This disclosure relates to trench drains, sometimes called channel drains, and more specifically, to a trench pan and grate assembly that can be used either as an individual unit, or as one of a plurality of such assemblies joined together such as in a series, to create a trench drain system.
Elongate drains, or so-called “trench” drains, are commonly used where there is need to drain a generally extended flat surface, such as a section of a building floor, across a garage door opening, an edge of a parking lot or driveway, and the like. One type of trench drain is a heavy duty type trench for heavy use conditions. It is usually formed of a pre-cast polymer concrete drain unit. This type of trench drain typically has a specific pitch built into each separate trench unit, such that extensive engineering specifications are required for the manufacture, layout and installation of the trench. For example, as many as 20 or more different pieces, each having its own built-in slope, are required to create a trench drain run of a given length. Such heavy duty trench drains are relatively difficult and labor intensive to assemble on-site. Also, since each trench piece is necessarily different, such trench drain systems require substantial manufacturing and mold costs. Further, so that such a system can readily be installed, each separate trench piece is required to be warehoused and purchased, thus making such a sloped-type heavy duty trench drain system extremely costly to make, specify, purchase, warehouse and install.
Another type of trench drain is typified in U.S. Pat. No. 5,529,436, as owned by Tuf-Tite, Inc., the assignee of the present disclosure. That form of trench drain comprises multiple components including a trench, a grate, and snap-on end caps, but each trench drain section is the same as the next, i.e., they are interchangeable. Integral but removable drain components permit the assembly of multiple size pipes to the bottom of the trench. Regardless what diameter pipe is chosen to be used, that pipe connects to an underlying pitched drainage pipe for the trench drain, as the channel bottom of the trench drain itself is generally “neutral” (i.e., non-sloped) relative to the flat surface in which it is cast in place. That is, there is no pitch of any type provided to the internal bottom surface of the channel forming the trench drain. While generally easy to install and economical in use, an occasional objection has been raised to that type of trench drain, namely that fluids, once entering through the grate member and collecting in the underlying trench, can stand and not be fully drained away, i.e. since the floor of the channel making up the trench is neutral.
Further yet, there is a so-called trench frame product, with associated grate, that does not require any type of specially-formed underlying trench channel structure. Rather, as normally intended to be installed, a separate frame member is directly fastened to the top portion of an underlying primary drain pipe, whereby after the pipe's top segment is removed, i.e. cut away, that pipe itself becomes, in effect, the channel for the trench so created. Then, at least one sloped secondary drain pipe is attached to the primary pipe, i.e., for draining away fluids collected within the combination trench frame and connected primary header pipe. Disclosure of that type trench frame and grate product is set forth in U.S. patent application Ser. No. 11/110,588 filed Apr. 20, 2005 entitled Trench Drain Frame and Grate Assembly, which is also owned by the assignee of the present disclosure.
Notwithstanding these and other various trench drain-type products, there has remained a need for an elongate trench drain product that can permit connection to several different versions of a given plumbing pipe size, that has sufficient built-in slope to prevent any standing water, and that can be used either separately, or as part of a plurality of identical units connected into a series of a desired configuration, to create an extended trench drain system.
Previously, the known injection-molded plastic grates used with trench drains were all formed with polyethylene injection molding materials having a so-called melt number greater than 1.0, and normally they were made with HDPE molding material. However, to the extent known, there have been no trench drain grates formed with injection molding material having a so-called fractional melt, i.e. with a melt number less than 1.0. Also, as best known, while so-called gas-assist injection molding procedures have been previously used in forming non-grate type of on-site waste and drainage products, such as risers, riser lids, and riser pans, no such gas-assist procedures have been successfully used in forming grates for on-site waste and drainage products. Further, there have been prior unsuccessful (and as best understood since they have since ceased) attempts at using gas-assist procedures when injection-molding of fractional melt materials into unrelated (non-grate) type products, such as flat air conditioner pads. Thus, until the present disclosure, there has been no known use of gas-assist procedures for injection-molding of grates that are intended for use with drainage and on-site waste products.
Prior known injection-molded plastic grates, once formed, suffered from numerous twists and warpage. For example, they always needed to be fastened down securely to an underlying trench drain or trench frame component to become relatively flat. That is, such prior known injection-molded grates were normally not flat, square and straight enough to be able to be sold and used as separate grate units alone, i.e. such as to be purchased for use with separately-formed trenches at a job site. Further, many end users desire at least a 6″ wide grate, i.e. rather than a 4″ plastic grate as is commonly sold, such as by the assignee of the present disclosure, with trench drain and trench frame units. But there is the risk that such wider grates would not be sufficiently strong to handle medium-to-heavy vehicle traffic, and might break or deform with such heavy duty use. Thus, there has remained a need for plastic grate products that could be formed to be heavy duty and dimensionally stable.
The present disclosure provides a combination trench pan and grate assembly where the pan is long and narrow, i.e. with a length-to-width ratio greater than 1:1, and thus, generally rectangular in shape, and has downwardly-ramped transition bottom walls terminating in a round pipe receiving fitting that is, through use of a bushing, able to advantageously accommodate the common different types of commercially-available plastic plumbing pipe of a given nominal size. A plurality of individual trench pan and grate assemblies can be formed end-to-end into an elongate trench drain system. That is, each assembly can be connected, through a bottom stub pipe and upwardly-facing sweep tee component, to an underlying sloped main drainage pipe. Importantly, however, because the floor of each trench pan is ramped, i.e., downwardly sloped, rather than being neutral, no water or other fluids are allowed to stand within each respective trench pan. Instead, as collected, such fluids are immediately drained out of the trench pan's bottom to the underlying drain pipe.
During installation, unlike many prior trench drain components, no separate mounting equipment is required to position and hold the trench pan in place, while the concrete is being cast about it. This is because the trench pan is first fastened in place in the correct position and height, such as by solvent welding, to the top of an underlying generally vertical stub pipe section, which in turn extends upwardly from an appropriate sweep tee (or sanitary tee) which itself connected to the underlying sloped drainage pipe. That same underlying sloped drainage pipe can be connected to yet other selectively-placed trench pans in the same manner, whereby an entire layout out of separately-positioned trench pan and grate assemblies can be installed in a given floor surface or drainage area, or alternatively, a running end-to-end series of such identified assemblies can be formed.
An integrally-formed but removable strainer plate covers off the pipe receiver fitting that extends downwardly from the ramped bottom walls of the trench pan. The separate grate member is installed and fastened down, via threaded fasteners, to the trench pan to complete the assembly. While the present disclosure is not limited in this regard, the elongate trench pans can be formed, for example, as short as 12 inches long, or instead as long as 3 feet, or even longer. Through use of the present trench pan and grate assembly, the problem of standing water is eliminated. Further, a secondary drain pipe is not needed. Further yet, there is no need for any special order, multiple component sloped trench drain system, i.e. where each component must be specifically and carefully fastened to adjacent ones of the correct slope and size, so as to allow the overall slope trench drain to be formed.
Rather, with the present disclosure, only a single type trench pan and grate unit, i.e. of one shape and one size, is needed to make a trench drain, whether installed singly at one location, installed instead at multiple separate locations, or installed in an abutting series arrangement.
Also, the grate used with the present trench pan is preferably formed of a fractional melt injection-molding material, and then through use of gas-assist molding procedures, results in a grate having substantially improved impact strength characteristics and dimensional stability.
Having reference to the drawings, wherein like reference numerals indicate corresponding elements, there is shown in
Extending downwardly from the sloped bottom wall 32, below the ring surface 36, is a female hub section acting as a pipe-receiving fitting 44. In one sample made in accordance with the present disclosure, the trench pan 22 is formed so that the pipe fitting 44 was sized to accept 4-inch PVC plumbing pipe, and particularly so-called Schedule 40 4-inch plastic plumbing pipe. However, if either one of so-called SDR-35 or ASTM 2729 4-inch plastic plumbing pipe is desired to be used instead, then the adapter bushing 26 (see
Because of the adapter bushing 26, one trench pan 22 can be used with any of the multiple different types of commonly-available plastic plumbing pipe of a given size, i.e. given diameter. Of course, the diameter of the pipe fitting 44 can be formed to be of any desired size so as to accommodate a chosen, yet different, diameter of commonly available plumbing pipes, such as, for example, formed to accept nominal 3 inch or 6 inch size pipes, instead of a nominal 4 inch size pipe.
Further, for the sample that was made in accordance with the present disclosure, but it will be understood the disclosure is not limited in this regard, the overall width of the trench pan was chosen to be approximately 6 inches, and the overall length was approximately 12 inches. However, it will be readily understood that, while still preferably using an approximately 6 inch width (or even greater width if needed), the overall length of the elongate trench pan 22 could be formed to be, for example, approximately 3 feet, i.e., so as to be of maximum length to take best advantage of commercially available shipping cost efficiencies. Further, whether formed of a shorter, e.g., a 12 inch length, or a longer, e.g., a 36 inch length, the overall height of the trench pan 22 would preferably remain approximately 4-¼ inch. In any case, regardless of the overall length chosen for the trench pan 22, the bottom wall 32 would continue to have sufficient slope, i.e., a slight draft angle towards the middle, so as to properly collect and drain away fluids via the ramped bottom walls 34a-34d.
Turning to
Turning now to
More specifically, such flared areas 92 are formed so as to be internally hollow (see
Advantageously, with the present disclosure, where gas-assist is used, such fractional melt materials can now be satisfactorily used in injection molding plastic grate parts. Normally, such fractional melt materials could not be used for forming a grate, as they are so thick and sluggish in use as to not move to completely fill in all the various mold cavities, except perhaps through use of very significantly increased mold injection pressures (i.e. such as in the elevated range of between 25,000 and 27,000 psi), but that requires significantly more costly molding equipment, and has its own problems. Instead, only normally-required injection pressures, i.e. in the normal range of approximately 20,000 to 22,000 psi, need be used now when forming the gas-assist-created grate of the present disclosure. This is a significant advantage, and provides cost savings.
In any event, the use of such low melt molding materials results in a grate 22 having superior strength and superior dimensional stability properties, as compared to the prior known grates as formed of high melt molding materials. For example, the high strength grate 22 made in accordance with the present disclosure, i.e. as formed of fractional melt material, using gas-assist molding procedures, would likely at least double the impact resistance for the grate, as compared to a similarly sized grate part, but as made using an injection molding HPDE material that instead had a melt index greater than 5.0.
Further, the known prior art grates for trench drains were made without gas-assist procedures and with a greater-than-1.0 melt HDPE material, with the results that those grates were often formed as curled or otherwise out-of-alignment, except when they were screwed down within a trench drain or trench frame. However, advantageously, the grate 24 as made in accordance with the present disclosure (i.e., via gas-assist procedures using fractional melt material) now remains substantially dimensionally stable and of increased impact strength. That is, the presently-disclosed grates remain generally straight, flat and square-cornered, as believed to be within +/−1%. This is a significant improvement over prior art injection-molded grates, since the prior grates were not sufficiently dimensionally stable as to be separately useable in angle iron rail-type trench drains, i.e., trench drains as formed up from angle iron rails encased in and above a concrete trench. In contrast, the dimensionally-stable grates of the present disclosure will lie substantially flat (i.e. they do not curl up or have out-of square corners), such that they can be readily used in such alternate-type trench drain systems.
Instead of using an injection-molded plastic grate, a grate suitably-sized and formed of cast iron or other metal could be used with trench pan 22. Thus, it will be understood that the presently disclosed trench pan is not limited to use only with injection-molded plastic grates.
As seen in
Thus, with the trench drain and grate assembly of the present disclosure, the end user gets all of the advantages (i.e. sloped floor to prevent standing fluids) of prior expensive pre-sloped trench drain products, but without the cost, and which all can be accomplished with only one cost-effective part to make, store, purchase, warehouse, and also which can be used as a single location trench drain, or in an end-to-end running series of such trench drain and grate assemblies.
Finally, by using gas-assist molding procedures, for the first time an injection-molded grate for use with on-site waste and drainage component can be formed of fractional melt materials that provide substantial impact strength and substantial dimensional stability, and without the need for use of extra high cost molding equipment having extraordinarily high injection molding pressures. Also, for the first time, the present disclosure allows the resulting gas-assist, fractional melt, injection-molded grates to be sold and used as separate items, due to their resulting flatness and other dimensional stability.
While certain preferred embodiments have been disclosed herein, it will be appreciated that variations may be made thereto without departing from the scope of the appended claims.