Patent Application
20250084606
This invention provides an underground utility enclosure system and method for installation over a junction point for underground utility conduit, cables, wires, and pipes.
Utility services such as electricity, gas, water, and communications can be run underground, and are likely to be run underground in newly developed areas. Existing overhead utilities can be replaced with underground utilities. Underground utilities are distributed by pipes and by cables and wires, sometimes run through conduit and sometimes as direct-burial cable. At several points along a run of underground utilities a junction point exists where a drop to a house or building is made, where a branch is split off, where a repair or splice needs to be made, or where a booster, pump, repeater, or amplifier needs to be installed. The junction points require at least occasional access. During initial construction technicians need access to the junction points to make and test all of the connections, and later access is needed for repair, testing, and extensions.
Presently, underground utilities junction points are enclosed in utility enclosures or vaults usually made of cast concrete or composite material, which have several disadvantages. Because they are rigid cast structures, they must be made to exact fixed dimensions and configurations of openings and structures. Therefore, a very large number of enclosures having different dimensions and configurations must be made through a time-consuming and expensive casting process. Because of this, it is not unusual to see up to nine-month waiting times for a construction site to receive the exact enclosures needed. The enclosures are bulky and heavy, causing the costs of storage and transport to rise. Because the concrete or composite material is brittle and breakable, the costs and complexities of handling during transport and installation rise, and an enclosure might break at the job site during handling or installation, leaving the job site without a unique enclosure, which might take months to replace.
A contractor bidding on or working on a large installation job will have to determine the exact dimensions and configurations needed for each of the many junction points, including any junction points requiring any change from the standard specifications. And then the enclosures will have to be ordered, manufactured, transported, and stored, with the necessary handling and tracking, before installation.
Where a vault or a concrete or other brittle enclosure is used, all underground obstructions such as rocks or boulders, demolition debris, dead tree roots, or existing utilities need to be completely removed before installation of the enclosure to avoid damaging the enclosure. During installation even slight mistakes in setting the angle of placement will likely require complete re-excavation and re-setting.
The worksite will probably not receive its final grading until long after the utility enclosures have been installed and set, and any miscalculation of the eventual grade, or any subsequent changes to the landscaping plans, can result in the top of the utility enclosure being too far above or below grade. If an eventual sloping profile is planned for a worksite not yet having that profile during installation of underground utilities, mistakes in installation can result in misalignments of utility enclosures creating obstacles or hazards.
What is needed is an underground utility enclosure made of a strong non-brittle material, inexpensive, highly resistant to breakage during storage, transport, handling, installation, and long-term use, but flexible enough to allow slight deformation to accommodate obstacles and to accommodate needed adjustments, and capable of being modified on-site using basic hand tools.
U.S. Pat. No. 3,974,599 for an “Underground Reinforced Plastic Enclosure,” issued on Aug. 17, 1976 to assignee Indian Head, Inc., provides for an underground reinforced plastic enclosure comprising a vertically and circumferentially stiffened body. The body is made of a fiberglass polyester resin and the stiffeners are of a reinforced plastic mortar. The body is suitable for surrounding a transformer or an oil switch used in underground utilities. On the body is seated a top cap made of reinforced plastic mortar. The top cap is formed with a central opening. Seated on the top cap is a reinforced plastic mortar cover plate or a metal grate. Depending from the top cap is a fiberglass polyester resin baffle and tamper shield. The body seats on a base of reinforced plastic mortar. A grade adjustment skirt also depends from the top cap outwardly from the baffle and tamper shield.
U.S. Pat. No. 10,240,316 for a “Locking Subgrade Vault,” issued on Mar. 26, 2019 to assignee Oldcastle Precast, Inc., provides for a subgrade vault system with a locking lid assembly. Specifically, a subgrade vault suitable for housing utility and similar equipment is provided, the vault comprising a main body portion, a cap, and a lid that may be selectively secured with one or more rotatable locking mechanisms to prevent or deter unauthorized access to vault content.
U.S. Pat. No. 9,435,099 for a “Locking Subgrade Vault,” issued on Sep. 6, 2016 to assignee Oldcastle Precast, Inc., provides for a subgrade vault system with a locking lid assembly. Specifically, a subgrade vault suitable for housing utility and similar equipment is provided, the vault comprising a main body portion, a cap, and a lid that may be selectively secured with one or more rotatable locking mechanisms to prevent or deter unauthorized access to vault contents.
U.S. Pat. No. 5,743,673 for a “Watertight Sealing System with Relief Valve for Manhole Having a Spill Bucket,” issued on Apr. 28, 1998 to inventor Sergio M. Bravo, provides for a sealing assembly for sealing a manhole against entering liquid, and the assembly includes a support ring fixed to the manhole's skirt and a sealing member resting on the support ring. The sealing member has a base with a foam ring under it, and pressing members on top of it for pressing the base against the support ring with the foam in between. The sealing member also has a top which is flexibly connected to the base. The top is fixed to the manhole cover with a gasket between it and the cover. A relief valve is provided to prevent the enclosed space within the manhole formed by the sealing member from overpressuring.
U.S. Pat. No. 10,358,285 for a “Thermoset Polymer Utility Vault Lid,” issued on Jul. 23, 2019 to assignees Channell Commercial Corporation et al., provides for a fiber reinforced polymer material lid or cover for a utility vault made from an unsaturated polyester thermosetting resin matrix, glass fiber reinforcement, an inorganic filler, and an ultraviolet inhibitor. The lid or cover has a flat textured upper surface having a plurality of bosses having different heights extending above the upper surface and a bottom surface having an outer perimeter rim with a recessed interior cavity having a number of continuous support ribs extending through the recessed interior cavity from opposite sides of the outer perimeter of the rim to transfer load placed on the lid or cover and minimize deflection under the load to the outer perimeter rim.
U.S. Pat. No. 3,672,103 for a “Modular Utility Vault,” issued on Jun. 27, 1972 to assignee City of Fort Collins, provides for a modular construction for underground utility vault. Semicylindrical end sections are molded in the form of a relatively thin shell from fiberglass or other moldable material of similar physical characteristics. The shells are formed with a series of radially offset circumferentially extending ribs which provide increased rigidity to the shell and also form shelves for supporting elements such as transformers, connection points, etc. within the vault. The end section is one form of structural module which may, in some installations, be combined with a second modular element in the form of a flat side panel having a cross-sectional configuration matching that of the end section. Two end sections may be secured to each other to form a cylindrical vault or, alternatively, two end sections may be assembled with one or more pairs of side panels attached to and mounted between the opposed end sections. A cover element of laminated molded sheet material closes the opening at the upper end of the completed vault and is provided with internal stiffening ribs. A lock and retainer-hinge assembly are employed to releasably lock the cover in position and enables the cover, when unlocked, to either be swung upwardly as on a hinged mounting or removed entirely.
U.S. Pat. No. 8,835,757 for a “Locking Subgrade Vault,” issued on Sep. 16, 2014 to assignee Oldcastle Precast, Inc., provides for subgrade vault system and method of forming the same. Specifically, a subgrade vault suitable for housing utility and similar equipment is provided, the vault comprising a main body portion, a cap, and a lid that may be selectively secured to prevent or deter unauthorized access to vault contents.
UK Publication No. 2 324 324 for “An Underground Chamber,” published on Oct. 21, 1998 by inventors Mokhtar Kourgli et al., discloses a chamber that is suitable for installation underground, especially for the housing of roadway utilities, and the chamber includes a wall component. The wall component is constructed from plastics material and comprises a wall portion connected along a line of weakness to an edge portion. The line of weakness allows the edge portion to be foldable with respect to the wall portion of the wall component, and this edge portion may then be secured to an adjacent wall component.
This invention provides an underground utility enclosure system and method for installation over a junction point for underground utility conduit, cables, wires, and pipes. The underground utility enclosure provides lighter less-expensive shatterproof enclosures, which can be more quickly manufactured and transported, more easily stored and handled on-site, and more easily installed with less heavy equipment and fewer personnel. A corrugated enclosure body made of a shatterproof polymer material has annular correlation, and allows for slight deformation to accommodate underground obstacles and allows on-site cutting and modification with available hand tools to adapt to different installation needs, allowing the purchase and storage of a smaller number of different sizes and configurations of enclosures to address a greater number of installation circumstances. At least three anchor loops provide for efficient handing and installation. A fitted lid available in various materials provides appropriate strength at an appropriate cost for different installation needs.
Reference will now be made to the drawings, wherein like parts are designated by like numerals, and wherein:
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The underground utility enclosure 1 provides a corrugated enclosure body 2, at least three anchor loops 3, and a fitted lid 4.
The corrugated enclosure body 2 is made from a thermoplastic polymer material having the required strength and elasticity to be molded into a corrugated tube and retain its shape while allowing for the slight deformations of the corrugated enclosure body 2 which are treated below. The thermoplastic polymer material should not have any tendency to break or shatter when dropped or struck because such dropping and striking will be a common occurrence during storage, handling, transport, installation, and use of the underground utility enclosure 1. A preferred embodiment of the corrugated enclosure body 2 is made from high-density polyethylene (HDPE) which has the needed properties, is resistant to solvents, and is available as recycled material. Other polyethylenes such as medium-density polyethylene (MDPE) are suitable, but are less common and less commonly available as recycled material. Acrylonitrile butadiene styrene (ABS) is suitable if it is treated to resist damage from ultraviolet light, but ABS is less-commonly recycled and is susceptible to damage from some solvents. Polypropylene (PP) is suitable but is vulnerable to ultraviolet radiation and is less-commonly recycled. A nylon synthetic polyamide polymer can also be suitable. The corrugated enclosure body 2 is molded as a tube having annular corrugation, which is equally spaced parallel corrugations whose main plane is perpendicular to the body axis. The corrugated enclosure body 2 has an inside surface and an outside surface. In use, installed in the ground, the corrugated enclosure body 2 has a vertical, top to bottom axial orientation. The annular corrugation provides both overall strength and some limited and controlled flexibility. The inherent slight elasticity of the thermoplastic polymer material and the flexibility provided by the annular corrugation allow for deformation of the corrugated enclosure body 2 to accommodate an obstacle or to bend the enclosure to accommodate a difference between the angle of the underground bottom portion and the desired angle of the top portion, as treated in detail below.
The underground utility enclosure 1 provides at least three anchor loops 3 arrayed around and protruding from the outside surface of the corrugated enclosure body 2. In a preferred embodiment three anchor loops 3 are arrayed around the corrugated enclosure body 2 equidistant and in a 120-degree angular relationship. Each anchor loop 3 forms a loop or an eye providing an attachment point for a rope, wire, cord, chain, or strap which can together form a harness for lowering the corrugated enclosure body 2 into a hole in the ground while allowing for exact placement and maintaining or adjusting the alignment of the main axis of the corrugated enclosure body 2, as treated in detail below. The anchor loops 3 can be provided as eye bolts or similar anchors, or as protruding loops molded, heat-welded, or otherwise affixed onto the corrugated enclosure body 2. The anchor loops 3 can also be formed from rope or strap material, either with each anchor loop attached separately to the corrugated enclosure body 2, or with the anchor loops attached to another rope or strap encircling the corrugated enclosure body 2.
The underground utility enclosure 1 provides a fitted lid 4 to cover the top of the corrugated enclosure body 2. A suitable rabbet, recess, ledge, lip, or seat is formed into the top of the corrugated enclosure body 2 to accommodate the fitted lid 4. The top of the corrugated enclosure body 2 can be reinforced with additional material where reinforcement is needed because of the size of the top opening, the weight of the lid, and the anticipated forces on the lid during use. A variety of fitted lids 4 can be provided for different anticipated loads and circumstances, which allows supplying heavy-duty and traffic-rated fitted lids 4 where needed, without increasing the costs of lighter-duty fitted lids 4. A heavy-duty, traffic-rated, or very large fitted lid 4 can be made from a strong metal or composite material or combination of materials, can be made thicker, and can have added bracing materials or bracing structures. Lighter-duty and smaller fitted lids 4 can be made from less strong materials and can be made less thick and with less bracing. Such a lighter-duty lid might be made from substantially the same thermoplastic material as the corrugated enclosure body 2. Fitted lids 4 can be provided in embodiments with or without openings or handles, and in embodiments ranging from completely sealed against water intrusion through water resistance to allowing the flow of water. In applications where the connections and junctions of the underground conduits, cables, wires, or pipes are sufficiently insulated and waterproofed, it might not be necessary to use completely sealed fitted lids 4. In applications where the fitted lid 4 and the top of the corrugated enclosure body 2 would be subject to damage from, for example, landscape maintenance equipment such as mowers, trimmers, or plows, a protective collar or bumper can be placed around or cast in place around the top of the corrugated enclosure body 2 and fitted lid 4, as treated in detail below.
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The corrugated enclosure body 2 will be placed into the hole and over the terminations at the junction point. The anchor loops 3 provide for the attachment of ropes, wires, cords, chains, or straps as a harness for lifting and lowering the underground utility enclosure 1 into the hole, for adjusting the position and angle during installation, and for stabilizing the position and angle during backfilling of the hole. Because of the at least three anchor loops 3 arrayed around the corrugated enclosure body 2 equidistant and in a 120-degree angular relationship, a properly configured harness should hold the corrugated enclosure body 2 in a substantially vertical position, and manipulation of the separate legs of the harness can adjust or correct the angle. The hole is backfilled to complete the installation of the underground utility enclosure 1.
For smaller embodiments of the underground utility enclosure 1, because of the relatively light weight and resistance to damage during handling, the underground utility enclosure 1 can be installed by hand by one or two persons, either directly manipulating the anchor loops 3 or using a small harness. Also because of the relatively light weight and resistance to handling damage, large embodiments of the underground utility enclosure 1 can be installed using less-powerful lifting equipment than would be required for heavier easily damaged enclosures.
After installation and backfilling of the hole, if the positioning of the underground utility enclosure 1 needs to be adjusted, as might be needed if, for example, the landscaping plan for the site is significantly altered, the hole can be partially re-excavated at least to expose the anchor loops 3, a harness can be re-attached, and the underground utility enclosure 1 can be re-positioned, or can be removed and replaced.
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Many other changes and modifications can be made in the system and method of the present invention without departing from the spirit thereof. I therefore pray that my rights to the present invention be limited only by the scope of the appended claims.
