and an interior surface extending between the base and the upper edge; a frame including an upper surface and a lower surface, the lower surface positioned proximate the upper edge of the channel, the frame configured to transmit load exerted on the upper surface to a substrate surrounding the channel; and a drain cover supported on the frame.

In some aspects, a majority of the lower surface of the frame is unsupported by the channel.

In some aspects, a majority of the lower surface of the frame is configured to directly engage the substrate.

In some aspects, the channel is an elongated channel extending along an axis, a portion of the frame extending in a lateral direction transverse to the axis, the portion spaced apart from the channel by a vertical gap.

In some aspects, the channel includes a support rib protruding from an exterior surface of the channel.

In another independent aspect, a channel for a trench drain includes an upper edge, a base, an interior surface extending between the base and the upper edge, an exterior surface opposite the interior surface, and a support rib protruding from the exterior surface, the support rib having an outer profile that has a shape that corresponds to the interior surface of the channel.

In some aspects, the interior surface includes a first lower portion that is at an angle relative to a direction of height of the channel and a second upper portion that is substantially parallel to the direction of height of the channel.

In some aspects, the outer profile of the support rib includes a lower angled portion that corresponds to the first lower portion of the interior surface and an upper vertical portion that corresponds to the second upper portion of the interior surface.

In some aspects, the outer profile of the support rib can be received within and secured by an inner surface of a second channel that is identical to the channel.

In another independent aspect, a trench drain includes a channel including an upper edge, a base, an interior surface extending between the base and the upper edge, and an exterior surface opposite the interior surface; a clamp coupled to the exterior surface of the channel and configured to couple to a support member spaced apart from the channel; a frame having a lower surface positioned adjacent the upper edge of the channel, and a drain cover supported on the frame.

In some aspects, the clamp extends downward below the base of the channel.

In some aspects, the clamp extends horizontally from the channel and upper surface of the clamp is located at least 2 inches below the upper edge of the channel.

In some aspects, the channel includes a first channel portion and a second channel portion, the first channel portion has a first clamp and the second channel portion has a second clamp, and the first clamp and the second clamp are configured to couple to a single channel strut member spaced apart from the channel

In some aspects, the frame is configured to transmit load exerted on an upper surface of the frame to a substrate surrounding the channel, the frame includes a lug that increases a surface area of the frame that can contact the substrate.

In some aspects, the lug includes a foot configured to rest on an arm protruding from the exterior surface of the channel.

In some aspects, the lug is a first lug, the frame includes a second lug, and the first lug extends a first distance from the lower surface of the frame, the second lug extends a second distance from the lower surface of the frame, and the first distance is greater than the second distance.

In another independent aspect, a trench drain includes a channel including a first upper edge, a second upper edge spaced apart from the first upper edge, a base, an interior surface extending between the base and the first upper edge and the base and the second upper edge, and an exterior surface opposite the interior surface; a wing coupled to the exterior surface of the channel and configured to couple to a channel strut member spaced apart from the channel; a frame having a first rail positioned adjacent the first upper edge of the channel and a second rail positioned adjacent the second upper edge of the channel; and a drain cover supported on the frame.

In some aspects, the channel includes a first channel portion and a second channel portion, the first channel portion has a first wing and the second channel portion has a second wing, and the first wing and the second wing are configured to couple to a single channel strut member spaced apart from the channel

In some aspects, the frame includes a crossbar that couples the first rail to the second rail.

In some aspects, the channel includes a recess configured to receive the crossbar proximate the first upper edge or the second upper edge.

In some aspects, the channel strut member is coupled to the wing such that a gap is formed between the channel strut member and the exterior surface of the of the channel.

In some aspects, the channel strut member has a width that is a first distance, the gap has a width that is a second distance, and the second distance is greater than 0.75 times the first distance.

In some aspects, the channel strut member has a width that is a first distance, the gap has a width that is a second distance, and the second distance is less than 1.5 times the first distance

In some aspects, the wing includes an aperture configured to align with an aperture of the channel strut member such that a rod or fastener can extend through the aperture of the wing and the aperture of the channel strut member for coupling the wing to the channel strut member.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially exploded perspective view of a trench drain according to one embodiment.

FIG. 2 is a perspective view of a trench drain according to another embodiment.

FIG. 3A is a perspective view of a trench drain according to another embodiment.

FIG. 3B is a perspective view of a channel for the trench drain of FIG. 3A.

FIG. 3C is a section view of the trench drain of FIG. 3A, viewed along section 3C-3C.

FIG. 4A is a perspective view of a trench drain according to another embodiment.

FIG. 4B is a perspective view of a channel for the trench drain of FIG. 4A.

FIG. 4C is a perspective view of a frame for the trench drain of FIG. 4A.

FIG. 4D is a section view of the trench drain of FIG. 4A, viewed along section 4D-4D.

FIG. 5 is a perspective view of a frame for a trench drain according to another embodiment.

FIG. 6 is a perspective view of a trench drain according to another embodiment.

FIG. 7A is a perspective view of a trench drain according to another embodiment.

FIG. 7B is a perspective view of a channel for the trench drain of FIG. 7A.

FIG. 8 is an exploded view of a trench drain according to another embodiment.

FIG. 9 is a perspective view of a trench drain according to another embodiment.

FIG. 10A is a perspective view of a trench drain according to another embodiment.

FIG. 10B is a perspective view of a channel for the trench drain of FIG. 10A.

FIG. 10C is a perspective view of a frame for the trench drain of FIG. 10A.

FIG. 11A is a perspective view of a trench drain according to another embodiment.

FIG. 11B is a perspective view of a channel for the trench drain of FIG. 11A.

FIG. 11C is a perspective view of a frame for the trench drain of FIG. 11A.

FIG. 12A is a perspective view of a trench drain according to another embodiment.

FIG. 12B is a perspective view of a channel for the trench drain of FIG. 12A.

FIG. 12C is a perspective view of a frame for the trench drain of FIG. 12A.

FIG. 13 is a perspective view of a channel for a trench drain stacked with another channel for a trench drain according to another embodiment.

FIG. 14A is a perspective view of a trench drain according to another embodiment.

FIG. 14B is another perspective view of the trench drain of FIG. 14A.

FIG. 14C is a perspective view of a channel for the trench drain of FIG. 14A.

FIG. 14D is a perspective view of a frame for the trench drain of FIG. 14A.

FIG. 15A is a perspective view of a trench drain according to another embodiment.

FIG. 15B is another perspective view of the trench drain of FIG. 15A.

FIG. 15C is a perspective view of a channel for the trench drain of FIG. 15A.

FIG. 15D is a perspective view of a frame for the trench drain of FIG. 15A.

FIG. 16 is a perspective view of a trench drain according to another embodiment.

FIG. 17 is a perspective view of a trench drain according to another embodiment.

FIG. 18 is a perspective view of a trench drain according to another embodiment.

FIG. 19A is a perspective view of a trench drain according to another embodiment.

FIG. 18B is a top view of a portion of the trench drain of FIG. 19A.

FIG. 20 is a side view of a portion of the trench drain of FIG. 19A.

FIG. 21 illustrates a perspective view of a connection for two channels of a trench drain assembly according to one embodiment.

FIG. 22 illustrates a perspective view of a connection for two channels of a trench drain assembly according another embodiment.

FIG. 23 illustrates a perspective view of a connection for two channels of a trench drain assembly according another embodiment.

FIG. 24A illustrates a perspective view of a first end of a channel of trench drain according to another embodiment.

FIG. 24B illustrates a perspective view of a second end of a channel according to the embodiment of FIG. 24A.

FIG. 24C illustrates a perspective view of the channels of FIGS. 24A and 24B connected together.

FIG. 24D illustrates a section view of the connected channel assembly of FIG. 24C.

FIGS. 25A and 25B illustrate systems for supporting a channel for a trench drain.

FIGS. 26A-26D illustrate a clamp for receiving reinforcing rods or the like.

FIGS. 27-44 illustrate various systems for coupling a drain cover to a frame and/or channel.

FIGS. 45-50 illustrate various systems for coupling adjacent channels to one another.

FIGS. 51-69 illustrate methods and systems for coupling a reinforcing member to a trench drain.

DETAILED DESCRIPTION

Before any embodiments are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of the configuration and arrangement of components set forth in the following description or illustrated in the accompanying drawings. The embodiments are capable of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof are meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.

Relative terminology, such as, for example, “about,” “approximately,” “substantially,” etc., used in connection with a quantity or condition would be understood by those of ordinary skill to be inclusive of the stated value and has the meaning dictated by the context (e.g., the term includes at least the degree of error associated with the measurement accuracy, tolerances [e.g., manufacturing, assembly, use, etc.] associated with the particular value, etc.). Such terminology should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression “from about 2 to about 4” also discloses the range “from 2 to 4.” The relative terminology may refer to plus or minus a percentage (e.g., 1%, 5%, 10%, or more) of an indicated value.

FIGS. 1-2 illustrate a trench drain 100 that includes a channel 104, a frame 108, and a drain cover 112 such as a grate. The trench drain 100 is an elongated drain having a length substantially longer than a width or a height. The trench drain 100 may have a substantially consistent cross-section along the length, and the channel 104 may have a predetermined slope to facilitate drainage of fluid in the channel 104. In addition, support ribs 116 and clamps 120 may be positioned at predetermined intervals along the underside (i.e., outer surface) of the channel 104.

An interior surface 122 of the channel 104 may be generally V-shaped or U-shaped (e.g., have a V-shaped or U-shaped profile as viewed perpendicular to the longitudinal direction) and include a lower base 124, two angled surfaces 128 extending upwardly from the base 124, and two vertical surfaces 132 extending upward from the angled surfaces 128. In some embodiments, the base 124 may have a rounded profile and there is a smooth transition portion extending between the lowest point of the interior surface 122 and the angled surfaces 128 on each side of the interior surface 122. Each angled surface 128 may be substantially planar and may extend upwardly from the base 124 at an angle (relative to a vertical direction). The angle between the two angled surfaces 128 may be approximately 90 degrees (e.g., 85-95 degrees, 80-100 degrees). For example, each angled surface 128 may extend upwardly from the base 124 at an angle of approximately 45 degrees. The vertical surfaces 132 may extend upwardly from the respective angled surfaces 128 in a vertical direction (i.e., a direction opposite the gravitational direction when the channel 104 is installed), terminating at a distal end to define an upper edge of the channel 104.

An exterior surface 136 of the channel 104, opposite the interior surface 122, may also be an underside of the channel 104 when installed. The exterior surface 136 may be generally similar in shape to the interior surface 122 (increased in size by the thickness of the channel 104) except at the support ribs 116 and clamps 120.

The support ribs 116 may be spaced apart from one another at predetermined intervals along the length of the channel 104 with a support rib 116 located at each lengthwise end (one lengthwise end shown in FIGS. 1-2) of the channel 104 and one or more support ribs 116 located at their own predetermined intervals between the two lengthwise ends. The support ribs 116 may extend downward and outward away from the interior surface 122. Each support rib 116 may include a large flat base upon which the channel 104 is supported and may further include a plurality of steps extending upward from the large flat base toward the upper edge of the channel. Each of the steps may include a base that is parallel to the large flat base such that each support rib 116 extends upward along a stepped path towards the upper edge of the channel.

One or more of the support ribs 116 may include a clamp 120 coupled thereto. In some embodiments, the clamp 120 may include a central opening 140 through which a reinforcing rod (e.g., rebar) is insertable for securing the channel 104 within a poured concrete base. As shown, the clamp 120 may include a living hinge and a pair of openings 142 (extending horizontally therethrough) for a fastener to tighten the clamp 120 around the reinforcing rod.

In some embodiments, the channel 104 may include one or more crossbars 144 extending between opposing vertical surfaces 132 at the upper edge of the channel 104. The crossbars 144 may include a central opening 148 for receiving a fastener (not shown) for securing the drain cover 112 to the channel 104.

The frame 108 may include opposing L-shaped rails 160 interconnected to one another at predetermined intervals along the length of the frame 108. As shown, a lower leg 164 of each of the L-shaped rails 160 can rest upon the upper edge of the channel 104. The upper leg 168 of each of the L-shaped rails 160 may extend upward from the lower leg 164 to, together with the lower legs 164, define a receiving area for the drain cover 112. The frame 108 can provide additional strength and rigidity to the channel 104 and increases the amount of weight that can be supported on the trench drain 100. In some embodiments, the frame 108 may be made of a metal material (e.g., steel, aluminum). The frame 108 may further include brackets 172 coupled (e.g., integrally formed, welded) to the exterior of the frame 108. As shown in FIG. 2, each bracket 172 may extend downward from the point of attachment to the respective L-shaped rail 160, outward to rest upon the upper edge of the channel 104, downward to extend towards the exterior surface 136 of the channel 104, and then angled outwards away from the channel 104. The angled portion of the bracket 172 may include an opening 176. In some embodiments, the opening 176 can receive a fastener for coupling the frame 108 to the channel 104. In other embodiments, the opening 176 can receive a fastener for coupling the frame 108 to the poured concrete (before cured) that surrounds the trench drain 100.

The drain cover 112, as shown, may be a grate having a substantially planar upper surface 180 that rests within the frame 108 to cover the channel 104 and prevent large debris from entering the channel 104. The upper surface 180 may include a plurality of openings 184 therein to allow fluids (e.g., water such as rainwater) to pass therethrough and to the channel 104. As shown, the openings 184 may be arranged in a pattern and spaced apart along a majority of the upper surface 180. The drain cover 112 may further include one or more fastener openings 188 for receiving a fastener (not shown) to secure the drain cover 112 to the crossbar 144 of the channel 104. The overall height of the drain cover 112 may be created in part based on C-shaped legs 192 extending downward from the upper surface 180 at the widthwise edges of the upper surface 180. In the embodiment shown, the legs 192 may extend the entire length of the drain cover 112 with each leg 192 resting upon a respective one of the lower legs 164 of the frame 108.

With reference to FIG. 1, the channel 104 may further include horizontal extensions 152 at the upper edge of the channel extending outward from the generally V-shaped profile. The extensions 152 can provide a larger surface upon which the frame 108 rests. During installation, poured concrete may fill a space between the horizontal extensions 152, thereby providing direct concrete support for the frame 108 (i.e., the underside of the frame 108 is in direct contact with the concrete) mounted to the channel 104. In some embodiments, the extensions 152 may have openings 156 extending vertically therethrough for coupling the frame 108 to the channel 104 (e.g., via threaded fasteners).

FIG. 2 illustrates an embodiment in which gaps between the extensions 152 are omitted, instead having a single elongated horizontal extension 252 running a full length of the channel 104. The elongated horizontal extension 252 may be a shelf upon which the frame 108 rests. With a concrete pour filling the area beneath the elongated horizontal extension 252, the frame 108 may be indirectly supported by the poured concrete with the elongated horizontal extension 252 located therebetween.

FIGS. 3A-3C illustrate another variation of a trench drain 300. Features that are similar to the trench drain 100 shown in FIG. 1 are identified with similar reference numbers, plus 200. Some similarities and differences between the trench drain 300 and the trench drain 100 are described herein.

The trench drain 300 includes a channel 304 and a frame 308 mounted to the channel 304. FIGS. 3A-3C (along with further embodiments shown in other figures) omit a drain cover, though a drain cover may be received within the frame 308, similar to a frame as shown in, for example, FIGS. 1 and 2. The frame 308 of the trench drain 300 includes opposing L-shaped rails 360 that each include a lower leg 364 and an upper leg 368. The rails 360 further include downward flanges 372 that protrude perpendicularly from the lower leg 364 in the opposite direction of the upper leg 368. The lower leg 364 rests upon or near the upper edge 394 of the channel 304 and the downward flanges 372 abut the exterior vertical wall 396 of the channel 304.

The downward flanges 372 are spaced such that they are only located where they can abut the exterior vertical wall 396 and are not located anywhere where they might interfere with an exterior protrusion from the upper end of the channel (e.g., horizontal extensions 352). The downward flanges 372 provide additional assistance in aligning the frame 308 to the channel 304 and provide additional surface area for the frame 308 to attach to the poured concrete. As shown, the downward flanges 372 are offset from the upper leg 368 such that a portion of the lower leg 364 will rest upon the poured concrete, providing direct support of the frame 308. The frame 308 further includes external lugs 376 spaced along the L-shaped rail 360 that provide additional rigidity to the frame 308 and increase the concrete bearing surface of the frame 308. In some embodiments, the downward flanges 372 have openings (not shown) extending horizontally therethrough for coupling the frame 308 to the channel 304 (e.g., via threaded fasteners).

The channel 304 may include crossbar slots 354 in in the horizontal extrusions 352. Each crossbar slot 354 on one side of the channel 304 has a corresponding crossbar slot 354 on the other lateral side of the channel 304 and is shaped to receive a crossbar (not shown).

FIGS. 4A-4D illustrate another variation of a trench drain 400. Features that are similar to the trench drain 300 shown in FIGS. 3A-3C are identified with similar reference numbers, plus 100. Some similarities and differences between the trench drain 400 and the trench drain 300 are described herein.

The trench drain 400 includes a channel 404 and a frame 408 mounted to the channel 404. As shown, the frame 408 includes a rail 460 having a profile similar to that of the rail 360 shown in FIGS. 3A and 3C. In contrast to the rail 360, the rail 460 has a downward flange 472 that runs continuously along the length of the rail 460. Additionally, external lugs 476 are spaced apart from one another at predetermined intervals along the rail 460 and each further include a support foot 480 that protrudes outwardly from a bottom end of the external lug 476. The support feet 480 provide additional concrete bearing surface and in some instances rest upon external protrusions from the channel 404. The external protrusions can be formed to support the frame 408 (e.g., channel pads 488 or an arm of a clamp 420 or the like may support the frame 408). Some of the support feet 480 may have an opening 484 extending vertically therethrough for coupling the frame 408 to the channel 404 by attaching to the channel pads 488 or other external protrusions (e.g., via threaded fasteners).

The channel 404 may include crossbar slots 454 in vertical surfaces 432 of the channel 404. Each crossbar slot 454 on one side of the channel 404 has a corresponding crossbar slot 454 on the other lateral side of the channel 404 and is shaped to receive a crossbar 444. The crossbar 444 can be integrally formed to the frame 408 as shown in FIG. 4A. Or, as shown in FIG. 4C, a removable crossbar 456 can be a separate component to be placed in the crossbar slots 454 and coupled to each rail 460 of the frame 408 via an attachment method (e.g., threaded fasteners through crossbar attachment openings 440). Providing a removable crossbar 456 allows the rails 460 of the frame 408 to be more easily and compactly stored, transported, and handled while still allowing the crossbar to be made of a stronger and more durable material than if the crossbar 444 were formed integrally in the channel 404. Use of a stronger and more durable material for the removable crossbar 456 provides better support for the drain cover (not shown). Once assembled, the removable crossbar 456 is substantially held in place by the crossbar slots 454 and attachment method to the rail 460 of the frame 408 such that the removable crossbar 456 will not move or displace as loads are transferred to the drain cover or frame 408. Moreover, the removable crossbar 456 is held in alignment such that a central opening (not shown on removable crossbar 456 but shown as 448 on crossbar 444) of the removable crossbar 456 will not become misaligned from a corresponding drain cover attachment bolt and will not spin when threading such bolt.

FIG. 5 illustrates another variation of a frame 508 for a trench drain (not shown). Features that are similar to the frame 408 shown in FIGS. 4A, 4C, and 4D are identified with similar reference numbers, plus 100. Some similarities and differences between the frame 508 and the frame 408 are described herein.

The frame 508 includes a rail 560 having a profile similar to that of the rail 460 shown in FIGS. 4A, 4C, and 4D. In contrast to the rail 460, the downward flange 572 of the rail 560 may have a shorter vertical height, which may reduce overall material and weight. Similarly, the frame 508 may include several shortened external lugs 578 that may terminate at the shortened bottom end of the downward flange 572. Some external lugs 576 extend beyond the shortened bottom end of the downward flange 572 and include support feet 580. The frequency and spacing of each type of external lug 576 or shortened external lug 578 may be selectively chosen to optimize concrete bearing surface of the frame 508 and alignment and attachment of the frame 508 to the channel (not shown) while reducing material weight.

FIG. 6 illustrates another variation of a trench drain 600. Features that are similar to the trench drain 400 shown in FIGS. 4A-4D and the frame 508 shown in FIG. 5 are identified with similar reference numbers, plus 200 and plus 100, respectively. Some similarities and differences between the trench drain 600 and the trench drain 400 are described herein.

The trench drain 600 includes a channel 604 and the frame 608 mounted to the channel 604. As shown, the frame 608 includes a rail 660 having a profile similar to that of the rail 560 shown in FIG. 5. In contrast to the rail 560, rail 660 utilizes at least one wide support foot 692 that is wider than an external lug 676 that it is attached to. The wide support foot 692 includes a support foot opening 696 extending vertically therethrough for coupling the frame 608 to the channel 604 by attaching to channel pads 688 or other external protrusions such as a support arm of a clamp 620 as shown in FIG. 6 (e.g., via threaded fasteners). The wide support foot 692 overhangs the external protrusion it rests upon so that it is partially supported by the external protrusion and partially supported by poured concrete. Also as shown, one or more external lugs 676 with support feet 680 may be located such that the external lug 676 and support foot 680 does not have any portion of an external protrusion or other portion of a plastic channel 604 beneath it so that the full support foot 680 may be supported by poured concrete.

FIGS. 7A and 7B illustrate another variation of a trench drain 700. Features that are similar to the trench drain 300 shown in FIGS. 3A-3C are identified with similar reference numbers, plus 400. Some similarities and differences between the trench drain 700 and the trench drain 300 are described herein.

The trench drain 700 includes a channel 704 and a frame 708 mounted to the channel 704. As shown, the frame 708 includes a rail 760 having a profile similar to that of the rail 360 shown in FIGS. 3A and 3C. In contrast to the rail 360, the rail 760 has downward flanges 772 that are substantially coplanar with an upper leg 768 of the rail 760. Angled flanges 776 may further extend from a bottom end of the downward flange 772 at an outward angle approximately 10-80 degrees from the vertical plane of the downward flange 772. The downward flange 772 and angled flange 776 can provide more concrete bearing surface for the frame 708.

The channel 704 may include angled posts 724 coupled to the channel 704 via ribs/brackets 732. The angled posts 724 can have a vertical angle that corresponds to the vertical angle of the angled flange 776 of the frame 708 so that the angled flange 776 mounts to the angled posts 724. As shown, the angled flange 776 can further include a flange opening 780 perpendicular therethrough in relation to the vertical angle of the angled flange 776 for coupling the frame 708 to the angled posts 724 of the channel 704 (e.g., via threaded fasteners).

FIG. 8 illustrates another variation of a trench drain 800. Features that are similar to the trench drain 100 shown in FIG. 1 are identified with similar reference numbers, plus 700. Some similarities and differences between the trench drain 800 and the trench drain 100 are described herein.

The trench drain 800 includes a channel 804 and a frame 808 mounted to the channel 804. The frame 808 of the trench drain 800 is a Z-shaped frame formed of the L-shaped rail shown in FIG. 1 with a further interior leg 872 extending into the interior of the channel 804. The interior leg 872 can have a first portion 876 that is at a vertical angle and directed into the interior of the channel 804 from a terminal end of a lower leg 864. The interior leg 872 has a second portion 880 that extends generally vertically downward and rests along or near an interior vertical wall 816 of the channel 804 and, in some embodiments, rests upon a ledge 824 within the interior volume of the channel 804. The interior leg 872 can include horizontal through holes (not shown) spaced apart along a length of the interior leg 872 and configured to receive fasteners (e.g., threaded fasteners, rivets) for coupling the frame 808 to the channel 804. The lower leg 864 has threaded openings 832 extending vertically therethrough for coupling the drain cover (not shown) to the frame 808 (e.g., via threaded fasteners). The threaded openings 832 can have a protective casing 836 that encases the threaded opening 832 and prevents poured concrete from entering the threaded opening 832 from the underside of the frame 808.

FIG. 9 illustrates another variation of a trench drain 900. Features that are similar to the trench drain 100 shown in FIG. 1 are identified with similar reference numbers, plus 800. Some similarities and differences between the trench drain 900 and the trench drain 100 are described herein.

The trench drain 900 includes a channel 904 and a frame 908 mounted to the channel 904. As shown, the frame 908 extends downward from the L-shaped rails 960 in the form of a lower leg 912 and lower surface 916. When installed, the lower surface 916 of the lower leg 912 rests upon the poured concrete, providing direct support of the frame 908 upon the concrete. The frame 908 may also include a plurality of ribs 920 on the exterior of the frame 908, spaced apart along the length of the frame that provide further rigidity and strength to the frame 908. The frame 908 may also include a plurality of brackets 972 that extend away from the channel 904 and provide additional concrete bearing surface and help lock the frame 908 into place once set in concrete.

FIGS. 10A-10C illustrate a trench drain 1000 according to another embodiment. Features that are similar to the trench drain 100 shown in FIG. 1 are identified with similar reference numbers, plus 900. Some similarities and differences between the trench drain 1000 and the trench drain 100 are described herein.

The trench drain 1000 includes a channel 1004 and a frame 1008 coupled to the channel 1004. As shown, the trench drain 1000 includes a V-shaped channel 1004 having a profile similar to that of the channel 104 shown in FIG. 1. In contrast to the channel 104, the channel 1004 lacks horizontal extensions (horizontal extensions 152, 252 illustrated in FIGS. 1, 2, respectively) such that the width of the upper edge 1012 of the channel 1004 is significantly narrower than the upper edge of the channel 104 while having a similar sized profile otherwise.

When a frame 1008 is placed upon the upper edge 1012 of the channel 1004, at least a portion of the frame 1004 is not supported by the channel 1004. When installed in poured concrete, the portion of the frame 1008 not supported by the upper edge 1012 of the channel 1004 is supported directly by the poured concrete.

In the illustrated embodiment, a majority of the width is supported by endcaps 1016 of the channel 1004 at the longitudinal extents of the channel 1004. At locations between the longitudinal extents of the channel 1004, a significant portion (e.g., at least 30%, at least 40%, at least 50%,) of the underside of the frame 1008 is not supported by the channel 1004 but is instead supported by the poured concrete. In the embodiment shown, the underside of the frame 1008 includes a first portion 1020 that is supported by the upper edge 1012 of the channel 1004 and a second portion 1024 that is not supported by the upper edge 1012 of the channel 1004. In some embodiments, the first portion 1020 and the second portion 1024 are coplanar. In other embodiments, such as the embodiment shown in FIGS. 10A-10C, the first and second portions 1020, 1024 are parallel and offset from one another such that the second portion 1024 is located below the first portion 1020 when installed on the channel 1004.

FIGS. 11A-11C illustrate a trench drain 1100 according to another embodiment. Features that are similar to the trench drain 1000 shown in FIGS. 10A-10C are identified with similar reference numbers, plus 100. Some similarities and differences between the trench drain 1100 and the trench drain 1000 are described herein.

The trench drain 1100 includes a channel 1104 and a frame 1108 mounted to the channel 1104. The upper edge 1112 channel 1104 may include mounting apertures 1116 spaced apart along the upper edge 1112 for mounting the frame 1108 to the channel 1104. As shown, the apertures 1116 may be vertically oriented apertures and may each be located within a respective protrusion 1120 that extends outward in the widthwise direction from the upper edge 1112. The frame 1108 includes similarly sized and spaced apertures 1124 along the length of the frame 1108. Cutouts 1128 in the underside of the frame 1108 allow for the frame 1108 to mate with the protrusions 1120 of the channel 1104. In some embodiments, the protrusions 1120 and cutouts function as an alignment feature to maintain the location of the frame 1108 on the channel 1104 during installation. When aligned with one another, a fastener can be provided through the aligned apertures 1116, 1124 to secure the frame 1108 to the channel 1104.

FIGS. 12A-12C illustrate a trench drain 1200 according to another embodiment. Features that are similar to the trench drain 1100 shown in FIGS. 11A-11C are identified with similar reference numbers, plus 100. Some similarities and differences between the trench drain 1200 and the trench drain 1100 are described herein.

The trench drain 1200 includes a channel 1204 and a frame 208 mounted to the channel 1204. Rather than incorporating vertically oriented mounting apertures as shown in FIGS. 11A-11C, the trench drain 1200 includes horizontal mounting apertures 1216, 1224 in the channel 1204 and the frame 1208, respectively. The apertures 1216, 1224 are aligned with one another when the frame 1208 is mounted to the channel 1208. A fastener is inserted through the aperture 1224 in the frame 1208 and into the aperture 1216 in the channel 1204 to couple the frame 1208 to the channel 1204.

FIG. 13 illustrates a channel 1304 for a trench drain (not shown) according to another embodiment. Features that are similar to the channel 104 shown in FIG. 1 are identified with similar reference numbers, plus 1200. Some similarities and differences between the channel 1304 and the channel 104 are described herein

The channel 1304 may have a lower (underside) profile 1320 that increases the ease of stacking and supporting multiple channels 1304. The channel 1304 includes a flat and horizontal base surface 1306 that terminates at short, angled surfaces 1308 having an angle generally similar to the inner profile 1312 of the channel 1304 located directly above the angled surfaces 1308. The angled surfaces 1308 terminate at vertical surfaces 1316. The lower profile 1320′ of a similar stacked channel 1304′ is sized to rest within the inner profile 1312 of the channel 1304 for increased stability in storage and in transportation.

FIGS. 14A-14D illustrate a trench drain 1400 according to another embodiment. Features that are similar to the trench drain 1100 shown in FIGS. 11A-11C are identified with similar reference numbers, plus 300. Some similarities and differences between the trench drain 1400 and the trench drain 1100 are described herein.

The trench drain 1400 includes a channel 1404 and a frame 1408 mounted to the channel 1404. Similar to the trench drain 1100 of FIGS. 11A-11C, the frame 1408 is coupled to the channel 1404 via fasteners extending through vertical apertures 1416, 1424 in the channel 1404 and frame 1408, respectively. The apertures 1416, 1424 are spaced apart from one another along the lengths of the channel 1404 and frame 1408. In contrast to the trench drain 1100, the apertures 1416, 1424 are located outward (in the widthwise direction) from the upper edge 1412 of the channel 1404. The channel 1404 includes posts 1420 coupled to the main body 1428 of the channel 1404 via ribs/brackets 1432. Each aperture 1416 extends vertically through a respective one of the posts 1420. The frame 1408 includes wings 1436 extending downward from the portion of the frame 1408 that rests on the upper edge 1420 of the channel 1404. The wings 1436 contact the posts 1420 when the frame 1408 rests on the upper edge 1412 of the channel 1404. The wings 1436 include the apertures 1424 that align with the apertures 1416. A fastener extends through the aligned apertures 1416, 1424 to couple the frame 1408 to the channel 1404. The wings 1436 and posts 1420 extend outward to be encapsulated by the poured concrete, providing further strength and rigidity of the trench drain 1400 when installed.

FIGS. 15A-15D illustrate a trench drain 1500 according to another embodiment. Features that are similar to the trench drain 1400 shown in FIGS. 14A-14D are identified with similar reference numbers, plus 100. Some similarities and differences between the trench drain 1500 and the trench drain 1400 are described herein.

The trench drain 1500 includes a channel 1504 and a frame 1508 mounted to the channel 1504. Rather than incorporating vertically oriented mounting apertures as in FIG. 14A-14D, the trench drain 1500 includes horizontal mounting apertures 1516, 1524 in the channel 1504 and the frame 1508, respectively. The apertures 1516, 1524 are aligned with one another when the frame 1508 is mounted to the channel 1504. A fastener is inserted through the aperture 1524 in the frame 1508 and into the aperture 1516 in the channel 1504 to couple the frame 1508 to the channel 1504.

FIG. 16 illustrates a trench drain 1600 according to another embodiment. Features that are similar to the trench drain 100 shown in FIG. 1 are identified with similar reference numbers, plus 1500. Some similarities and differences between the trench drain 1600 and the trench drain 100 are described herein.

The trench drain 1600 includes a channel 1604 and a frame 1608 mounted to the channel 1604. The frame 1608 of the trench drain 1600 is a Z-shaped frame formed of the L-shaped rail shown in FIG. 1 with a further leg 1612 extending into the interior of the channel 1604. The interior leg 1612 may be generally vertical and rests along or near an interior vertical wall 1616 of the channel 1604 and, in some embodiments, rests upon a ledge 1624 within the interior volume of the channel 1604. The leg 1608 may include horizontal through holes 1620 spaced apart along a length of the leg 1612 and configured to receive fasteners (e.g., threaded fasteners, rivets) for coupling the frame 1608 to the channel 1604. The frame 1608 and/or the channel 1604 may further include two types of clips for securing the trench drain 1600 relative to the ground (within poured concrete). A first type of bracket is an L-shaped bracket 1628 extending downward and outward from the frame 1608 and/or the channel 1604. Each L-shaped bracket 1628 extends to a height beneath the upper edge of the channel 1604 such that a majority (e.g., all) of the bracket 1628 is buried within the poured concrete upon installation. A second type of bracket is a rebar bracket 1632 that receives a reinforcing rod (not shown) to further secure the trench drain 1600 within the poured concrete. The rebar bracket 1632 includes two vertically aligned openings 1636, 1640 extending through spaced apart bracket segments that are separated by a vertical bracket segment 1644. The vertical bracket segment 1644 may include a threaded aperture 1648 for receiving a set screw (not shown). A reinforcing rod is inserted through the two aligned apertures 1636, 1640 and moved (e.g., via power tools, hammers, etc.) to a desired height. The set screw is tightened against the reinforcing rod to secure the trench drain 1600 to the reinforcing rod at that height.

FIG. 17 illustrates a trench drain 1700 according to another embodiment. Features that are similar to the trench drain 100 shown in FIG. 1 are identified with similar reference numbers, plus 1600. Some similarities and differences between the trench drain 1700 and the trench drain 100 are described herein.

The trench drain 1700 includes a channel 1704 and a frame 1708 mounted to the channel 1704. The frame 1708 of the trench drain 700 is formed of a plurality of bends, extending fully over the upper edge 1714 of the channel 1704, extending downward around both of the exterior side and the interior side of the upper edge 1714. The frame 1708 further extends down to a horizontal seat 1716 of the channel 1704 within the interior of the channel 1704 below the upper edge 1714. The frame 1708 extends still further down within the channel 1704 to cover at least a portion of the vertical surfaces 1732 (similar to vertical surfaces 132). In the present embodiment, the upper edge 1714 is defined by a protrusion 1724 that extends upwards from the vertical surfaces 1732. As such, the drain cover 1712 rests between (in the widthwise direction) not only the frame 1708, but also between the protrusions 1724 of the channel 1704. The drain cover 1712 illustrated in FIG. 17 includes elongated slots 1728 as opposed to the smaller, distinct apertures in the drain cover 112 of FIG. 1.

FIG. 18 illustrates a trench drain 1800 according to another embodiment. Features that are similar to the trench drain 100 shown in FIG. 1 are identified with similar reference numbers, plus 1700. Some similarities and differences between the trench drain 1800 and the trench drain 100 are described herein.

The trench drain 1800 includes a channel 1804 and a frame 1808 mounted to the channel 1804. The trench drain 1800 may be provided with two different styles of rebar clamps/brackets 1820, 1832. The first rebar clamps 1820 are similar to the rebar clamp 120 (FIG. 1) and include a central opening 1840 through which a reinforcing rod (e.g., rebar) is insertable for securing the channel 804 within a poured concrete base. The first rebar clamp 1820 includes a living hinge and a pair of openings 1842 (extending in a widthwise direction of the channel 1804) for a fastener to tighten the first rebar clamp 1820 around the reinforcing rod. The second rebar clamps 1832 are similar to the rebar bracket/clamp 1632 (FIG. 16) and include two vertically aligned openings 1836a, 1836b through which a reinforcing rod is inserted. A set screw is tightened against the reinforcing rod through a threaded opening 1848 between the aligned openings 1836a, 1836b to secure the trench drain 1800 to the reinforcing rod at a desired height. In some embodiments, one of the sets of rebar clamps 1820, 1832 is provided on the channel 1804 and the other is provided on the frame 1808. In other embodiments, both sets of rebar clamps 1820, 1832 are provided on the frame 1808. In still other embodiments, both sets of rebar clamps 1820, 1832 are provided on the channel 1804. By providing both sets of rebar clamps 1820, 1832, an installer is able to choose to use the first set 1820, the second set 1832, or a combination of both sets 1820, 1832 to install the trench drain 1800. In some embodiments, the different sets 1820, 1832 accept different sizes of reinforcing rod and different applications (e.g., locations, ground material, desired rigidity or strength of the trench drain) may result in choosing one set of clamps as opposed to the other.

FIGS. 19A-19C illustrate a trench drain 1900 according to another embodiment. Features that are similar to the trench drain 300 shown in FIGS. 3A-3C are identified with similar reference numbers, plus 1600. Some similarities and differences between the trench drain 1900 and the trench drain 1600 are described herein.

As best shown in FIG. 19A, the trench drain 1900 includes a channel 1904 and a frame 1908 mounted to the channel 1904. The frame 1908 of the trench drain 1900 includes a rail 1960 having a similar profile to that of rail 560 shown in FIG. 5. Additionally, the frame 1908 may include several shortened external lugs 1984 and external lugs 1976 with support feet 1980 and wide support feet 1992 similar to the frame 608 shown in FIG. 6.

The channel 1904 may include wings 2000 that extend from an underside or outer surface of the channel 1904 in addition to clamps 1920. The wings 2000 may include an opening or slot 2004 (for example, positioned adjacent a distal end of the wing 2000) for receiving a reinforcing rod or bolt. A reinforcing member or channel strut 2008 may extend along the side of the channel 1904, and may be connected to the channel 1904 to provide additional rigidity to the channel 1904. Specifically, the channel strut 2008 may connect to the channel 1904 via the wings 2000. The wings 2000 may have a width greater than 1.5 inches (in some embodiments, for example, each wing may have a width of approximately 2.25 inches) to provide a larger interfacing surface area for the connection between the wing 2000 and the channel strut 2008. As best shown in FIGS. 19B, each channel strut 2008 may include several openings or slots 2012 spaced intermittently along a length of the strut. A slot 2012 of the channel strut 2008 may be aligned with the slot 2004 of the wing 2000, and a bolt or other fastener may be inserted through the slots 2004, 2012 to fasten the channel strut 2008 to the wing 2000.

The channel strut 2008 may provide additional rigidity to the channel 1904 and help prevent warping or deformation of the channel 1904 (e.g., due to load changes as concrete is poured and cured around the channel 1904, or due to temperature changes). The channel strut 2008 may also provide a stronger connection across the seams or joints of adjacent channels 1904 by having a single member or piece of channel strut extend across the seam and connect to wings 2000 on each channel 1904. In some embodiments, sections of the channel strut 2008 may be limited to extending along the channel 1904 in a region between the seams to reinforce the joints, thereby reducing material weight. In other embodiments, one or more channel struts 2008 may extend along a full length or nearly full length of the connected channels 1904.

Utilizing one or more struts 2008 to connect adjacent channels 1904 can also facilitate multiple sections of channel 1904 being connected prior to installing the channels 1904 in their final position. For example, several sections of channel 1904, which may be limited to a certain pre-fabricated length by manufacturing or transportation constraints, can be connected using the channel strut 2008 to create a single extended channel that can more efficiently be installed in the field. In some cases, the channel strut 2008 may be installed on several sections of channel 1904 in a warehouse or staging area where it is easier and more efficient to connect the channels 1904. The assembled extended channel may be transported using the channel strut 2008 to lift or otherwise maneuver the assembled unit. For example, hooks, cables, ropes, or the like may be wrapped around or connected to the channel strut 2008 to hoist or move the assembled unit. Thus, the time and labor needed to install the overall length of a given trench drain 1900 in the field may be reduced. The channel strut 2008 can also protect the various features of the channel 1904 from damage during storage, transportation, and installation. As shown in FIGS. 19A and 19C, channel strut 2008 may be positioned on each side of the channel 1904. In other embodiments, the channel strut 2008 may be positioned on only one side of the channel 1904. In other embodiments, a channel strut 1908 may be positioned on one side of the channel 1904 along one length or portion of the channel 1904, and another channel strut may be positioned on the other side of the channel 1904 along another length or portion of the channel 1904.

As best shown in FIG. 19B, the wings 2000 and the clamps 1920 may each extend out from the channel 1904 a similar distance such that the slot 2004 of the wing 2000 and the receiving opening of the clamp 1920 are both spaced approximately a distance D1 from the side of the channel 1904. This allows the reinforcing rod or rebar connected to the clamps 1920 to extend through the slots 2012 of the channel strut 2008. In other embodiments, the receiving opening of the clamp 1920 may be spaced a distance greater than or less than D1 such that the rebar could be on either side of the channel strut 2008. Distance D1 may be selected as a function of the channel strut 2008 width D2. Specifically, it may be desirable to configure the distance D3, measured as the distance between a side of the channel strut 2008 and the side surface of the channel 1904 proximate to each other, as a function of the channel strut 2008 width D2. The gap D3 may be large enough to allow concrete to flow between the channel strut 2008 and channel 1904 and small enough to provide sufficient reinforcing strength from the channel strut 2008 and to minimize the overall width of the channel 1904. For example, in some embodiments, the gap D3 may be in a range between approximately 0.75 times the distance D2 to 1.5 times the distance D2. In some embodiments, as shown in FIG. 19B, the gap D3 may be approximately equal to the distance D2.

In some embodiments, each of the features extending from the channel 1904 may be positioned at a height relative to the channel 1904 such that the uppermost portion of any feature is at least 2 inches below the upper edge of the channel 1904. In this way, at least 2 inches of concrete depth can be poured over each feature, which can reduce cracking of the concrete as it experiences loads.

FIG. 21 illustrates a connection 2100 for coupling one portion of channel 104 (or any other embodiment of channel herein described) to another portion of channel. As shown in FIG. 20, the length of the connection 2100 is relatively short (in comparison to the length of the channels 104) and has a similar V-shaped inner profile. Each lengthwise end of the connection 2100 includes a coupling feature 2104 for engaging a mating component on the respective lengths of channel 104 to be joined. In the embodiment of FIG. 21, the coupling feature 2104 may be a U-shaped clip 2104 (female connector) that is configured to receive a male connector on a lengthwise end of each of the channels 104. The U-shaped clip 2104 is oriented vertically such that, with two channels 104 placed end-to-end, spaced apart from one another by the length of the connection 2100, the connection 2100 is configured to be lowered down from above to slidingly engage the male connectors of the channels 104 within the U-shaped clips 2104. With the connection 2100 assembled to the channels 104, the two channels 104 are unable to be nondestructively separated by lateral force (in the lengthwise direction of the channels 104).

FIG. 22 illustrates a connection 2200 for coupling one portion of channel 104 to another, according to another embodiment. Features that are similar to the connection 2100 shown in FIG. 21 are identified with similar reference numbers, plus 100. Some similarities and differences between the connection 2200 and the connection 2100 are described herein.

The connection 2200 includes a first male connector 2204 on a first side (i.e., a left side) and a first female connector 2208 on a second side (i.e., a right side). The connection further includes a second male connector 2204 opposite the first female connector 2208 and a second female connector 2208 opposite the first male connector 2204. The connection 2200 may have rotational symmetry such that rotating the connection 2200 about axis 2212 by 180 degrees results in an identical shape (with the first and second male connectors 2204 switching respective locations and the first and second female connectors 2208 switching respective locations). Each of the male connectors 2204 may have a T-shaped profile extending vertically downward and may be configured to be received within a similarly sized and T-shaped aperture at the lengthwise end of a channel 104. Similarly, each of the female connectors 2208 may have a T-shaped aperture extending vertically downward and may be configured to receive a similarly sized and T-shaped protrusion at the lengthwise end of the channel 104. The connector 2200 thereby is configured to simultaneously engage a first channel 104 via the first male and female connectors 2204, 2208 and engage a second channel 104 via the second male and female connectors 2204, 2208 to secure the second channel 104 relative to the first channel 104. The rotational symmetry of the connection 2200 allows the connection not be utilized in two different positions and also permits for the connection 2200 to be coupled to either of the first and second lengthwise ends of the channels 104.

FIG. 23 illustrates a connection 2200 for coupling one portion of channel 104 to another, according to another embodiment. Features that are similar to the connections 2100, 2200 shown in FIGS. 21 and 22 are identified with similar reference numbers, plus 200 and plus 100, respectively. Some similarities and differences between the connection 2300 and the connections 2100, 2200 are described herein

Similar to the connection 2200, the connection 2300 may have rotational symmetry and can therefore be capable of being coupled to a channel 104 in two different rotational positions, each providing the same functionality. The connection includes a first female connector 2304 formed as a groove or recess at the first lengthwise end of the connection 2300 for attaching to a first channel 104. The connection includes a second female connector 2308, similar to the first female connector 2304, at the second lengthwise end of the connection 2300 for attaching to a second channel 104. Each of the female connectors 2304, 2308 define a recess delineated by two end surfaces 2312, 2316 offset from one another by ninety degrees or less (e.g., 90 degrees, 80-90 degrees, 70-90 degrees, 60-90 degrees, 45-90 degrees) such that a mating protrusion of the channel 104 can be inserted into the respective recess 2304, 2308 in a vertical direction 2320 or a horizontal direction 2324 (both of the vertical horizontal insertion directions 2320, 2324 being perpendicular to the lengthwise direction of the channel 104).

FIGS. 24A-24D illustrate first and second connections 2404, 2408 formed integrally at opposing ends of a channel 2400 for coupling one channel 2400 to another channel 2400′ to increase the overall length of the channel assembly. As shown in FIG. 24A, the first connection 2404, which is located at a first longitudinal end of the channel 2400 includes a rectangular protrusion 2412 at each widthwise edge. Each rectangular protrusion 2412 includes a semicircular cutout 2416 at the outer edge. As shown in FIG. 24B, the second connection 2408, which is located at a second longitudinal end of the channel 2400 (opposite the first longitudinal end) includes a rectangular recess 2420 defined in part by a lip 2424 that extends further outwards (in the widthwise direction) than the rectangular protrusions 2412. Each recess 2420 includes a semicircular protrusion 2428 extending from the lip 2424 into the recess 2420 and configured to correspond to the semicircular cutout 2416 of the first connection 2404. In other embodiments, the location of the semicircular cutout 2416 and the semicircular protrusion 2428 may be reversed. The rectangular protrusion 2412 is slidably receivable within the recess 2420 by placing the recess 2420 over the protrusion. One or both of the connections 2404, 2408 have some flexibility such that the semicircular protrusion 2428 can be moved into the cutout 2416 to complete a snap-fit between the two channels 2400, 2400′. When the channels 2400, 2400′ are assembled to one another, the inner profile 2432 of one channel 2400 rests within a recess 2436 of another channel 2400′ such that the two channels 2400, 2400′ form a lap joint 2440 at the seam between the two joints, limiting water leakage at the seam.

FIGS. 25A and 25B illustrate a channel 2500 that includes vertical supports 2504 for placing and installing the channel 2500. The supports 2504 can be connected to the bottom of the channel 2500 (FIG. 25A) or anywhere along the exterior sides or top of the channel 2500 (FIG. 25B).

As illustrated in FIGS. 26A-26D, a clamp 2600 (such as clamp 120) may have a hinge 2604 that may be a living hinge, providing increased toughness to the hinge 2604. As illustrated in FIGS. 26A-26C, a single hinge mold may include a first receiving feature 2608 for receiving a first reinforcing rod and a second receiving feature 2612 for receiving a second reinforcing rod of a different size. For example, the clamp 2600 may be capable of selectively receiving and engaging a rod having a diameter of 0.375 inches (e.g., #3 rebar) or a rod having a diameter of 0.5 inches (e.g., #4 rebar). As illustrated in FIG. 26B, the hinge mold and support arm 2616 that connects the clamp 2600 to a channel (such as channel 104) may be aligned. As illustrated in FIG. 26C, a single hinge mold can have two separate hinges 2604, one for the first receiving feature 2608, and another for the second receiving feature 2612. As illustrated in FIG. 26D, the receiving feature 2608 may be oval or eccentrically shaped. The receiving features 2608, 2612 may generally be configured to correspond to the shape of any reinforcing rod or reinforcing member.

FIG. 27 illustrates a method for retaining a drain cover 2700 within a frame 2704, according to one embodiment. As shown, the frame 2704 defines a trapezoidal opening between opposing widthwise portions of the frame 2704 such that the drain cover 2700 is held within the frame 2704 to prevent simple removal of the drain cover 2700 via a vertical lifting motion. In some embodiments, the drain cover 2700 may be inserted into the frame 2704 through a lengthwise end. In other embodiments, the frame 2704 is capable of elastically deforming to permit forceful insertion of the drain cover into the frame 2704 from above.

FIG. 28 illustrates another method of holding a grate/drain cover to a frame 2800. As shown, one or more of the crossbars 2804 of the frame 2800 may include a vertical pin 2808 that is laterally deformable via a thin wall construction and a central hollow or via an elastomeric or deformable material. When aligned with an opening in the grate, the pin compresses to extend through the opening, expanding once passing through to retain the grate to the frame 2800. FIG. 29 illustrates a further embodiment with the vertical pin 2908 instead located on an underside of the grate 2912 and extending through an opening 2916 in the crossbar 2904 of the frame 2900.

FIG. 30 illustrates a push fit pin 3000 that extends through an opening 3004 in the drain cover 3008 and into an opening 3012 in a crossbar 3016 of the frame 3020. As shown, the push fit pin 3000 includes a non-cylindrical (e.g., diamond-shaped) head 3024 that engages the similarly shaped opening 3012 in the crossbar 3016. The non-cylindrical head 3024 necessitates force to install the head 3024 within the opening 3012 to provide a more secure engagement.

FIGS. 31 and 32 illustrate components for coupling a drain cover 3100, 3200 to a frame (not shown) rather than a traditional threaded fastener. As shown in FIG. 31, a quick release pin 3104 is inserted through an opening 3108 in the drain cover 3100 and into engagement with an opening in a crossbar of a frame. In some embodiments a detent 3112 within the quick release pin 3104 or within the crossbar retains the pin 3104 within the frame to couple the drain cover 3100 to the frame. As shown in FIG. 32, a quarter turn pin 3204 is inserted through an opening 3208 in the drain cover 3200 and through an opening in a crossbar of a frame. The opening in the crossbar may be slotted or asymmetric such that by rotating the pin 3204 by a quarter turn (i.e., 45 degrees), the pin 3204 engages an underside of the crossbar to secure the drain cover 3200 to the frame. FIG. 33 illustrates an embodiment in which a plastic washer 3300 engages an underside of a bolt 3304 that extends through the grate 3308 to hold the bolt 3304 within the grate 3308 and prevent removal of the bolt 3304 from the grate 3308.

FIG. 34 illustrates a system for coupling a drain cover 3400 to a channel 3404. A fastener 3408 extends through an opening 3412 in the drain cover 3400. An expanding head 3416 of the fastener 3408 extends outwards to engage opposing sidewalls of the channel 3404 to secure the drain cover 3400 relative to the channel 3404. A spring 3420 mounted to and surrounding the fastener 3408 engages the expending head 3416 and the underside of the drain cover 3400 to maintain engagement of the head 3416 with the channel 3404.

FIG. 35 illustrates a still further embodiment for securing a drain cover 3500 to a channel or a frame. A clip, such as a spring clip 3504 extends through first and second openings 3508, 3512 of the drain cover 3500 such that opposing distal ends of the spring clip 3504 are located below the drain cover 3500 and in contact with opposing sidewalls or undersides of the channel and/or frame, while a center of the spring clip 3504 is located above the drain cover 3500 to hold the drain cover 3500 against the frame. FIG. 36 illustrates the use of expanding springs 3600, to hold a grate 3604 in place relative to a channel or a frame.

FIG. 37 illustrates how successive adjacent drain covers 3700, 3704 may overlap one another (e.g., via a lap joint), utilizing the weight of each successive drain cover 3700 to hold down the following drain cover 3704. In some embodiments, a fastener may extend through aligned apertures of the two drain covers 3700, 3704 to secure each drain cover to the adjacent drain cover. The fastener may further extend through a portion of the frame and/or channel to secure the drain covers 3700, 3704 to the frame/channel. In some embodiments (not shown), a magnetic lock may be used to couple a drain cover relative to a frame. The magnetic lock is a normally closed lock that is unlocked in the presence of a magnet in an appropriate location such that the drain cover appears to be secured from above with no fasteners. In some embodiments (not shown), a second frame, an overlaying frame, may be mounted above the grates to hold the grates down against the frame and the channel to prevent the grates from lifting out away from the channel.

FIG. 38 illustrates a twist lock 3800 utilized for coupling a drain cover 3804 to a frame 3808. As shown, the frame 3808 includes a protrusion 3812 extending inward upon which the drain cover 3804 rests and about which the drain cover 3804 rotates. In some embodiments, the drain cover 3804 is coupled to the protrusion 3812. By rotating the drain cover 3804 relative to the protrusion 3812, the drain cover 3804 is lowered into a locking position. In some embodiments, a flexible pin or bracket (such as those shown in FIGS. 28-30) may be coupled to the frame to secure the drain cover 3804 relative to the frame. FIG. 39 illustrates a channel 3900 having no rails and a flat bottom 3904.

FIG. 40 illustrates a latch 4000 similar to a door latch for securing the drain cover 4004 relative to the frame 4008 and channel 4012. The latch 4000 may be overcome and disengaged from the drain cover 4004 via a key 4014 (e.g., a screwdriver or other tool) or a handle to open the latch 4000. In the embodiment shown, the opposing edge of the drain cover 4004 may be received under a ledge 4016 defined by the frame 4008 to prevent removal of the drain cover 4004 from the frame 4008 when secured by the latch 4000. FIG. 41 illustrates an alternative manner of holding the opposing edge of a drain cover 4100. As shown in FIG. 41, a hinge 4104 couples one edge of the drain cover 4100 to the frame 4108. The drain cover 4100 rotates between open and closed positions and, in some embodiments, is further secured in the closed position.

FIG. 42 illustrates a flexible drain cover or grate 4200. In some embodiments, the flexible grate 4200 has an undeformed width and length to seat within a frame 4204 but is too large to reach a seated position. The flexible grate 4200 is elastically deformable to fit within the frame 4204 and reach the seated position where the grate 4200 returns to its undeformed position, seated within the frame 4204. In other embodiments, the undeformed position of the flexible grate 4200 is a bent or curved position that is elastically stretched and deformed to engage the frame 4204. In some embodiments (not shown), a grate can be a collapsible grate that can be decreased in size by folding over itself to facilitate separation of the grate from the frame. FIG. 43 illustrates that in some embodiments, a separate component 4300 such as a buffer or a sound dampening material may be located between the frame 4304 and the drain cover 4308.

FIG. 44 illustrates a further arrangement for coupling a drain cover 4400 to a frame. As shown, the drain cover includes posts 4404 biased outwards away from the drain cover 400 by a spring bias. The posts 4404 are receivable in apertures in the frame. To assemble the drain cover 4400 to a frame, the user locates the posts of one side of the drain cover 4400 into apertures on the frame. The posts 4404 on the opposing side are retracted towards the drain cover (e.g., manually, via an angled surface of the post 4404) such that the posts 404 extend beyond an upper edge of the frame and into engagement with the respective apertures, where the springs bias the posts 4404 into their engaged position. In alternative embodiments, the posts 4404 may be mounted to the frame and the drain cover 4400 includes apertures for receiving the posts 4404.

In some embodiments, a crossbar may be permanently integrated as part of the frame or channel of the trench drain. In other embodiments, the crossbar is a separate component that can be removed and attached to the channel and/or frame. The crossbar, channel, and/or frame can be configured such that the crossbar does not move or become misaligned during installation or use. In some embodiments, the drain cover may be attached to the frame using magnets, tape, adhesive, hook and loop fasteners, or similar connecting devices that can hold the drain cover in place in the frame during normal use but that may be removed by applying enough force in a direction not usually experienced during normal use. In some embodiments, the drain cover may be attached to the frame and/or crossbars using flanged head bolts, a device that requires a pen click to lock the drain cover into place and another pen click to unlock, a twist lock pin, or other similar fastening or locking mechanisms.

FIGS. 45-50 illustrate various systems for coupling adjacent channels to one another, thereby increasing the overall length of the trench drain. As shown in FIG. 45, a female-female connector 4500 has two hollow regions 4504, 4508 that each receive a respective one end of the channels 4512, 4516 to couple the channels 4512, 4516 to one another. As shown in FIG. 46, adjacent channels 4600, 4604 are coupled directly to one another with no intervening connector. As shown, a first channel 4600 includes an integrally formed male connector 4608 that is received within a female connector 4612 of the second channel 4604. In some embodiments, rather than incorporating a specific male/female connection between adjacent channels, a universal connection may be utilized such that the rotational orientation (i.e., which lengthwise end) of the channels being mated together is irrelevant as either end can be coupled to either end of the next channel. In some embodiments, the frame may span the gap between two adjacent channels to couple the two channels together (e.g., similar to as the channel strut 2008 shown in FIG. 19A). In some embodiments, the frame may have a greater length than either of the two channels such that it spans across the seam between the two channels. In other embodiments, the frame may have a similar (or alternatively, dissimilar) length to the channels, but is mounted offset from the channels such that the lengthwise end of the frame is spaced apart (in the lengthwise direction) from the seam between the channels.

As shown in FIG. 47, the two channels 4700, 4704 may mechanically attach to one another via a snap fit. As illustrated, the snap fit may be accomplished by moving a first channel 4700 vertically downward into engagement with the second channel 4704. In other embodiments, the snap fit may be accomplished via a lateral motion (i.e., in the widthwise direction) or by moving the two channels 4700, 4704 towards one another (i.e., in the lengthwise direction). As discussed above with respect to FIG. 47, FIG. 48 illustrates a snap fit between two channels 4800, 4804 via movement of the two channels 4800, 4804 in the lengthwise direction. As shown in FIG. 49, in some embodiments, the connection structure is mounted to the exterior of the channel 4900. Here, a boss 4904 is mounted to the exterior surface of the channel 4900 and defines an opening 4908 that receives a boss/protrusion on a mating channel. As illustrated in FIG. 50, rather than existing only at the distal end of the channel 5000, the connector 5004 may extend along the entire length of the channel 5000. For example, if the channel 5000 is an extruded component, it may be simpler to form the connector 5004 within the profile of the extrusion. The connector 5004 is a boss that forms a rail running along the outside edge of the channel 5000. A coupler may span the seam to engage adjacent rails 5004 to couple adjacent channels 5000 to one another.

FIGS. 51-69 illustrates alternative methods and systems for coupling reinforcing rod (rebar) or alternatives to reinforcing rod to a trench drain. In many of the embodiments provided below, the apparatus as described can be directly coupled to a channel, to a frame, or to a grate. FIG. 51 illustrates a bracket 5100 having an aperture 5104 therein. Rather than running the reinforcing rod 5108 through the aperture 5104 directly, the reinforcing rod 5108 is located adjacent to the bracket 5100 and is coupled to the bracket via a cable tie 5112 that extends around the reinforcing rod 5108 and through the aperture 5104. FIG. 52 illustrates a cutaway end view of a bracket 5200 having a tapered aperture 5204 extending vertically therethrough. The tapered aperture 5204 receives a tapered wedge or plug 5208 having a tapered outer profile similar to the inner profile of the tapered aperture 5204. The plug 5208 further includes a cylindrical central opening 5212 that receives the reinforcing rod. As downward pressure is applied to the reinforcing rod, the plug 5208 engages the tapered aperture 5204 to tighten the cylindrical opening 5212 about the reinforcing rod, thereby securing the reinforcing rod to the bracket 5200. In some embodiments, a framing channel or channel strut may be coupled to the frame, channel, or grate such that a reinforcing rod can be inserted through one of the plurality of apertures located along the length of the framing channel (similar to as shown in FIGS. 19A, 19B, and 20).

FIG. 53 illustrates a bracket 5300 for use with a reinforcing rod, for example, a threaded rod. The bracket 5300 includes a threaded aperture 5304 that receives the threaded rod. A height of the frame/channel to which the bracket 5300 is connected is finely adjusted by rotating the threaded rod within the threaded aperture 5304. FIGS. 54A and 54B illustrate a bracket 5400 having a central opening 5404 with an annular rubber insert 5408 located therein. The annular rubber insert 5408 includes a central opening 5412 for receiving the reinforcing rod. The rubber insert 5408 provides some flexibility to allow the reinforcing rod to be rotated a limited amount to increase the ease of installation. Further, the rubber insert 5408 grabs against the reinforcing rod to secure the reinforcing rod to the bracket 5400. Each of FIGS. 55, 56A, and 56B illustrate brackets 5500, 5600 having a central opening 5504, 5604 and a component extending into the central opening 5504, 5604 to interact with a reinforcing rod placed therein. As shown in FIG. 55, fingers (e.g., made of a stiff elastic material) 5508 extend radially inward into the opening 5504 to engage the reinforcing rod and provide a small amount of resistance against axial movement of the reinforcing rod within the opening 5504, thereby increasing the strength of the connection between the bracket 5500 and the reinforcing rod and increasing the amount of force required to move the reinforcing rod upward out of the opening 5504. FIGS. 56A and 56B illustrate tabs 5608 (e.g., metal tabs) that deform and press against the reinforcing rod when inserted into the aperture 5604, similar to the fingers 5508 shown in FIG. 55. As shown in FIG. 57, in some embodiments, the brackets 5700 for supporting the reinforcing rods may be aligned with one another on opposing (widthwise) sides of the trench drain 5704. In other embodiments, the brackets 5700 may be offset from one another such that each lengthwise cross-section of a trench drain 5704 includes no more than one bracket 5700.

FIG. 58 illustrates a top view of a bracket 5800 configured to receive a reinforcing bar within a central opening 5804. A set screw 5808 extends through a horizontal aperture to selectively engage a radial outer edge of the reinforcing bar and tighten the reinforcing bar against an edge of the opening 5804. As shown in FIG. 59, a bracket 5900 configured to receive a reinforcing bar may rotate about a rotational axis 5904 between a use position (shown in solid lines) and a storage position (shown in dashed lines) to decrease the overall width of the trench drain during transport and storage.

FIG. 60 illustrates a channel 6000 having an interior profile 6004 and a substantially flat base surface 6008. The base surface 6008 extends outward in the widthwise direction to define horizontal brackets 6012 located at the lowermost extent of the channel 6000. Each bracket includes an aperture 6016 for receiving a reinforcing rod. As shown in FIG. 61, a channel 6100 includes a main body 6104 (e.g., U-shaped or V-shaped body), one or more reinforcing ribs 6108 and a foot 6112 coupled to the body 6104 via a leg 6116. As shown, the foot 6112 is a large flat foot that can be embedded within an initial thin pour of concrete. The rib 6108 provides structural stability to the thin-walled main body 6104 and is embedded within a further (deeper) concrete pour.

In some embodiments, the brackets utilized to couple the reinforcing rod to the trench drain may be formed of a metal material. Further, the brackets may be coupled to the metal frame. As illustrated in FIG. 62, the hinge 6200 of the rebar clamp 6204 may be a living hinge, providing increased toughness to the hinge. Separate hinges 6200 may be manufactured to receive different sizes of reinforcing rod. In some embodiments, the trench drain may be provided with a single bracket mount to which a plurality of different attachments can be mounted. For example, the bracket mount can receive rebar, threaded rod, a channel strut framing member, and lumber. In some embodiments, the bracket mount individually receives each of the above. In other embodiments, the bracket mount may receive more than one of the above simultaneously.

As disclosed in FIG. 63, in some embodiments, the mounting height for the brackets/clips 6300 that receive the reinforcing rod may be located at a lower location (i.e., nearer to the base 6304 of the channel 3608 than to an upper edge 6312 of the channel) along the channel 6308. By locating the brackets/clips 6300 at a lower height, the height of the poured concrete above the brackets/clips 6300 is increased. As shown in FIG. 64, a bracket 6400 for receiving anchors 6404 are located at a height below (entirely below) the channel 6408. As shown, the bracket 6400 includes a central portion 6412 located and fastened below the base of the channel 6408. Arms 6416 extend downward and outward to distal ends at a width that is wider than a width of the channel 6408. Apertures 6420 extend through the bracket 6400 adjacent to the distal ends for receiving the anchors 6404. As shown, the anchors 6404 may be other than reinforcing rod. The anchors 6404 may be a stake having a head that is struck by a hammer until the head of the anchor 6404 engages the bracket 6400. FIG. 65 illustrates another embodiment of an anchor 6500 other than reinforcing rod. As shown, the anchor 6500 includes an inverted-U shaped profile, thereby having two points of contact that are driven into the ground. As shown, one or more of the legs of the anchor can extend through an aperture 6504 within a mounting bracket 6508 for securing the anchor 6500 to a trench drain.

In some embodiments, the bracket/clip for mounting the reinforcing rod may be made of a flexible, elastic, stretchy material. Flexible materials are less likely to break during installation when the bracket/clip may be dropped or hit by a tool. FIGS. 66 and 67 illustrate clips 6600, 6700 for receiving multiple different sizes of reinforcing rod (such as #3 and #4 rebar). In the embodiment shown in FIG. 66, the clip 6600 includes a smaller inner opening 6604 and a larger outer opening 6608 surrounding the smaller opening 6604. In some embodiments, the outer opening 6608 may be formed by a breakaway portion that is selectively removable if an installer is utilizing a larger diameter reinforcing rod. In other embodiments, the portion of the clip 6600 between the inner and outer openings 6604, 6608 may be deformable upon insertion of a larger diameter reinforcing rod, but undisturbed upon insertion of a smaller diameter reinforcing rod. As shown in FIG. 67, the bracket 6700 includes two C-shaped channels 6704, 6708 of different sizes located back-to-back adjacent one another. The smaller C-shaped channel 6704 is configured to support a smaller diameter reinforcing rod and the larger diameter C-shaped channel 6708 is configured to support a larger diameter reinforcing rod.

FIG. 68 illustrates an anchor 6800 similar to an auger to be used in place of a reinforcing rod. As shown, the anchor 6800 includes a generally cylindrical body 6804 and a spiral flighting 6808 extending upward along the body 6804 from a lower end to scrape and cut out drilled materials. An upper end of the anchor 6800 includes a shaft 6812 engageable by a power tool such as a drill or a mixer for rotating the anchor 6800 and lowering the anchor into the ground.

FIG. 69 illustrates a clip 6900 for a reinforcing rod mounted to an exterior of a channel 6904. As shown, the clip 6900 is adjustable along the height of the channel 6904 such that minute adjustments may be made to the height of the channel 6904 at each clip 6900 to facilitate an appropriate slope of the channel 6904.

It will be understood that certain features and sub-combinations are of utility and may be employed without reference to other features and sub-combinations. Features described and illustrated with respect to certain embodiments may also be implemented in other embodiments. This is contemplated by and is within the scope of the claims. Since many possible embodiments of the disclosure may be made without departing from the scope thereof, it is also to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative and not limiting.

The constructions described above and illustrated in the drawings are presented by way of example only and are not intended to limit the concepts and principles of the present disclosure. As is evident from the foregoing description, certain aspects of the present disclosure are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. Many changes, modifications, variations and other uses and applications of the present construction will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the disclosure are deemed to be covered by the disclosure. While the preceding is directed to embodiments of the present disclosure, other and further embodiments of the disclosure may be devised without departing from the scope thereof.

Claims

1. A trench drain comprising: a channel including an upper edge, a base, and an interior surface extending between the base and the upper edge;a frame including an upper surface and a lower surface, the lower surface positioned proximate the upper edge of the channel, the frame configured to transmit load exerted on the upper surface to a substrate surrounding the channel; anda drain cover supported on the frame.

2. The trench drain of claim 1, wherein a majority of the lower surface of the frame is unsupported by the channel.

3. The trench drain of claim 1, wherein a majority of the lower surface of the frame is configured to directly engage the substrate.

4. The trench drain of claim 1, wherein the channel is an elongated channel extending along an axis, a portion of the frame extending in a lateral direction transverse to the axis, the portion spaced apart from the channel by a vertical gap.

5. The trench drain of claim 1, wherein the channel includes a support rib protruding from an exterior surface of the channel.

6. A channel for a trench drain, the channel comprising: an upper edge;a base;an interior surface extending between the base and the upper edge;an exterior surface opposite the interior surface; anda support rib protruding from the exterior surface, the support rib having an outer profile that has a shape that corresponds to the interior surface of the channel.

7. The channel of claim 6, wherein the interior surface includes a first lower portion that is at an angle relative to a direction of height of the channel and a second upper portion that is substantially parallel to the direction of height of the channel.

8. The channel of claim 7, wherein the outer profile of the support rib includes a lower angled portion that corresponds to the first lower portion of the interior surface and an upper vertical portion that corresponds to the second upper portion of the interior surface.

9. The channel of claim 8, wherein the outer profile of the support rib can be received within and secured by an inner surface of a second channel that is identical to the channel.

10. A trench drain comprising: a channel including an upper edge, a base, an interior surface extending between the base and the upper edge, and an exterior surface opposite the interior surface;a clamp coupled to the exterior surface of the channel and configured to couple to a support member spaced apart from the channel;a frame having a lower surface positioned adjacent the upper edge of the channel, and a drain cover supported on the frame.

11. The trench drain of claim 10, wherein the clamp extends downward below the base of the channel.

12. The trench drain of claim 10, wherein the clamp extends horizontally from the channel and upper surface of the clamp is located at least 2 inches below the upper edge of the channel.

13. The trench drain of claim 10, wherein the channel includes a first channel portion and a second channel portion, wherein the first channel portion has a first clamp and the second channel portion has a second clamp, and wherein the first clamp and the second clamp are configured to couple to a single channel strut member spaced apart from the channel.

14. The trench drain of claim 10, wherein the frame is configured to transmit load exerted on an upper surface of the frame to a substrate surrounding the channel, wherein the frame includes a lug that increases a surface area of the frame that can contact the substrate.

15. The trench drain of claim 14, wherein the lug includes a foot configured to rest on an arm protruding from the exterior surface of the channel.

16. The trench drain of claim 15, wherein the lug is a first lug, wherein the frame includes a second lug, and wherein the first lug extends a first distance from the lower surface of the frame, the second lug extends a second distance from the lower surface of the frame, and the first distance is greater than the second distance.

17. A trench drain comprising: a channel including a first upper edge, a second upper edge spaced apart from the first upper edge, a base, an interior surface extending between the base and the first upper edge and the base and the second upper edge, and an exterior surface opposite the interior surface;a wing coupled to the exterior surface of the channel and configured to couple to a channel strut member spaced apart from the channel;a frame having a first rail positioned adjacent the first upper edge of the channel and a second rail positioned adjacent the second upper edge of the channel, anda drain cover supported on the frame.

18. The trench drain of claim 17, wherein the channel includes a first channel portion and a second channel portion, wherein the first channel portion has a first wing and the second channel portion has a second wing, and wherein the first wing and the second wing are configured to couple to a single channel strut member spaced apart from the channel.

19. The trench drain of claim 17, wherein the frame includes a crossbar that couples the first rail to the second rail.

20. The trench drain of claim 19, wherein the channel includes a recess configured to receive the crossbar proximate the first upper edge or the second upper edge.

21. The trench drain of claim 20, wherein the channel strut member is coupled to the wing such that a gap is formed between the channel strut member and the exterior surface of the of the channel.

22. The trench drain of claim 21, wherein the channel strut member has a width that is a first distance, wherein the gap has a width that is a second distance, and wherein the second distance is greater than 0.75 times the first distance.

23. The trench drain of claim 21, wherein the channel strut member has a width that is a first distance, wherein the gap has a width that is a second distance, and wherein the second distance is less than 1.5 times the first distance.

24. The trench drain of claim 20, wherein the wing includes an aperture configured to align with an aperture of the channel strut member such that a rod or fastener can extend through the aperture of the wing and the aperture of the channel strut member for coupling the wing to the channel strut member.