Note: Descriptions are shown in the official language in which they were submitted.
CA 02875433 2014-12-19
EXTENDABLE SLEEVE FOR POURED CONCRETE DECK
BACKGROUND
[0001] Concrete floors in multistory buildings are poured onto flat plywood
decks that are
later removed, or poured onto corrugated sheet metal supports that are left in
place. In both
cases passages through the concrete decks are needed for various plumbing
pipes, electrical
conduits, ventilation tubes, etc. In the event of fire or flooding, these
passages through the
concrete must be sealed in order to prevent passage of air, smoke, fire or
water. Current fire and
smoke seals use an intumescent material that involves taking flat strips of
intumescent material
and fastening it around a cylindrical container of predetermined diameter
using adhesives or
other mechanical fasteners. The intumescent material often includes a graphite
or fibrous
material that can be messy and hazardous to handle and ingest, and often
carcinogenic.
Fastening the flat strips to the passage tubes is labor intensive, prone to
errors and may raise
health concerns. Because the intumescent material has a limited expansion, and
because many
applications require effective internal smoke and water sealing, the
containers are generally
made to order for specific pipe sizes. Further, because of the variable
thickness of concrete slabs
specified by builder contractors, manufacturers are forced to either custom
build the container
hardware or to supply containers in large increments that force customers to
buy extra kits or cut
the container on¨site. In any event, current options do not allow economically
effective
manufacturing-to-specification solutions. Upon installation, the pipes
actually used may differ
from those initially planned or may be offset from the center more than the
expansion of the
intumescent material can accommodate, so the prefabricated, size specific fire
seals may not fit,
or fit as well as intended or needed, or may not work as well as designed
during actual use.
There is thus a need for an improved fire seal and container for intumescent
material that will
accommodate a wider variety of pipe diameters within a single device be more
easily assembled
and installed, and better suit variations in pipe location and slab thickness
than devices currently
used.
[0002] The passages through the concrete are formed by fastening a passage
tube, typically
plastic or metal to the support before the concrete is poured. The concrete
decks vary greatly in
-1-
CA 02875433 2014-12-19
thickness from four to eight inches, but may be as thin as two inches and as
thick as 18 inches or
more. Current passage tubes are premade to specific diameters and lengths,
making it difficult to
stock a sufficient supply for use and to accommodate variations in the passage
tubes at the job
site. There is thus a need for a more flexible length passage tube able to
accommodate pipes of
varying diameters.
[0003] The tubes must be fastened to the plywood support, or have a larger
base to span
enough corrugations to provide a stable tube support, especially for smaller
diameter, longer
passage tubes. Providing a large base suitable for corrugated supports is
expensive and
unnecessary for plywood supports. Moreover, several pipes may sometimes be
clustered
together when passing through the floor and in such cases the individual
passage tubes need to be
placed close together at distances driven by CISPI standards. If the passage
tube has a large base
for use on a corrugated support, it becomes difficult to achieve the desired
spacing when the
large support is used on either plywood or corrugated supports. There is thus
a need for an
improved tube support more suitable for the different support applications.
[0004] The passage tubes are provided in different lengths to accommodate
the variable
thickness of the concrete decks. Long passage tubes are sometimes cut shorter,
wasting material
and often resulting in inaccurate cuts as the worker may measure wrong.
Sometimes an
extension can be added to a shorter passage tube to increase the overall
length, but again workers
can measure wrong, resulting in non-compliant passages through the concrete.
Also, the
extended tubes may be hit, kicked or stood on and in such cases extension
tubes may break.
There is thus a need for an improved passage tube with a sturdier, easily
adjusted length.
[0005] In addition to a smoke and fire seal the passages through the
concrete must provide a
water seal around the pipes or conduits passing through the passage tube.
Flat, plastic or rubber
sheets are used with holes cut out for the pipe to pass through and these are
also installed in the
passage tube at the time the passage tubes are made. If the pipes are too
large for the holes the
sheets tear, if the pipes are too small the seal is poor and if the pipes are
offset from the holes in
the sheets then inadequate seals may formed. There is thus a need for an
improved water seal in
passage tubes.
[0006] When the concrete deck is poured around the passage tubes the upper
end of the tubes
are blocked to prevent concrete from filling the passage tube. Mechanical
trowels and riding
trowels are used to finish the concrete surfaces of the poured decks and the
closed ends of the
-2-
CA 02875433 2014-12-19
tubes are often covered with a thin layer of concrete in doing so. The
concrete covering makes it
difficult to locate the passage tubes. Workers sometimes tape nylon strands to
items over which
concrete is poured so the strands extend out of the concrete surface after
finishing and bend for
the troweling machines. But taping strands to things is time consuming, may be
unintentionally
omitted or not planned at all, and the tape may tear lose or otherwise fail to
restrain the strands
during pouring of the concrete or troweling. There is thus a need for an
improved way to locate
passage tubes in freshly poured concrete floors.
[0007] The passage tubes may need to be configured differently depending on
whether they
are to contain metal or cast iron pipes or plastic pipes, in part because the
water seal with the
outside of a cast iron pipe has different requirements than for plastic or
copper pipes. For
example, exterior pipe diameters differ significantly between pipe types of
even the same
nominal internal size. Workers can sometimes look inside the passage tube to
see the opening
size in the water seal but that is time consuming, and invites error from
judging opening
diameters by visually looking down a dark tube of varying length. There is
thus a need for an
improved way to allow workers to identify the types of pipes a passage tube is
designed to
accommodate.
[0008] After concrete floors are poured to entrain passage tubes there may
be spills of large
volumes of water. It is desirable to prevent such water spills from entering
the passages and
passing through the passages. There is thus a need for an improved passage
tube for entrainment
in concrete floors.
BRIEF SUMMARY
[0009] An assembly is provided to form an adjustable length, tubular
passage in poured
concrete decks. The assembly has a tubular cylinder of intumescent material
held in a two-part
base by a clip supporting the bottom of the tubular cylinder of intumescent
material and fastened
to the base. A first, cylindrical tube engages the base's top to clamp a
diaphragm seal against the
base. The seal has a pipe opening and a funnel shape to accommodate pipe
offsets and to better
seal against the pipe. The first tube has spaced, radially extending, parallel
ridges at
predetermined distances from the base. Cutting between the ridges adjusts the
length of the
tubular passage to known lengths. Longitudinal channels separate the ridges
into first and
second sets of ridges. Printed indicia in the channels or in the grooves
between adjacent ridges
can state the lengths. The two sets of ridges can be at different distances
from the base for
-3-
CA 02875433 2014-12-19
greater variability of length adjustment. A cylindrical extension tube fits
over the first tube and
has inwardly extending lugs on opposing sides of a first end of the extension
tube. The lugs pass
along the longitudinal channels with the extension tube being rotated to
engage the lugs with
various ridges to adjustably fix the passage length to the end of the
extension tube. A second end
of the extension tube optionally engages the base bottom for use with
corrugated supports. A
cap with repositionable locating filaments optionally closes the either the
first extension tube or
the first tube, depending on need. The locating filaments are attached to the
underside of the cap
and extend inside nested first tube and extension tube for shipment, with the
filaments being
repositioned to connect to the outside of the cap and extend along the
longitudinal axis during
use. The locating filaments connect to the cap below the outer surface so the
filaments bend
during troweling of the concrete and extend above the finished concrete
surface to allow users to
locate the tubular passage after concrete finishing.
100101 In more detail, there is advantageously provided a tubular passage
assembly for
poured concrete decks formed on a support surface. The assembly includes a
base having a
cylindrical sidewall with an upper end and an opposing bottom end and
extending along a
longitudinal axis. The upper end of the sidewall has an inward extending upper
flange defining a
circular opening encircling the longitudinal axis. The lower end of the base
has an outward
extending base flange to support the base on the support surface during use. A
cylindrical tube
of intumescent material encircles the longitudinal axis and fits inside and
adjacent to the sidewall
and is restrained from movement in a first direction along the longitudinal
axis by the upper
flange. A retaining clip has an annular portion abutting the bottom of the
tubular cylinder of
intumescent material to restrain the tubular cylinder of intumescent material
from movement in a
second direction along the longitudinal axis. The retaining clip has a
plurality of tabs extending
through the base sidewall to restrain movement of the retaining clip along the
longitudinal axis
during use.
[0011] In addition to the base assembly, the tubular passage assembly may
include a flexible
diaphragm seal having an outer periphery engaging an upper end of the base and
having an inner
periphery defining an opening encircling the longitudinal axis during use. A
portion of the
diaphragm adjacent the inner periphery has a funnel shape extending out of a
plane orthogonal to
the longitudinal axis through the outer periphery.
-4-
CA 02875433 2014-12-19
[0012] In further variations, the first tube has opposing upper and lower
ends with the lower
end configured to engage the base. The first tube also may have an inward
extending flange
adjacent the lower end configured to engage the periphery of the diaphragm and
press it against
the base to form a fluid tight seal when the first tube is engaged with the
base. The first tube may
further includes a first set of parallel ridges extending outward from the
first tube with each of
the first ridges in a plane orthogonal to the longitudinal axis and the first
set of ridges each
extending less than half way around the first tube. The first tube may also
include a second set
of parallel ridges extending outward from the first tube with each of the
ridges in a plane
orthogonal to the longitudinal axis. The second set of ridges each extends
less than half way
around the first tube and located on an opposing side of the first tube than
the first set of ridges.
The first and second ridges each have ends spaced apart to define first and
second longitudinal
channels on opposing sides of the first tube. The first tube may further
include a first set of
visible indicia adjacent a plurality of the first set of ridges where the
indicia defines a distance
from the bottom of the base to the visible indicia associated with each of the
plurality of the first
set of ridges. The first tube may also have a second set of visible indicial
adjacent a plurality of
the second set of ridges defining a distance from the bottom of the base to
the visible indicia
associated with each of the plurality of the second set of ridges, with at
least one of the first and
second set of indicia indicating a distance specified in metric or English
distance units.
[0013] In further variations, a plurality of the ends of two adjacent
ridges in the first set of
ridges are joined by first axially extending end segments with the first
axially extending end
segments joining only two adjacent ridges. A plurality of second axially
extending end segments
may join adjacent ridges which ridges are each joined to a different one of
the first axially
extending end segments. The first axially extending end segments are located a
first
circumferential distance from a center of the first channel and the second
axially extending end
segments located a second circumferential distance from the center of the
first channel with the
second circumferential distance being greater than the first circumferential
distance to form a
first circumferential recess at each second axially extending end segment.
Further, a plurality of
the ends of two adjacent ridges in the second set of ridges may be joined by
third axially
extending end segments with the third axially extending end segments joining
only two adjacent
ridges. A plurality of fourth axially extending end segments may join adjacent
ridges which are
each joined to a different one of the third axially extending end segments.
The third axially
-5-
CA 02875433 2014-12-19
extending end segments are located a third circumferential distance from the
center of the first
channel and the fourth axially extending end segments located a fourth
circumferential distance
from the center of the first channel, with the fourth circumferential distance
being greater than
the third circumferential distance to form a second circumferential recess at
each fourth axially
extending end segment.
[0014] In still further variations, the base may have an outwardly
extending limit stop and
the first tube has a tab located to hit the limit stop as the first tube
engages the base so as to
position the first tube a known distance from a bottom of the base and ensure
proper compression
of the diaphragm seal. Further, the base may have external screw threads
threadingly engaging
internal screw threads on the lower end of the first tube to engage the first
tube to the base, with
the base and first tube each having a motion limit stop located to engage when
the first tube is at
a predetermined distance from the bottom of the base. Further, the base may be
formed of two
segments separated along a plane through the longitudinal axis but fastened
together to form the
base after the tubular cylinder of intumescent material is inserted into at
least one segment of the
base.
[0015] In still further variations, the tubular passage assembly may
include a first extension
tube having opposing top and bottom ends with the top end threaded internally
and the bottom
end threaded externally with the same threads as the top end. The bottom end
of the first
extension tube has first and second locking lugs each extending inward from a
different opposing
side of the first extension tube with the first and second locking lugs being
sized and located to
slide along the first and second channels, respectively. Rotation of the first
extension tube places
each locking lug between two adjacent ridges of one of the first or second
sets of ridges. Further,
the upper end of the first extension tube may have internal threads sized to
threadingly engage
external threads on the cap with the first extension tube being large enough
to fit over the first
tube. This first extension tube may also act as a lower extension in
cooperation with threads
formed in the base located to threadingly engage threads on one end of the
extension tube. Still
further, additional extension tubes may be threaded into the first extension
tube if needed, to
further lengthen the tube.
[0016] In further variations, the flexible diaphragm is made of silicone or
TPR (thermo
plastic rubber) and has sidewalls curving upward away from the base and toward
the longitudinal
axis, with the curved sidewalls located intermediate the inner and outer
periphery. The base
-6-
CA 02875433 2014-12-19
flange may extend along at least two opposing sides of the base and may
further include a first
stabilizing plate configured to releasably fasten to one of the at least two
opposing sides of the
base flange and restrain rotation of the upper end of the base toward the
juncture of the base
flange with the stabilizing plate. A second stabilizing plate may be provided
on an opposite side
of the base flange. Further, the stabilizing plate(s) may be joined to the
flange by a living hinge
and screwed or nailed to the concrete forms for stabilizing purposes, or
rotated along the living
hinge toward the flexible diaphragm and latched there to keep the plate out of
the way if not
being used to stabilize the base.
[0017] An improved cap is also provided for use with the tubular passage
assembly. The cap
has a circular top having an upper and lower side with an annular skirt
depending therefrom.
First and second latches each extend inward from an opposing side of the
skirt. The latches are
configured to releasably engage one of the ridges on the outside of the first
tube in order to fasten
the cap to the first tube. Also, the cap may have external threads for
attaching to the first
extension tube. Between the threads and the top of the cap, the cap may have
an inwardly
tapered peripheral edge that forms a short, conical or beveled edge in the
concrete when the cap
is removed. The cap has a connector on at least the upper side of the top with
the connector
located in a recess. A filament base has at least one filament extending
therefrom and is
configured to releasably engage the connector to hold the at least one
filament generally parallel
to the longitudinal axis. The juncture of the filament to the filament base
being located below
the upper side of the top and sufficiently far from the recess edge so that
the at least one filament
can be troweled against the upper side of the top and not break, the filament
having a length
sufficient to be visible after the cap is covered with a thin layer of
troweled concrete during use.
[0018] There is also provided a kit for forming a tubular passage along a
longitudinal axis for
passage of a pipe through a poured concrete deck. The kit includes a base
assembly having a
base formed of two opposing housing portions fastened together to form a
cylindrical sidewall
portion containing a tubular cylinder of intumescent material adjacent the
cylindrical sidewall
portion. The tubular cylinder of intumescent material encircles the
longitudinal axis and has its
motion limited in a first direction along the axis by the housing and has
movement in the
opposing direction along the axis limited by a clip engaging the housing. The
kit may include a
first flexible diaphragm seal having a central opening selected to seal
against a range of pipe
diameters during use. The seal has a funnel portion between an outer periphery
and the central
-7-
CA 02875433 2014-12-19
opening. The kit may also include a first cylindrical tube configured to
fasten to a top of the base
assembly during use and encircle the longitudinal axis during use. The first
tube and base are
configured to clamp a periphery of the flexible diaphragm between them
sufficiently to form a
fluid tight seal.
[0019] In further variations, the first tube of the kit has a plurality of
outwardly extending,
equally spaced ridges on an exterior surface thereof and extending along a
majority of a length
of the first tube. The kit also may include a first cylindrical extension tube
having a first end
configured to fit over the first tube and having at least one lug configured
to engage a selected
one of the plurality of outwardly extending ridges to releasably fasten the
first extension tube to
the first tube. The kit may further include a first tube that fastens to the
top of the base by a
double lead threaded connection. The base may have internal, double lead
threads on a bottom
thereof which threads encircle a lower portion of the tubular cylinder of
intumescent material and
are configured to threadingly engage mating threads on the first cylindrical
extension tube. The
kit may also include a second flexible diaphragm seal clamped between two
opposing rings may
also be provided, with at least one of the rings having threads or snap locks
configured to
connect to the housing or to the first tube.
[0020] The first tube may also form a separate improvement. The first tube
may form a
tubular passage along a longitudinal axis for passage of a pipe through a
poured concrete deck.
The first tube may include a tubular cylinder having an opposing upper and
lower ends extending
along the longitudinal axis during use. The cylinder has a first diameter
along a majority of its
length with a larger diameter lower end and internal threads around the inside
of the larger
diameter lower end. The cylinder may have a first plurality of parallel ridges
extending radially
outward along a majority of a length of the cylinder and a second plurality of
parallel ridges
extending radially outward along a majority of a length of the cylinder and
axially offset from
the first set of ridges. The first and second sets of ridges are preferably
separated by first and
second channels extending parallel to the longitudinal axis. In further
variations, a plurality of
the ridges in the first set has distal ends joined by vertical segments at the
distal ends of said
plurality of ridges.
[0021] In the above tubular passages and kits, for use on corrugated
supports, a hole is cut
through the corrugation and the base positioned over the hole. An extension
tube the same as the
first extension tube is passed upward through the hole in the corrugation and
fastened to the
-8-
CA 02875433 2014-12-19
bottom of the base. The extension tube may have one or more pilot holes
extending inward from
an outer surface of the extension tube, with the pilot holes preferably being
blind holes but
located so the hole is aligned between adjacent ridges on the first tube so
that a self-threading
fastener (also optionally provided with the kit) may pass through the blind
hole and between
adjacent ridges to fasten the extension tube to the first tube.
[0022] Preferably the base has mating screw threads encircling the tubular
cylinder of
intumescent material and thus outward of that cylinder and accessible from the
lower side of the
base. To enable the screw threads to extend into the base and encircle the
tubular cylinder of
intumescent material the retaining clip is offset so that the tabs bend upward
to form an offset
accommodating the bottom screw threads with the tabs then extending outward
through openings
in the cylindrical sidewalls of the base that encircle the tubular cylinder of
intumescent material.
As needed, a removable adhesive cover or cap is placed over the bottom of the
base to keep
debris from entering the base during shipment, during installation, during
pouring of the concrete
and during application of fire retardant spray. The removable adhesive cover
or cap may be
removed and placed on the open end of an extension tube that is screwed into
the bottom of the
base if desired.
[0023] The base flanges may have two removable tabs formed in the base. One
tab may
indicate metal and the other plastic. If the shaped diaphragm and base
assembly are selected for
use with metal pipes passing therethrough, then the plastic tab is removed so
that a user can see
from looking at the tab on the base that the passage tube is intended for use
with metal pipes. If
the shaped diaphragm is selected for plastic pipes then the metal tab is
removed so that a user can
see from looking at the tab on the base that the passage tube is intended for
use with plastic
pipes. The indicia indicating metal or plastic pipe is preferably visible from
at least the upper
side and preferably visible from both the upper and lower sides of the base.
Alternatively, the
indicia may consist of color-coded inserts installed in openings in the base
flange.
[0024] There is also advantageously provided a kit for an assembly forming
a tubular
passage for poured concrete decks formed on a support surface. The kit and
assembly include a
base having a cylindrical sidewall with an upper end and an opposing bottom
end and extending
along a longitudinal axis. The upper end of the sidewall have an inward
extending upper flange
defining a circular opening while the lower end of the base has an outward
extending base flange
to support the base on the support surface during use. A tubular cylinder of
intumescent material
-9-
CA 02875433 2014-12-19
is provided and fits inside and adjacent to the sidewall where it encircles
the longitudinal axis
and is retained in position along the longitudinal axis during use. Various
retaining mechanisms
for the intumescent material can be used as described herein, and as known to
those skilled in the
art. The kit and assembly also include a first flexible diaphragm seal having
an outer periphery
engaging an upper end of the base and having an inner periphery defining an
opening encircling
the longitudinal axis during use. A portion of the diaphragm adjacent the
inner periphery has a
funnel shape extending out of a plane orthogonal to the longitudinal axis
through the outer
periphery. The kit and assembly may also include a first tube having opposing
upper and lower
ends with the lower end configured to engage the base. The first tube may have
an inward
extending flange adjacent the lower end configured to engage the periphery of
the diaphragm and
press it against the base to form a fluid tight seal when the first tube is
engaged with the base.
The first tube further includes a first set of parallel ridges extending
outward from the first tube
with each of the ridges in a plane orthogonal to the longitudinal axis and
spaced apart a first
distance. The kit and assembly also include a first extension tube having a
sidewall with
opposing top and bottom ends. The bottom end of the first extension tube has
first and second
locking lugs each extending inward from a different opposing side of the first
extension tube.
The first and second locking lugs may be sized and located to slide along the
first and second
channels, respectively, with rotation of the first extension tube placing each
locking lug between
two adjacent ridges of the first set of ridges when the first extension tube
is centered on the
longitudinal axis and overlaps a portion of the first tube. The kit and
assembly also may include
a pilot hole extending partially through the sidewall from an exterior side of
the first extension
tube. The pilot hole is located on the extension tube relative to one of the
first and second
locking lugs so that the pilot hole is located in a radial plane passing
between two adjacent first
ridges.
[0025]
In further variations, a self-tapping threaded fastener extends through the
pilot hole
and wall of the extension tube and into the first tube between two adjacent
first ridges to connect
the first extension tube to the first tube. There may be two pilot holes on
opposing sides of the
first extension tube and the kit and assembly may further include two threaded
fasteners. Each
fastener may extend through a different one of the pilot holes and wall of the
extension tube and
into the first tube between two adjacent first ridges to connect the first
extension tube to the first
-10-
CA 02875433 2014-12-19
tube. The first set of ridges preferably extends less than half way around the
first tube and the
first tube may include a second set of parallel ridges as described herein.
[00261 The kit and assembly may also include a second flexible diaphragm
seal having a
circular periphery located between a connecting ring and a clamping ring and
held therebetween.
The second diaphragm seal has an inner periphery defining an opening
encircling the
longitudinal axis during use with a portion of the diaphragm adjacent the
inner periphery having
a funnel shape extending out of a plane orthogonal to the longitudinal axis
through the outer
periphery and extending in the same axial direction as the funnel shape of the
first diaphragm
during use. The connecting ring is configured to engage the upper end of the
first tube,
preferably by threads or a snap-lock connection. An 0-ring seal may be located
between an
outward facing surface of the connecting ring and an inner surface of the
first tube, with the 0-
ring seal located between the first and second diaphragm seals during use.
[0027] The kit and assembly may include a circular top having opposing
upper and lower
surfaces with a depending skirt and an inclined sidewall located between the
depending skirt and
the top surface of the cap. The inclined sidewall has a larger diameter
adjacent the top surface of
the cap and a smaller diameter adjacent the skirt. The inclined sidewall has a
diameter larger
than an outer diameter of the top end of the first extension tube so as to
extend outward of the
first extension tube and form a beveled surface in concrete entraining the cap
and first extension
tube during use when the cap is fastened to the first extension tube. The
inclined sidewall has a
diameter larger than an outer diameter of the top end of the first tube so as
to extend outward of
the first tube and form a beveled surface in concrete entraining the cap and
first tube during use
when the cap is fastened to the first tube during use. The cap may have the
other features
described herein.
[0028] The assembly or kit may also include an aerator box. The aerator box
may have two
parallel side walls joined at opposing ends to a different one of two opposing
end walls to
encircle the longitudinal axis and form the sides of an enclosure. The side
walls and end walls
are connected to a top having a cylindrical flange configured to connect to
the bottom of the
base. The parallel side walls are spaced apart the same distance as two
opposing sides of the base
flange. The two opposing end walls are spaced apart a larger distance but less
than twice the
distance between the parallel side walls. At least some of the end walls and
side walls have a
-11-
CA 02875433 2014-12-19
lower end with an outwardly extending flange suitable for fastening the
aerator box to a concrete
pouring form.
[0029] The kit and assembly may also include a variation of the base
wherein the base flange
has two opposing and parallel sides and two opposing ends. Each of the
opposing ends has a
hinge extending across the end orthogonal to the sides and forming a distal
end portion that may
rotate about the hinge toward the sidewall of the base. The hinge may be a
living hinge formed
in a base flange made of a polymer. The hinged distal end of the base flange,
the aerator box, the
cap with the inclined peripheral edge, and the second module may each comprise
a separate
improvement.
[0030] The kit and assembly may also include an elongated support plate
having an opening
encircling the longitudinal axis and allowing access to the bottom of the base
opposite the
cylindrical sidewall of the base. The support plate has a length sufficient to
extend beyond the
ends of two opposing ends of the base flange. The support plate may have a
generally
rectangular and planar shape with a plurality of fingers extending from an
upper surface of the
plate. The fingers may be configured to pierce the base flange and connect the
support plate to
the base flange. A plurality of the fingers may also be configured and located
to extend through
a plurality of slots extending through the base flange to connect the support
plate to the base
flange.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] These and other features and advantages of the invention will become
more apparent
in light of the following discussion and drawings, in which like numbers refer
to like parts
throughout, and in which:
[0032] Fig. 1 is an exploded perspective view of an extendable sleeve for
forming a tubular
passage in a poured concrete floor;
[0033] Fig. 2 is a top perspective view of a base of Fig. 1;
[0034] Fig. 3 is a bottom perspective view of the base of Fig. 2;
[0035] Fig. 4 is a top perspective view of an assembly including a base and
a first tube of the
extendable sleeve of Fig. 1;
[0036] Fig. 5 is a top perspective view of the assembly of Fig. 4 further
including a first
extension tube;
[0037] Fig. 6 is a sectional view of the assembly of Fig. 5, taken along 6-
6 of Fig. 5;
-12-
CA 02875433 2014-12-19
[0038] Fig. 7 is a partial perspective view of a portion of Fig. 6 showing
the juncture of the
first tube and the extension tube;
[0039] Fig. 8 is a partial perspective view of a portion of Fig. 5 showing
the juncture of the
first tube and extension tube;
[0040] Fig. 9 is a top perspective view of the extendable sleeve of Fig. 1
with a second
extension tube thereon;
[0041] Fig. 10 is a top perspective view of the extendable sleeve of Fig.
1;
[0042] Fig. 11 is a bottom perspective view of the base and first tube and
cap of Fig. 1;
[0043] Fig. 12 is a section view of the extendable tube of Fig. 6 with a
cap and locating
filaments thereon in a position for shipping;
[0044] Fig. 13 is a top perspective view of a cap of Fig. 1;
[0045] Fig. 14 is a bottom perspective view of the cap of Fig. 11, with
locating filaments in a
shipping position;
[0046] Fig. 15 is a top exploded perspective view of a base, first tube and
cap of Fig. 1 with
the first tube cut to a very short length;
[0047] Fig. 16 is a bottom, exploded, perspective sectional view of the
base and cap of Fig.
15;
[0048] Fig. 17 is a top, exploded perspective view of a the extendable
sleeve of Fig. 1 with a
bottom extension tube;
[0049] Fig. 18 is a perspective view of the juncture of a corrugated form
stabilizing plate
with the base of Fig. 17;
[0050] Fig. 19 is a bottom perspective view of the assembly of Fig. 17;
[0051] Fig. 20 is a bottom perspective view of the assembly of Fig. 17 but
with the bottom
cover removed;
[0052] Fig. 21 is a bottom, perspective section view of the diaphragm seal
of Fig. 1;
[0053] Fig. 22 is a section view of the extendable sleeve of Fig. 17 on a
corrugated support;
[0054] Fig. 23 is a sectional view taken along 23-23 of Fig. 24a;
[0055] Fig. 24a is a top view of two halves of the base housing, each of a
different base,
joined together;
[0056] Fig. 24b is a side view of the joined half-housings of Fig. 24a;
[0057] Fig. 25a is a perspective view of a tubular cylinder of intumescent
material;
-13-
CA 02875433 2014-12-19
[0058] Fig. 25b is a perspective view of a tubular cylinder of intumescent
material with
interior ribs or crennelations encircling a pipe;
[0059] Fig. 26a is a perspective, sectional view taken along section 26a-
26a of the base of
Fig. 26b;
[0060] Fig. 26b is a perspective view of a further embodiment of the base
of Fig. 1;
[0061] Fig. 27 is an exploded perspective view of a water seal for use with
the passage tube
assembly 10 of Fig. 1;
[0062] Fig. 28 is a perspective view of the water seal of Fig. 27 in an
assembled
configuration;
[0063] Fig. 29 is a top view of the water seal of Fig. 28;
[0064] Fig. 30 is a sectional view taken along 30-30 of Fig. 29;
[0065] Fig. 31 is a perspective view of a water dam for use with the
passage tube assembly
of Fig. 1;
[0066] Fig. 32 is an exploded view of the water dam of Fig. 31;
[0067] Fig. 33 is a cross-sectional view of the water dam of Figs. 31 and
32;
[0068] Fig. 34 is an exploded perspective view of an aerator for use with
the passage tube
assembly 10 of Fig. 1;
[0069] Fig. 35a is a side view of the assembled aerator and passage tube of
Fig. 34;
[0070] Fig. 35b is a front view of the assembled aerator and passage tube
of Fig. 35a; and
[0071] Fig. 35c is a sectional view taken along 36c-36c of Fig. 35b;
[0072] Fig. 36 is a perspective view of a further embodiment of a base
flange;
[0073] Fig. 37a is a perspective view of a further embodiment of the cap of
Figs. 13-15;
[0074] Fig. 37b is a side view of the cap of Fig. 37a;
[0075] Fig. 37c is a side view of the cap of Fig. 37a with the inclined
surface more radially
outward;
[0076] Fig. 38a is a perspective view of a base of Fig. 1 with modified
supporting plates;
[0077] Fig. 38b is a top view of the base of Fig. 38a and 38c;
[0078] Fig. 38c is a side view of the base of Fig. 38a;
[0079] Fig. 38d is a bottom view of the base of Fig. 38a and 38c;
[0080] Fig. 39 is a perspective view of a passage tube assembly with
threaded fasteners
extending into ports to lock parts together.
-14-
CA 02875433 2014-12-19
[0081] Fig. 40 is a perspective view of the assembled aerator and passage
tube having ring
stiffeners on an outer extension tube; and
[0082] Fig. 41 is a side view of an extension tube having longitudinal
stiffeners.
DETAILED DESCRIPTION
[0083] Referring to Figs. 1-20 a passage tube assembly is provided having a
base 12 formed
of a housing 14 having two-parts 14a and 14b which clamp radially about a
longitudinal axis 16
of the passage tube assembly 10 and base 12, with fasteners 18a clamping
mating bosses 18b,
18c on opposing housing parts together in order to secure the housing parts
14a, 14b together.
The base preferably has a flange 17 extending outward from the lower end of
the base 12. As
used herein, the relative terms inner and outer, inward and outward, are with
respect to
longitudinal axis 16. The relative terms above and below, upper or lower,
upwards and
downwards are also relative to the position along longitudinal axis 16 with
respect to flange 17
on base 12 in the orientation of Figs. 1 and 4-6, so that housing 14 and
passage tube assembly are
above base flange 17.
[0084] Referring especially to Figs. 1-3 and 6, the housing parts 14a, 14b
each have a curved
sidewall extending along the longitudinal axis 16 and an inwardly extending
lip 20 on an upper
end to restrain upward axial movement of an tubular cylinder 22 of intumescent
material placed
inside the housing 14. The housing parts 14a, 14b may each have a lower lip
(not shown) at a
lower end to restrain downward axial movement of the tubular cylinder 22 of
intumescent
material, in which case the tubular cylinder 22 of intumescent material is
placed in one part of
the base 12 or housing parts 14a, 14b before the two parts are joined and
fastened together to
form the base 12. But using two, (one upper and one lower lip) may complicate
molding so
preferably only one lip is used, upper lip 20, with the tubular cylinder 22 of
intumescent material
held at the bottom of the base 12 by a retaining clip 24 having tabs 26 that
pass through mating
openings 28 in each of the two-part housing 14 as the two parts of the housing
are assembled.
[0085] The retaining clip 24 has an annular bottom portion 30 to hold the
bottom of the
tubular cylinder 22 of intumescent material, with the annular bottom portion
being offset axially
from four extending tabs 26 for reasons discussed later. After assembly, the
tabs 26 extend from
the inside to the outside of housing 14 and the tabs are then bent to lock the
retaining clip 24 in
place so the tubular cylinder 22 of intumescent material is constrained on
three sides by the
annular bottom portion 30 of the clip 24 and the base's sidewall 19 and upper
lip 20, so that
-15-
CA 02875433 2014-12-19
thermal expansion of the tubular cylinder 22 of intumescent material is
directed generally inward
toward longitudinal axis 16.
[0086] The two parts of housing 14a, 14b are fastened together by snaps
locks, threaded
fasteners, other mechanical locks, or adhesives, with screws 18 being
illustrated in the Figures.
The lower end of the base 12 has flange 17 extending outward from the base's
sidewall 19 with
holes 32 in the flange to allow the flange to be nailed, screwed or otherwise
fastened to a support
33. That provides an easily molded housing 14 that may be quickly assembled to
form base 12,
with retaining clip 24 holding the tubular cylinder 22 of intumescent material
in place within the
base 12.
[0087] The tubular cylinder 22 of intumescent material may be a continuous
annular ring or a
split ring with two adjacent ends separated by a slot. However, the cylinder
22 may also be
formed by methods obtained from prior art, including rolled shapes of
intumescent materials.
The tubular cylinder 22 of intumescent material is preferably preformed for
easy of assembly.
The tubular cylinder 22 of intumescent material may be formed in a corrugated
shape to expand
faster and to expand to a greater distance than previously achieved.
[0088] Referring to Figs. 1-3 and 11-12, the upper end of the base 12 may
have external
threads 34 so that a lower end of a first sleeve or tube 36, preferably a
graduated tube 36, can
threadingly engage the base 12 via mating internal threads 35 (Fig. 12) on the
inner surface of
the first tube 36 adjacent the lower end of the first tube 36. By graduated,
it is meant the outer
surface of the tube 36 has physically protruding length indicators, described
later.
Advantageously, the cylindrical wall forming first tube 36 is generally
concentric with the lip 20
on the base 12, requiring a lateral, outward offset, stepped or enlarged
portion 37 so that the
bottom end of first tube is larger in diameter than the remaining upper
portion of tube 36, with
the internal threads 35 formed on that enlarged stepped portion.
[0089] The threads 34 are preferably double lead threads, with one lead on
each half 14a,
14b of the housing. Thus, the mating threads 35 on first tube 36 are also
preferably double lead
threads. A rotation stop 38a on sidewall 19, just below the threads 34 abuts a
mating stop 38b on
the bottom end of first tube 36 in order to limit the engagement of mating
threads on the base 12
and first tube 36 and also accurately positions the first tube 36 relative to
the base 12 and
particularly positions the tube 36 relative to base flange 17.
-16-
CA 02875433 2014-12-19
[0090] As best seen in Figs. 1, 6, 12, 16 and 21, the first tube 36 clamps
an outer periphery of
a shaped seal diaphragm 40 against the cylindrical wall forming base 12,
preferably against the
inwardly extending upper lip 20 of the base 12. The first tube 36 may have an
inwardly
extending flange 39 (Fig. 12, 16) located concentric with the location of
upper lip 20 or another
portion of base 12 to squeeze and seal against the seal 40. The inward flange
39 is preferably at
the juncture of the enlarged or stepped portion 37 with the remainder of the
first sleeve or tube
60 so as to provide a larger radially extending surface to abut the periphery
of diaphragm seal 40.
The depending skirt 45 of the diaphragm seal 40 is advantageously located
between an inner
surface of the stepped portion 37 and an outer surface of the base 12 adjacent
lip 20. Thus, the
lip or skirt 45 on the diaphragm seal 40 resists radially inward motion when
it is clamped
between the base 12 and the first tube 36. That provides a strong, fluid seal
for the outer
periphery of diaphragm seal 40 with the mating base 12 and first tube 36. The
periphery seal is
believed capable of meeting and preferably exceeding regulatory fluid
retention requirements.
[0091] The diaphragm 40 has a central opening 42 that is preferably
surrounded by an
inclined or curved, funnel shaped wall 44 that encircles and defines opening
42. As used herein,
the term "funnel shaped" includes walls that are straight and inclined (e.g.,
like a cone) and also
includes curved walls. The funnel shaped wall 44 in turn preferably joins a
generally planar
annular portion 43 having a depending skirt 45 at an outer periphery thereof
The opposing
surfaces of the base 12 and the first tube 36 advantageously, but optionally
have sealing surfaces,
such as opposing tongue-and-groove configurations, in order to further ensure
the parts sealingly
engage opposing surfaces of the diaphragm seal 40. The opposing surfaces of
the base 12 and
first tube 36 clamp the outer periphery of the diaphragm seal 40 adjacent the
depending flange 45
and in the flat annular portion 43 near the juncture with the flange 45.
[0092] In use, a pipe extends along longitudinal axis 20 and through the
opening 42 which
seals against the outer surface of the pipe. The opening 42 is selected to be
sufficiently smaller
in diameter than the outer diameter of the pipe that a fluid tight seal is
established meeting and
preferably exceeding regulatory requirements. The pipe basically stretches the
elastic opening
42 and funnel shaped portion 44 to form a friction seal with the pipe.
Further, the base 12 and
pipe are fit relative to each other so the pipe passes through the diaphragm
seal 40 in the axial
direction along which the funnel shaped portion 44 is directed, the upward
direction. That
allows fluid collected between the inside of the first tube 36 and the outside
of the pipe to press
-17-
CA 02875433 2014-12-19
the funnel shaped portion 44 against the pipe further increasing the sealing
force. As desired, the
funnel shaped portion 44 may have concentric ridges encircling the opening 42
in order to
increase the grip between the funnel shaped portion 44 and the pipe during
use, and to further
increase the water seal between the parts.
100931 The funnel shape wall 44 also allows lateral movement of the opening
42 in order to
accommodate pipe locations that are offset from the desired center position
along axis 16. The
curved, funnel walls 44 also allow more flexibility in the opening 42 before
tearing and may lie
against the pipe to provide a better seal. An elastomeric or rubber diaphragm
40 is believed
suitable, preferably silicon or neoprene or Thermo Plastic Rubber (TPR). The
seal 40 is
preferably made of a thin, flexible material. As used herein for the seal 40,
thin means a
thickness between opposing surfaces that is less than about 10% the diameter
of the seal at the
outer periphery and preferably less than 5% of the diameter of the seal at the
outer periphery.
The opening 42 is smaller than the diameter D of the smallest pipe that is
intended to be passed
through the tubular passage assembly 10 and seal 40 so the pipe stretches the
opening 42 and
creates a frictional grip to help form a water seal. Pipe diameters D from .5
inches to 4 inches
are common, with larger diameters D up to 8 inches being less common.
100941 Referring to Figs. 1 and 4-12, the first tube 36 has a first and
second set of outwardly
extending ridges 46, 48, respectively forming intervening slots between the
respective ridges of
each set. The first ridges 46 and intervening first slots each extend about
half way around a first
side or first partial circumference of the first tube 36. The second set of
ridges 48 and second
slots between those second ridges extend about half way around the opposing,
second side or
second partial circumference of the first tube 36. The ridges 46, 48 on the
first and second sides
of the first tube 16 are equally spaced apart about the distance of a saw
blade used by
construction workers. The first set of ridges are offset from the second set
of ridges, with the
first set of ridges being spaced in fractions of an inch and the second set of
ridges being spaced
metrically, preferably in millimeters. Visible indicia 50 (Figs. 1 & 7) on the
first tube 36
discloses a distance from the bottom of the base to each slot, or to the
bottom of each ridge (46,
48) forming the slot, so that a worker can cut the first tube 36 to desired,
known length by cutting
at a slot, with the saw blade guided by the opposing ridges 46 or 48 on each
side of the slot. The
ridges may be viewed as graduations on the outside of the first tube 36, which
is why the first
tube 36 may also be referred to as a graduated tube. Regardless of
terminology, the graduated
-18-
CA 02875433 2014-12-19
ridges 46, 48 and printed indicia 50 identify a plurality of graduated
distances from the bottom of
the flange 17 of base 12.
100951 The first and second sets of ridges 46, 48 and their intervening
slots are in radially
aligned planes extending orthogonal to axis 16. These sets of ridges 46, 48
are separated by first
and second longitudinal channels 52a, 52b located on opposing sides of the
first tube 36. As
desired, the printed indicia 50 may be located in one or both longitudinal
channels 52a, 52b, or
on the outer sides of cylinder 36 in the spaces between adjacent ridges 46 or
48. The ends of two
adjacent ridges 46 or two adjacent ridges 48 within each set of ridges may be
joined by axially
extending end segments 54 (Fig. 7), with alternating pairs of ridges joined by
offset end
segments 56 (Fig. 7) that are offset circumferentially a short distance from
end segments 54 each
other to form staggered axial end connections. A latching protrusion 58 (Fig.
7) may extend
axially from or near the axially extending end segments 54 to form a snap lock
connection
described later.
100961 A first extension tube 60 is provided with threads 64, 66 on
opposing lower and upper
ends of the tube, respectively, preferably with external threads on one end
and internal threads on
the other end. The threads 64, 66 are preferably double lead threads with one
lead beginning on
an opposing side of the tube 60 as the other lead. The depicted embodiment has
external lower
threads 64 and internal upper threads 66. Opposite the external threads 64 on
the lower end of
extension tube 60 are first and second, locking lugs 70 (Fig. 6) extending
inward from opposing
inner sides of the extension tube 60 at or adjacent to the end of the
extension tube 60. Each
locking lug 70 is sized in its circumferential direction to fit within one of
the first and second
channels 52a, 52b so the extension tube 60 can slide along the outside of the
first tube 36. The
locking lugs 70 are sized fit into the gaps formed by the staggered axial end
segments 54, 56 so
that rotating the first extension tube 60 places at least one and preferably
both of the locking lugs
70 between two adjacent ridges 46 or 48 on the first tube 36. The latching
protrusion 58
advantageously engages a mating recess on the upper edge of the adjoining
locking lug 70, to
snap-lock the extension tube 60 to the first tube 36. The ends of the ridges
46, 48 and the axial
end segments 54, 56 restrain rotation of the lugs 70 and also provide an axial
strength if a worker
strikes or steps on the extension tube 60. Thus, the lugs 70 hit end segments
54, 56 to stop axial
movement of the tube 60 until the lugs are rotated into the channels 52a, 52b.
-19-
CA 02875433 2014-12-19
[0097] The first extension tube 60 is a known length L and by viewing the
distance reflected
by the visible indicia 50 marked on the outer sides of the first tube 36 and
aligned with the lower
edge of the first extension tube 60, the length from the bottom of flange 17
on the base 12 to the
upper, distal end of the extension tube 60 is known. For example, if the lower
edge of extension
tube 60 is aligned with the ridges 46 or 48 corresponding to printed indicia
50 indicating a
distance of 3 inches from the bottom of flange 17 on base 12, and if the
extension tube 36 is 5.5
inches end to end, then the distal end of the first extension tube 70 is 3+5.5
= 8.5 inches from the
bottom of base 12. That system allows easy adjustment of the height of the
passage tube
assembly.
100981 When the first extension tube 60 is fastened to the first tube 36
the free or distal end
of the extension tube 60 can be closed off or another extension tube 60 can be
added. If another
extension tube 60 was added to the above example, the distance of passage tube
assembly would
be 3 + 5.5 + 5.5 = 14 inches from the flange 19 to the end of the second
extension tube 60.
Additional extension tubes may be added by use of the mating threads 66 on the
distal end of the
first extension tube 60, as seen in Fig. 9. Again, the extension tubes 60 are
each of known length
and preferably all the same length so the height to the end of a stack of
extension tubes can be
readily determined by adding one or more extension tubs 60. Depending on how
the end of the
distal extension tube 60 is closed, some length accommodation may need to be
made to
accommodate for the closure.
[0099] The end of the last extension tube 60 can be closed by a cap 72
having a skirt that fits
inside or outside the distal end of the last extension tube 60, but preferably
the cap 72 has threads
74 configured to threadingly engage 66 on the end of extension tube 60. The
cap threads 74 are
thus preferably also double led threads, with one lead beginning on an
opposite side of the cap as
the other lead. Since the threads 66 are preferably internal threads the cap
threads 74 are
preferably external threads, preferably on a depending skirt 75 depending from
a slightly larger
annular top that results in an annular flange 76 abutting the distal end of
the extension 60 to more
accurately define the length of the tubular passage assembly 10 when the
flange 76 abuts the
distal end of extension tube 60, increasing the length of tubular passage
assembly 10 by the axial
length of the flange 60. The annular flange 76 abutting the distal end of
extension tube 60 also
provides a stronger assembly to transfer forces along longitudinal axis 16
through the extension
tube 60.
-20-
CA 02875433 2014-12-19
[00100] Referring to Fig. 5-8 and 15-16, if the first tube 36 is cut to
length between ridges 46,
48 and no extension tube 60 is used, or if the first tube 36 is not cut but no
extension tube 60 is
used, then the cap 72 is fastened to the ridges 46, 48 on the first tube 36 by
one or more latches
or lugs or snaps 78 (Fig. 14-16) extending inward from the cylindrical skirt
on which the threads
74 are formed. The lugs 78 may optionally, but less preferably correspond to
lugs 70 and fit
within channels 52a, 52b and engage ridges 46, 48 in the same or similar
manner, the description
of which is not repeated. Preferably though, the lugs 78 may take the form of
snap locks with a
surface inclined to resiliently bend and slide over the ridge 46, 48 on the
distal end of the first
tube 36 and latch into the groove between the adjacent ridges. Opposing ends
of lugs 78 may be
bounded by slits through the skirt 75 on which the lugs are formed to provide
a resilient latch
that can bend to slide over the ridges 46, 48. The skirt 75 of the cap 72 thus
has a releasable
fastening mechanism on both sides of the skirt, with cap threads 74 on the
outer surface of the
skirt and snap locks or lugs 78 on the inner surface of the skirt.
1001011 Referring to Figs. 1 and 12-16, the cap 72 may have an inner and outer
mount or
connector 80a, 80b respectively each on respective internal and external
surfaces of the cap 72.
At least one and preferably two pairs of locating filaments 82 extend from a
filament base 84 that
is configured to mate with each of the connectors 80a, 80b. The connectors 80
may comprise a
shaped recess or shaped protrusion, with the mating filament base 84
comprising a protrusion or
recess with a mating shape. During shipment, as seen in Fig. 12, the filament
base 84 may be
releasably connected to the inside connector 80a of the cap 72, preferably at
the center of the cap
72 so the locating filaments 82 extend along the longitudinal axis 16 inside
the extension tube 60
and/or inside the first tube 36. The filament 82 and its base 84 may be
shipped separately, but
then they may be more easily separated and lost so it is preferably to ship
the parts as a unit.
During installation, the cap 72 is removed, the length of tubular passage
assembly 10 adjusted by
cutting the first tube 36 or positioning one or more extension tubes 60 on the
first tube 36.
[00102] Referring to Figs. 1, 10-11 and 13, after the length of the tubular
passage assembly 10
is adjusted, the cap 72 is screwed onto the distal extension tube 60 or
latched onto the ridges of
the first tube 36 ¨ but only after the connector and locating filaments are
removed from the
inside of the cap 72 and fastened to the connector 80b on the outside of the
cap 72 so the locating
filaments 82 extend upward along the longitudinal axis of the tubes and away
from the base 12
of the tubular passage.
-21-
CA 02875433 2014-12-19
[00103] When concrete is poured and finished, the locating filaments 82 will
stick out of the
concrete so the distal end of passage tube assembly covered by cap 72 can be
located. The
locating filaments 82 are selected to be thin enough to bend and not break
during troweling of
the concrete, and the connector 80 and filament base 84 are configured and
located relative to the
cap 72 so the locating filaments bend at the juncture with the connector
rather than break during
troweling. Nylon monofilaments about 20 to 40 thousandths of an inch in
diameter and about 2-
6 inches in length are believed suitable. The monofilaments could be color
coded to reflect the
type of pipe with which the tubular passage assembly 10 is intended for use,
such as red for
metal and white for plastic. Similarly, tabs could be provided having matching
color coding.
The removable tabs 124 are visible only from the bottom after the concrete
deck is poured so
color coded filaments 82 could provide a visible indicator from the top side
of the concrete
surface. Since the pipes are preferably run from the bottom up, and since the
filaments 82 and
cap 72 may be lost or attached to the wrong passage assembly 10, the removable
tabs 124 are the
preferred identification mechanism.
[00104] Referring to Figs. 12-16, the exterior connector 80b is preferably
located in a recess
94 preferably a cylindrical recess centered on longitudinal axis 16 during
use. The recess 94
preferably has rounded or chamfered edges to reduce cutting, damaging or
breaking of abutting
locating filaments 82. The connector 80b and filament base 84 are sized so the
juncture of the
locating filaments 82 with the filament base 84 is located below the exterior
surface of the cap 72
so that when a trowel blade or float repeatedly bends a filament 82 flat
against the concrete
surface the filament does not break off but resiliently resumes its position
parallel to the
longitudinal axis 16. The exterior, axial facing surface of the cap 72 may
have wrenching
recesses 96 into which a user can insert wrenching tools, such as the jaws of
channel-lock pliers,
in order to help rotate the cap and remove it after concrete has hardened.
[00105] Referring to Fig. 12, during shipment, the first extension 60 may
be placed outside of
and concentric with the first tube 36, with the lugs 70 sliding in channels 52
and then rotated to
engage the lower ridges 46 or 48 adjacent base 12 to fasten the extension tube
60 to the first tube
36. The cap 72 can be threadingly fastened to the threads 66 on the first
extension tube 60, with
the locating filaments 82 inside the tubes 36, 60 where they will not be
broken easily or lost.
The cap 72 prevents debris from entering the tube from the upper end of the
assembly and thus
provides a safety guard to protect personnel foot traffic on the unfinished
building floor.
-22-
CA 02875433 2014-12-19
[00106]
Referring to Figs. 1-9 and 11-12, the flange 17 19 extending outward from the
base
12 can be fastened to a support 33, with Fig. 22 showing a corrugated support
33. Deck
corrugations can vary from two to six inches from top to bottom. The support
33 may be a flat
surface such as a plywood support or other flat support during use. If the
diameter of the base 12
and first tube are large enough so they always extend across at least two or
three adjacent
corrugations of a corrugated support 33 then the tubular passage assembly 10
is largely self-
supporting and the flange 17 may mount to triangular shaped ears of a square
with the circular
passage of sidewall 19 having the roughly same diameter as the length of a
square shaped flange
17 and centered in that square flange. If the diameter of sidewall 19 and tube
36 are smaller,
then the base flange 17 must extend over enough corrugations to provide a
stable support for the
tubular passage assembly 10 and to allow fastening to the corrugated support
33 (Fig. 22). In
short, larger flanges 17 may be needed for tubular passages 10 having smaller
diameter passages
when the tubular passages are used on corrugated supports 33 rather than flat
supports 33.
[00107] Referring to Figs. 1 and 17-20, if a corrugated support 33 is used,
then removable
stabilizing plates 100 may be attached to a plurality of flanges 17,
preferably to opposing flanges
17. One or more, and preferably a plurality of offset fingers 102 on one side
of a rectangular
stabilizing plate may mate with correspondingly located openings 104 along an
edge of one of
the base flange 17. Preferably the fingers 17 are generally rectangular strips
with rounded distal
ends bent to place the rounded distal ends in a plane parallel to but above
the plane of the
stabilizing plate 100. The openings 104 preferably take the form of slots
spaced to correspond
with the locations of the fingers 102. Each of the rounded distal ends of the
fingers 102 pass
from the bottom of the flange 17, through a corresponding openings 104 in the
flange 17 and rest
against the top of the flange 17 to connect stabilizing plates to the flange.
The stabilizing plates
provide a wider base to extend across one or more corrugations of the support
33. As desired,
stiffening ribs 105 may be formed on or in the plates 100.
[00108] The fingers 102 engage the top of the flange 17 and the adjacent
portion of stabilizing
plate 100 engages the adjacent bottom portion of the flange 17 to provide a
stable support for the
base 12 as long as weight is exerted downward along longitudinal axis 16. If
the base 12 is lifted
upward along axis 16, the fingers 102 of the stabilizing plate 12 rotates
about the edges of the
openings 104 so the outer end of the plate 100 sags downward and inward toward
axis 16. To
prevent this a holding latch 106 preferably extends upward from the same side
of the plate as the
-23-
CA 02875433 2014-12-19
A
fingers 102 and the holding latch has a notch that engages an upper side of
the base 12,
preferably engaging an upper surface of base flange 17, to keep the
stabilizing plate 100 engaged
with the flange 17 and to restrain sagging of the outer edge of the plate 100
toward the
longitudinal axis 16. A recess, preferably a slot 108 may extend into an edge
of the base flange
17 and be located to correspond with the holding latch 106 so the holding
latch can more
securely engage a surface of the base 12 along a portion of the length of the
slot 106.
[00109]
In use, a stabilizing plate 100 is preferably but optionally fastened to two
opposing
sides of the base 10 to provide a broader base for the tubular passage
assembly 10. The base
flange 17 preferably has a recess 106 and finger openings 104 on one or more
sides, preferably
on opposing sides, and more preferably on each of four sides of a rectangular
base, where
reference to a rectangular base is used herein to include a square base.
[00110] Referring to Figs. 1-4, 23 and 24A-24B, two separate but adjacent
passageway
extensions 10 may be joined together, preferably at their base flanges 17. The
base 12a may
have an elongated latch 110 extending away from base to engage a mating recess
in a different
base 12b. In the depicted embodiment the base flange 17 has latch 110
extending from the base
flange 17, preferably generally horizontally, with a latching end 112
configured to engage a
catching surface 114 on a different flange 12b associated with a different
base 12b. The latches
110 and catching surfaces 114 are located so that if first and second bases
12a, 12b are placed
against each other the latch end 112a of a first base 12a on flange 17a can
engage the catch 114b
on a second base flange 17b to hold the two bases 12a, 12b together.
Preferably, at least one side
of each base 12 has one latch 110 and one catch 114 (e.g., a recess) located
toward opposing
ends of the at least one side, so that the latches 110a, 110b from at least
two different base
flanges 17a, 17b engage a recess 114b, 114a in the other base flange 17b, 17a
to fasten at least
the two different base flanges together. Different types of mating projections
and recesses can be
used, preferably with a male engaging member on one base 12 and a female
member on a second
base 12. While at least two adjacent tubular passage assemblies 10 may be
joined this way, the
joinder still allows stabilizing plates 100 to be fastened to the sides of
base 17 not joined by the
latches 110 and mating catches 112.
1001111 Also shown in Figs. 23, 24A, 25B are a latching members preferably
taking the form
of snap lock member 116a and a mating catch 116b each located on opposing
sides of sidewall
19 and located so that the snap lock members 116a on one housing 14a engage a
mating catch
-24-
CA 02875433 2014-12-19
116b on mating housing 14b to latch the housing parts 14a, 14b together. The
snap lock member
and catch provide a fast connection between housing parts 14a, 14b. The member
and catch
116a, 116b are located below the boss receiving the threaded fastener 18, on
the split line
separating the housing parts 14a, 14b. That split line is located on a plane
containing the
longitudinal axis 16.
[00112] Referring to Figs. 17-20, for corrugated supports 33, a hole is cut
through the
corrugation support and the base 12 is positioned over the hole so the
longitudinal axis 16 is
centered in the hole. An extension tube 60 is passed upward through the hole
in the corrugation
and fastened to the bottom of the base 12. Preferably the end of the extension
tube 60 having
external threads 64 passes through the corrugation and engages base 12. The
base 12 may have
mating screw threads 120 encircling the axis 16 and tubular cylinder 22 of
intumescent material
and thus located outward of that cylinder 22 and accessible from the lower end
of the base. The
threads 120 are double lead threads, with one lead on each half 14a, 14b of
the housing. To
enable the screw threads 120 to extend into the base 12 and still encircle the
tubular cylinder 22
of intumescent material, the retaining clip 24 has annular supporting surface
30 offset downward
from tabs 26 so that the tabs have a portion extending axially to form an
axial offset
accommodating the bottom screw threads 120 with the distal ends of tabs 26
then extending
outward through openings 28 in the cylindrical sidewalls 19 of the base 12
that encircle the
tubular cylinder 22 of intumescent material.
[00113] As needed, a removable adhesive cover 122 is placed over the bottom of
the base 12
to keep debris from entering the base during shipment, installation, pouring
of the concrete and
subsequent application of fire retardant spray. The removable adhesive cover
may be removed
and placed on the open end of extension tube 60 that is screwed into the
bottom of the base if
desired. Alternatively, separate adhesive covers or removable caps can be
provided. As the
extension tube 60 has internal threads 66, an additional cap 72 could be
provided and used. But
since the bottom opening in tube 60 that is covered by adhesive cover 122 is
not normally
expected to have any concrete pushing against the cover 122, it need not be as
strong as cap 72
onto which concrete may be poured and onto which workers may step during use.
[00114] Referring to Figs. 2 and 17-20 and especially to Figs. 2 and 18,
the base flange 17
may have two removable tabs 124a, 124b installed into or formed in the base,
preferably in
flange 17. One tab 124a may indicate metal and the other tab 124b may indicate
plastic. If the
-25-
CA 02875433 2014-12-19
shaped diaphragm 40 is selected for use with metal pipe the plastic tab 124b
is removed so that a
user can see from looking at the remaining tab 124a on the base 12 that the
passage tube is
intended for use with metal pipes. If the shaped diaphragm 40 is selected for
plastic pipes then
the metal tab 124a is removed so that a user can see from looking at the
remaining tab 124b on
the base 12 that the passage tube assembly is intended for use with plastic
pipes. Tabs 124 may
be scored, perforated or otherwise surrounded by weakened material so the
selected tab can be
punched out, broken off or otherwise removed. Alternatively, the tabs 124 may
be separate
pieces that are selectively pressed into mating openings 126 in flange 17.
This provides a way to
readily identify at the factory which type of pipe with which the passage tube
assembly is to be
used.
[00115] Referring to Figs. 25a and 25b, the tubular cylinder 22 of intumescent
material is
made of a material that expands significantly under heat so as to block off
the space between the
pipe and the adjacent parts of the expandable sleeve 10 which are encased in
concrete. Since
plastic pipes sometimes melt under sufficient heat, the tubular cylinder 22 of
intumescent
material may need to expand to fill more than the space between the cylinder
22 and the adjacent
pipe as it may need to compress a melting and flexible walled pipe to ensure
blockage of gases
and water through the expandable sleeve 10. In order to help the tubular
cylinder 22 of
intumescent material conform readily it may have kinks or bends or undulations
as in Fig. 25b
and may be cast in a single ring or formed in strips that are bent to conform
to the surrounding
structure and held by adhesive tape or encircling bands or supports.
[00116]
The height of the undulating ridges 128 relative to the adjacent valley 130,
and the
spacing of the ridges 128 will vary with the diameter of the tubular cylinder
22 of intumescent
material. The undulations or crenellations are preferably evenly spaced. A
preferred
intumescent material for these undulating cylinders 22 is as described in
Patent Nos. 6,790,893
and 6,645,278.
[00117] The tubular cylinder 22 of intumescent material is preferably extruded
or molded at a
temperature below that at which the material begins to expand significantly.
Alternatively, the
material may be used in flat strips that are wrapped around molds having the
desired cylindrical
shape, or having an undulating walled cylindrical shape. Still further, strips
of material may be
impressed on opposing sides to form undulations and the strip then formed into
a cylindrical
shape. If formed of strips, the opposing ends of the strips may be left
separate, but adjacent each
-26-
CA 02875433 2014-12-19
other to form the cylindrical shape with setting of the material retaining
that shape, or the
adjacent ends may be fastened by various fasteners such as clips, staples,
stakes, adhesive, tape,
etc. to maintain the shape. The strips of material formed into a cylinder may
also have the outer
surface wrapped with and fastened to a cylindrical tube of material to
maintain the shape. As
used herein, the reference to a "cylindrical" tube or ring of intumescent
material refers to a tube
or ring that is a continuous piece of material, or separate pieces abutting
each other or separate
pieces joined together or held together ¨ unless expressly defined otherwise.
[00118] For assembly, the appropriate base 12, tubular cylinder 22 of
intumescent material,
retaining clip 24 and diaphragm seal 40 are selected for the desired type of
pipe and range of
pipe sizes. The tubular cylinder 22 of intumescent material is placed into the
annular base 30 of
clip 24 and the tabs 26 are inserted through the slots 28 in one half of
housing 14 to wedge the
cylinder 22 into place against the lip 20 and against the interior of the
corresponding sidewall 19.
Then the other half of the housing 14 is then aligned with the remaining tabs
26 and the two parts
of the housing 14a, 14b are joined and fastened together in abutting
relationship to form a base
assembly 12. The tabs 26 on retaining clip 24 are bent to inhibit removal and
lock the tubular
cylinder 22 of intumescent material in place against vertical motion along one
direction of
longitudinal axis 16. Advantageously, bending tabs 26 also offer increased
security in retaining
the assembly 10 within the poured concrete, as for example, if the plastic
parts are exposed to
fire or fire-fighting activities such as sprays of high pressure water.
Somewhere along the
assembly process, the appropriate tab 124 is either removed or inserted, as
the case may be, so
that the tab in place on the tubular passageway 10 indicates whether the
assembly 10 is for use
with metal or plastic pipes, resulting in a base assembly with visible indicia
indicating the type of
pipe application suitable for use with the base assembly.
[00119] After the base assembly 12 is completed, the selected diaphragm seal
40 is then
placed on top of the lip 20 of base 12, and the first tube 36 is attached to
the base 12, preferably
by engaging double lead threads 35 on the tube 36 with mating threads 34 on
the base 12. The
stops 38a, 38b abut to limit rotation with the parts being sized so the limit
stops 38a, 38b engage
when the outer periphery of diaphragm seal 40 is securely clamped between base
12 and first
tube 36, and preferably clamped between lip 20 on base 12 and inward extending
flange 39 on
the first tube 36. The limit stops 38a, 38b also locate the distal end of
first tube 36 a known
distance from the base flange 17, preferably a known distance from the bottom
of the base flange
-27-
CA 02875433 2014-12-19
17, with the visible indicia 50 on the tube 36 reflecting distances along
longitudinal axis 16 from
that base flange 17. The base assembly may include the base 12, retainer 24
and intumescent
tube 22 and it may be shipped separately or as part of a kit. The base
assembly, diaphragm seal
40 and first tube 36 may be shipped as a separate assembly or as parts of a
kit, with or without
cap 72 and filament 82 and its mount 84.
[00120]
But preferably a first extension tube 60 is fit over the first tube 36 and
fastened
thereto by lugs 70 sliding along channels 52 and rotated to engage ridges 46,
48, with cap 72
fastened to the distal end of the extension tube 60 as in Fig. 12. The
filament base 84 and
filament(s) 82 are preferably connected inside the assembly (Figs. 12, 14).
The open bottom in
base 12 may be left open, or covered by another cap 72 or by a removable cap
122. Additional
extension tubes may be shipped with this assembly. The base assembly may be
shipped by itself,
or shipped as a kit with the first tube 36, cap 72, cover 122, one or more
extension tubes 60 and
one or more (preferably 2 or 4) stabilizing plates 100, or any combinations
thereof
1001211 A user takes the assembled base 12 and verifies it is for the type of
pipe intended for
use with the passage assembly 10 by looking at tabs 124. The user then adjusts
the first tube 36
to the desired length by cutting the tube 36 between ridges 46, 48 using the
visible indicia 50 as a
guide, or by adjusting the relative position of the first extension tube 60 on
the first tube 36,
again using visible indicia 50 as a guide. As needed, additional extension
tubes 60 may be added
as described above to increase the length, with the position of the first
extension tube 60 relative
to the first tube 36 reflecting fine adjustments on the fixed length provided
by the joined
extension tube(s) 60. After adjusting the length, the user fastens the base 12
to the support 33
onto which concrete is to be poured. As needed, the user may attach one or
more stabilizing
plates 100. Typically, fasteners such as screws (for corrugated supports 33
and nails for wooden
supports 33) pass through holes 32 in the flange 17 or stabilizing plates 100
to fasten the passage
tube assembly 10 to the support 33. If a corrugated support 33 is used, a hole
is cut through the
support 33 and the user fastens an extension tube to the bottom of base 12 by
removing any
protective bottom cover (e.g., cap 72 or cover 122) and then engaging threads
64 of extension
tube 60 with threads 120 in the bottom of base 12 so the extension tube
depends from the base
12. The end of extension tube 60 is then passed through the hole in the
support 33 with the distal
end of the depending extension tube 60 covered by cap 72 or cover 122, or open
as the user
-28-
CA 02875433 2014-12-19
desires. The flange 17 and/or stabilizing plates 100 are then fastened to the
corrugated support
33.
[00122] Shortly before concrete is poured, the cap 72 is removed from the top
end of the
passage tube assembly. The base 84 and filament(s) 82 are removed from the
bottom of the cap
and affixed to the top of the cap 72, as shown in Figs. 9-11, 17, 20 and 22
and the cap is then put
back on the tube assembly so the locating filaments stick upward. Concrete is
then poured, with
the tubular passage assembly 10 forming a casing entrained in the concrete.
The ridges 46a, 46b
and the various projections and changes in contour on the base 12 and tubes
36, 60 help embed
the parts in the concrete so as to inhibit removal. Optional ridges 134 may
extend outward from
the stepped portion 37 of the first tube 36 to help embed the parts in the
concrete, and act as
labyrinth seals against the passage of moisture between the passage tube
assembly 10 and the
concrete encasement. The depending extension tube 60 helps prevent the
concrete from entering
the tubular assembly 10 from between the top and bottom of the corrugations in
the support 33.
[00123] After the concrete is finished and hardened sufficiently, the location
of the passage
assembly 10 may be identified by the filament(s) 82 sticking above the
concrete. The cap 72
may be removed by inserting the jaws of a channel lock pliers in the wrenching
recesses 96 and
rotating the cap. The cover 122 or cap may be removed from the bottom of base
12 or the
depending extension tube 60 fastened to the base. The workers can then pass
pipes through the
tubular passage assembly by passing them upwards through the opening 42 of
flexible
diaphragm seal 40. The flexible, funnel shaped seal 40 allows some variation
in pipe diameter
and location so as to make it easier for workers to install the pipes between
floors and to
accommodate misalignments.
[001241 The ridges 46, 48 extend radially outward from the cylindrical first
tube 36. The
ridges 46, 48 extend for a majority of the length of the first tube, and
preferably extend the entire
length or substantially the entire length of the tube from the stepped portion
37 to the upper distal
end of the tube. By substantially the entire length is meant about 90 percent
or more of the
specified length. The ridges 46 are axially offset from the ribs 48, such that
the distance between
ribs 46 may be measured in inches and the distance between ribs 48 may be
measured in
millimeters or centimeters. The space between the adjacent ridges 46, 48 is
preferably the same
within both sets of ridges 46, 48. The space between the adjacent ridges 46,
48 is preferably
-29-
CA 02875433 2014-12-19
larger than the width of the respective ribs measured along the longitudinal
axis 16, with the
space advantageously being about the width of a saw blade used on construction
sites.
[00125] Except for the seal 40, the various other parts of the passage tube
assembly 10 are
preferably made of plastic, with ABS, PVC or polypropylene plastic being
preferred. The
extension tubes 60 and first tube 36 are preferably each about 5.5 inches long
and overlap about
one inch with the base 12 in releasable attachment thereto. The base 12 adds
about two inches to
the height of the assembly so that a base 12 and first tube 36 are about 7.5
inches from the
bottom of base flange 17 to the distal end of the first tube 36, with a cap
adding about 1/8 inch of
additional height that is removed after concrete is poured. Adding one
extension tube 60
increases the assembly height to about 12 inches from the deck or support,
upon which the
bottom surface of base flange 12 rests. While the extension tube 60 is about
5.5 inches long,
there is about .5 inches of engaged threads 64, 66 on the two mating parts.
Thus, the distance
from the bottom of base 12 to the top of the assembly with tubes 36, 60
represents the length of
the passage from the upper surface of the deck
[00126]
If a fire occurs, the tubular cylinder 22 of intumescent material will expand
under a
suitable temperature to block off air flow through the inside of the tubular
passage assembly 10.
If flooding occurs, the flexible diaphragm seal 40 seals against the pipe
passing through opening
42 of the seal 40, with the initial water pressing the upwardly extending
funnel portion 44 against
the pipe so as to improve the seal and increase the weight of water needed to
invert the seal
and/or allow leakage past the seal.
[00127] Referring to Figs. 27-30, the shaped diaphragm seal 40 may be used
with a shortened
housing to form an additional water seal module 140 suitable for attachment to
the passage tube
assembly 10. The diaphragm seal 40 is as previously described with shaped wall
44 defining
opening 42. The diaphragm skirt 45 extends over a circular, axially extending
end 142 of a
connecting ring 141 having a radially outwardly extending flange 144 and may
have a screw
thread on the radially outward periphery of that flange 144. The diaphragm
seal 40 is against
which the end of the skirt 44 preferably abuts during use. The connecting ring
141 has a
depending skirt 146 below the flange 144 and an optional seal retaining recess
148 immediately
abutting the bottom side of the flange 144. The skirt advantageously has
threads or releasable
locking tabs 150 located to releasably engage the upper threads 66 on the
extension tube 60 with
the skirt 146 being configured to mate with the extension tube 60. The locking
tabs 150 are
-30-
CA 02875433 2014-12-19
shown as plastic tabs with a lateral latch surface resiliently urged outward
to engage a mating
ridge or thread on the mating part. An optional seal 152, such as an 0-ring
seal, may be placed
in the groove 148 to form a fluid tight seal between the skirt and the
adjacent portion of the
extension tube 60 during use at least sufficient to exclude poured concrete
and cement.
[00128] A clamping ring 154 clamps the diaphragm seal 40 between the clamping
ring 154
and the connecting ring 141. The clamping ring 154 has a depending skirt 155
configured to
engage the thread on the outer periphery of flange 144 and further has an
inwardly extending
radial flange 154 located to abut the upper surface of diaphragm seal 40
around the outer
periphery of that seal during use. The clamping ring 154 has an upwardly
extending skirt 158
which may have threads thereon, with interior threads being depicted in the
figures. The
upwardly extending skirt 158 is configured to threadingly engage cap threads
74 (Fig. 1) on cap
72 during use. Other releasable engagement mechanisms can be used, such as the
resilient latch
150.
[00129]
During use, the seal 40 is clamped between flanges 144, 156 of the retaining
ring 141
and clamping ring 154, respectively. The mating rings 141, 154 fix the
periphery of the
diaphragm seal 40 while the opening 42 in the seal 40 allows a flexible fluid
seal with the tubular
member passing therethrough. The water seal module 140 may be affixed on the
upper or lower
end of the passageway 10 so as to be flush with the poured concrete and
embedded therein. It
provides a second water seal for redundancy. The removable cap 72 keeps debris
out during
pouring of concrete and is removed for insertion of the pipe etc. through the
opening 42 of the
diaphragm.
1001301 Referring to Fig. 27 and 28, the diaphragm seal 40 is shown with an
optional, axially
extending rim 159. The rim 159 is integrally molded with the seal 40 and
extends for a short
distance along the length of the longitudinal axis 16. The rim 159 strengthens
the opening 42 in
the seal and helps reduce tearing and unintended enlargement of the seal. The
rim also provides
additional resistance to expansion and helps form a tighter seal with the
elongated members
passing through the seal opening 42.
[00131] Referring to Figs. 31-33, the water seal module 140 module is
connected to the end of
extension tube 60 on the bottom, and connected to a dam 160 on the upper end
of the module
140. The dam 160 preferably threads into the threads on the upper skirt 154 of
the water module
140 to provide a tubular barrier or dam a few inches high to prevent water or
debris from
-31-
CA 02875433 2014-12-19
A
entering the opening formed by the extension tube 60 and other parts of the
passageway 10. The
dam 160 comprises a tube, preferably cylindrical and having a bottom end
configured to mate
with the upper end of the water module 140. The lower end of the water module
140 is shown as
engaging the upper end of extension tube 60, with internal threads or other
locking mechanisms
configured to engage the locking tab 150 on the skirt 146 of the water module
140.
[00132] The dam 160 may have a length of a few inches, preferably about two
inches and
advantageously less than 6 inches. After the tubular passage 10 and/or water
module 140 or
extension tube 60 is embedded in a concrete floor, the cap 72 is removed and
dam 160 is
fastened to the upward opening end of the passageway 10, extension 60 or water
module 140.
Affixing the dam 160 forms a short barrier at floor level and helps prevent
water and debris from
easily flowing into the passageway formed by passage tube assembly 10 or water
module 140.
The dam 160 is short in length so that it doesn't block access to the assembly
10 and so it does
not unduly hinder passing elongated members through the assembly 10 or module
140. The
flange 158 may be ribbed to provide better interlocking with the concrete that
embeds the flange
during use, with the figures showing one exemplary ribbed design that may also
provide gripping
surfaces to rotate the parts during installation and use.
[00133] Referring to Figs. 34-35, an aerator box 170 is shown in connection
with the passage
tube assembly 10. The aerator box 170 has two opposing, flat sides 172 spaced
apart a distance
that is about the same as the corresponding edges of the flange 17 on base 12
and larger than the
diameter of the passageway through tube assembly 10. The flat sides 172 are
each joined by an
end wall 174 to encircle axis 16 and form the sides of a box enclosure with
the end walls 174
being shown with a curved shape. The aerator box 170 has a top 176 joined to
the top edges of
sides 172 and ends 174 and having an axially extending and preferably threaded
cylindrical
flange 178 extending therefrom. The flange 178 is configured to fit inside and
threadingly
engage threads 120 on the base 12 (Figs. 16, 20), just as extension tube 60
does. Opposite the
top 176 and its flange 178, is an outwardly extending flange 180 that is
connected to and
preferably extends radially outward from the sides 172 and ends 174.
[00134] The sides and ends 172, 174 and top 176 form the aerator box 170 to
define an
enclosed space. The flange 178 connects the aerator box 170 to the base 12.
The outwardly
extending flange 180 allows the aerator box 170 to be fastened to a sheet or
form for pouring
concrete. The ends 174 are spaced further apart than sides 172, and sides 172
may be close to
-32-
CA 02875433 2014-12-19
the outer diameter of flange 178. The extra space allowed by the larger
spacing between ends
174 provides an enlarged cavity in the poured concrete to allow access and air
flow to the base
12. The ends 174 are advantageously spaced a distance apart that is less than
about twice the
distance between sides 172. The ends 174 are preferably about 4-8 inches
further apart than flat
sides. That allows a space about 2 inches on opposing ends of the aerator box
to accommodate
hands or wrenches or air flow. Sides 172 are preferably flat so the assemblies
can be placed
side-by-side or ganged with minimal space usage, while ends 174 are preferably
curved to
reduce stress concentrations in the concrete. The junctures of sides 174 and
ends 174 are
preferably curved with a radius large enough to avoid high stress
concentrations in the concrete
slab when concrete entrains the aerator box 170.
[00135] The aerator box 170 also allows plumbing fittings, such as elbow 182
to fit further
into the concrete before connecting to base 12, and that allows the pipe 184
connected to the
elbow 182 to extend along and very close to the poured concrete surface
without requiring an
elbow fitting with unequal length legs.
1001361
Referring to Figs. 18 and 36, in Fig. 18 the two stabilizing plates 100 were
each
removably attached to the flange 17 of base 12. In Fig. 36 the two stabilizing
plates are
integrally formed from a single piece of material, such as by punching or
cutting the desired
openings 32, fingers 102 and stiffening ribs 105, in order to form unitary,
enlarged elongated
plate 188. A circular opening 190 is formed in the plate 188. Preferably the
opening 190 is
about the same as the width of the plate, leaving enough structure joining the
opposing ends so
that the plate does not bend under its own weight during normal handling by
users for
installation. The opening 190 is also about the width needed to allow access
to the threads 120
in the bottom of the base 12 so the extension tube 60 or elbow 182 may pass
through the opening
190 to be connected to the base 12. The fingers 102 are located and configured
to extend
through the mating holes 104 in the flange 17 of base 12. The fingers 102 may
be bent sideways
or twisted to interlock the elongated plate 188 with the flange 17. In the
depicted embodiment
there are two rows of short, generally rectangular fingers 102, parallel to
each other and aligned
to mate with corresponding slots 104 in the flange 17 of base 12. If the
flange 17 and base 12 are
made of polypropylene or other suitably pliable material and if the fingers
102 made of metal it
is believed that the flange 17 is sufficiently pliable that the fingers 102
may be forced into the
flange without slots 104 in order to fasten the elongated plate 188 to the
base 12 and flange 17.
-33-
CA 02875433 2014-12-19
The forcing of the fingers 102 into the polypropylene flange 17 is facilitated
if the penetrating
edge of the fingers 102 is pointed or inclined.
[00137] Referring to Figs. 37a, 37b and 37c, a further embodiment of cap 72 is
shown. The
cap threads 74 and skirt 75 are the same as described previously. The prior
cap of Fig. 13-16 had
an annular flange 76 with an outer peripheral side that was generally parallel
to longitudinal axis
16 and of the same diameter as the outer periphery of the part 36, 60 with
which the cap threads
74 engaged. The cap of Figs. 37a, 37b has a top flange with an outer
peripheral side 192 that is
inclined inwardly to form a short, conical section that is tapered at an angle
of about 23 degrees
from the vertical along axis 16 and at an angle of about 67 degrees from a
plane orthogonal to
axis 16. The angle of inclination can vary greatly as long as the described
functions are
achieved, but preferably the angle is between about 45-75 degrees from the
orthogonal plane and
about 15-45 degrees from the axis 16. The inclined periphery 192 is located
radially outward of
or axially spaced apart from outward from the adjacent surface of the tube 36
or 60 with which
the cap threads 74 engage. Thus, the inclined periphery 192 forms a short,
conical, inclined
surface in the concrete when the concrete slab is poured and entrains the
sides of the cap 72 and
the cap is then removed. The concrete surface is poured flush with the top of
the cap 72 and the
inclined periphery surface 192 forms a beveled entrance to the tubular passage
10. The inclined
or beveled surface in the concrete formed by the inclined sidewall 192 angles
the otherwise 90
degree, sharp corner of the prior cap, reduces stress concentration in the
resulting concrete
surface found at the sharp corners, and may help guide the pipe into the
passageway formed by
the passage 10 and/or tubes 36, 60.
[00138] After the concrete cures the cap 72 may be hit with a hammer or other
device and the
inclined periphery 192 more easily releases the adhesion between the cap 72
and the embedding
concrete slab and thus allows the cap to be more easily removed than does a
periphery of the cap
72 is concentric with the axis 16. Thus, the top outer side 192 of the cap is
preferably angled
inward toward the threads 74 and extends outward from the abutting body of
tube 36, 60 to form
a conically inclined or beveled surface in the concrete. As the outer
periphery abuts the upper
end of tube 36 or extension tuber 60, the cap shape may vary slightly with the
nature of the
juncture of those parts. The cap of Figs. 37a, 37b has the inclined periphery
surface 192
extending from the skirt 75 on which threads are formed and the length of that
surface 192
preferably extends axially a distance sufficient so a portion of the inclined
surface 192 extends
-34-
CA 02875433 2014-12-19
beyond the outer diameter of the extension tube 60 in order to ensure a
beveled surface is formed
in the concrete. As shown in Fig. 37c, the inclined surface 192 is spaced
radially outward from
the skirt 75 on which the threads 74 or other engaging mechanism are located
and spaced
outward a distance about the same as the thickness of the extension tube 60
which is sufficient to
allow the inclined side 192 to form a beveled opening to the concrete surface
when the sidewall
192 is entrained with concrete to the level of the top of the cap 72. In Fig.
37c, there is an
annular, axial facing surface at the bottom of the inclined surface 192 which
preferably places
the bottom of the inclined surface at the outer periphery of the extension
tube 60 when the cap is
fastened to the upper end of that extension tube for entrainment in concrete.
[00139] Referring to Figs. 38a-38d, an alternative embodiment of the base 12
and its flange 17
and stabilizing plate 100 is shown. The split, two part base 12 with its
associated and flange(s)
17 are substantially as previously described and held together by fasteners
18a engaging bosses
18b and 18c. But the flange 17 is modified. The distal end portion of at least
one, and
preferably of two opposing sides of the base flange 17 may be elongated to
form a supporting
plate 200 that is connected to the flange 17 so the supporting plate 200 may
fold upward toward
and preferably connected to sidewall 19 of base 12. A hinge 202 allows the
rotation of the
supporting plate(s) 200 with the portion outward of the hinge 202 forming the
supporting plate
200 or distal end portion. Preferably a living hinge 202 may be used and it
may be formed by
molding, scoring, cutting or otherwise forming a sharply reduced cross section
in the thickness of
the flange 17 to define a weakened line 202 which may bend and form a living
hinge 202. The
hinge 202 is preferably formed in the bottom surface of the flange 17 (Fig.
38d). More
preferably the base 12, flange 17 and supporting plate(s) 200 are injection
molded plastic to form
a unitary, integrally molded part, that is formed at the same time, with a
reduced area forming the
living hinge 202. The living hinge 202 preferably extends from side to side
across flange 17 and
has a width that is less than the thickness of the flange 17 at the location
of the hinge 202.
Advantageously, the depth of the groove forming the living hinge 202 is less
than half the
thickness of the flange 17 at the location of the hinge 202. The material of
the flange 17 is also
appropriately selected to allow repeated bending of the supporting plate 200
about hinge 202
without fracturing after being fully flexed 5-10 times. A polymer material is
preferred, with
polypropylene being believed suitable. In a less preferable embodiment the
material of flange 17
and the groove forming hinge 202 are selected of a more brittle material or
material susceptible
-35-
CA 02875433 2014-12-19
=-=
to fatigue failure so that the groove forming hinge 200 forms a frangible line
allowing supporting
plate 200 to be broken off along the hinge 202 by fully flexing the hinge 202
a few times,
preferably less than five times and more preferably 2 or three times.
[00140] When in the deployed position substantially in the plane of flange 17
the supporting
plate(s) 200 extend the supporting flange 17 over a larger area and preferably
over abutting or
adjacent corrugations 33 (Fig. 22). By forming a living hinge, the flange 17
is relatively stiff
unless and until the supporting plates are first rotated about hinge 202 and
that makes handling
easier. The supporting plates 200 may have fastener openings 32 therein so the
plates 200 may
be fastened to the concrete forms and such fastening greatly stiffens the
flange 17 and plates 200
until concrete is poured over the assembly. If space is tight or if one or
more passage tube
assemblies 10 are ganged together adjacent one another, then the extended
supporting plates 200
are undesirable. Rotating the supporting plates 200 about hinge 202
effectively takes them out of
the way to allow close nesting and ganging of the bases 12 and passage tube
assemblies 10. By
having the hinges 202 connect the supporting plates 200 the complexity of
handling multiple
parts is avoided and the risk that the detachable supporting plates 100 will
be lost or not readily
available when needed is also avoided.
[00141] The supporting plate(s) 200 may be rotated about living hinge 200
toward base 12
sidewall 19 of the base 12 with a latch 204 (Fig. 38c) extending outwardly
from the sidewall 19a
or 19b to releasably engage the adjacent supporting plate 200, usually at an
edge of the plate or
at an opening formed in the plate 200 at a location to be engaged by the latch
204, or by a mating
latching surface connected to the plate and located to be engaged by the latch
200 ¨ depending
on the length of the plate 200. In the depicted embodiment the latch 204 is a
planar flange
extending vertically in a radial plane and having a right-angled notch in it
(Fig. 38a, 38c) so the
supporting plate 200 may rest against the lower, inclined portion of the notch
and limit the
rotation of the plate toward the base 12, while the upper and outer edge of
the notch latches the
plate 200 into position. An elongated latching member or beam latch 204
lacking any rotation
stop, is also believed suitable.
[00142] Preferably there are two hinges 202, located on opposing sides of the
sidewall 19, and
spaced apart the same distance as the two adjacent sides of the flange 17 so
as to form a square
flange 17 when the supporting plates 200 are latched to the sidewalls 19a, 19b
by the latches
204. In the depicted embodiment the supporting plates 200 have a length
measured outward of
-36-
CA 02875433 2014-12-19
the hinge 202 that is about half the height of the base 12 measured along axis
16 ¨ as best seen in
Fig. 38c. But the length of supporting plates 200 may vary, with the location
of the latch 204
varying as needed to hold the plate 200 in a non-deployed position, or with
various latching
surfaces, edges or openings being formed in the plates 200 to engage latches
204 extending from
the base 12.
[00143]
Figs. 33a-33d also show the connecting latches 110 and latch ends 112 and
latch
recesses 108. The rotation of the supporting plate 200 about hinge 202 would
hit the latch 110,
so an opening 206 is formed in the latch plate 200 to accommodate passage of
latch 110 through
the supporting plate 200 as the plate is rotated toward base 12 about hinge
202. Likewise, an
opening 206 in the supporting plate 200 allows the latch 110 to engage the
recess 108 in the
mating part.
[00144] Referring to Fig. 39, a passage tube assembly 10 is shown having a
base 12, a first
tube 36 and an extension tube 60. The first tube 36 has first and second sets
of ridges 46, 48 on
tube 36 which ridges are separated by corresponding grooves formed by the
adjacent ridges 46 or
adjacent ridges 48. The ridges and grooves are located at predetermined
locations along the axial
length of the first tube 36. The extension tube 60 is located coaxial with and
outside of the inner,
first tube 36. At least one, and preferably pairs of threaded fasteners 210
extend through the
outer tube 60 and into the inner tube 36, preferably at a location of one of
the grooves between
adjacent ridges 46, or adjacent ridges 48. A pilot hole 212 may extend at
least part way through
the wall of the outer extension tube 60, with the pilot hole preferably
located in a boss 214 that
may be molded into the side of the tube 60. Advantageously the pilot hole 212
does not extend
all the way through the wall of outer, extension tube 60 and ends with about
.02 or .03 inches of
wall thickness remaining. The pilot hole 212 thus dead ends within the wall of
tube 60 to form a
blind hole 212. The pilot hole 212 is preferably slightly smaller than the
outer diameter of the
threaded portion of fasteners 210. If the material of the tubes 36, 60 is
sufficiently flexible, the
threaded fastener 210 may be much larger than the pilot hole 212 without
breaking the tubes as
the fastener is inserted.
[00145] The pilot holes 212 are located at predetermined along the axial
length of the tube 60
which locations are selected to coincide to place the fasteners 210 between
adjacent ridges 46 or
adjacent ridges 48. The threaded fasteners 210 are preferably self-taping or
self-drilling screws
of a material suitable for use with concrete and the material of the tubes 36,
60, and are
-37-
CA 02875433 2014-12-19
preferably of steel or stainless steel. Once the length of the tube 36 and
outer tube 60 are
selected to place the top of the passageway 10 at the desired location of the
concrete surface
within which the passageway 10 will be embedded, the screws 210 are driven
through the blind
end of the pilot hole 212 in outer tube 60, across any gap separating the
tubes 36, 60, and into the
wall of the inner tube 36 so as to secure the two tubes 36, 60 together.
Preferably pilot holes 212
are located on diametrically opposing sides of tube 60 and preferably there
are two pilot holes
212 vertically aligned along an axis parallel to axis 16, on each opposing
side of tube 60. The
fasteners 210 guard against unintended changes in the length of the passage
tube assembly 10
during construction. A fastener 210 on each opposing side helps avoid tilting
of the outer tube
60 relative to the inner tube 36 and helps maintain the cap 72 parallel to the
desired exterior
surface of the concrete within which the passage tub assembly 10 is to be
embedded. A pair of
fasteners 210 are preferably used on each side to prevent tilting about a
plane through axis 16
and containing the fasteners 210, and to make the position and configuration
of the passage tube
assembly 10 more stable.
[00146] Because the locking lugs 68, 70 on the extension tube 60 position the
tube 60 relative
to the inner, graduated tube 36, the relative location of the two tubes 36, 60
are known, and thus
the location of the ridges 46, 48 relative to a point on the outer surface of
tube 60 is also known
or determinable. The location of the pilot holes 212 relative to the ridges
46, 48 may thus be
determined. The pilot holes 212 may thus be located so that the threaded
fasteners 210 extend
between adjacent ridges 46 or through them, or between adjacent ridges 48, or
through them.
Advantageously the threaded fasteners 210 comprise self-taping screws with an
outer thread
diameter larger than the space between two adjacent ridges 46 or two adjacent
ridges 48 and the
pilot holes 212 are located so the fasteners pass between those two adjacent
ridges and
threadingly engage two adjacent ridges 46 or two adjacent ridges 48. The
bosses 214 are
optional, but make it easier to locate the pilot holes 212. A boss 214 with an
annular outer rim
surrounding a recessed inner surface centered around pilot hole 212 is
preferred.
[00147] The tube 36 thus has a plurality of first ridges 46 that are equally
spaced apart a
distance sufficient to snugly receive one of locking lugs 68, 70 on the
extension tube 60, and
preferably has a plurality of second ridges 48 also equally spaced apart a
distance sufficient to
snugly receive one of locking lugs 68, 70, with the first set of ridges 46
axially offset from the
second set of ridges 48. The pilot hole(s) 212 may be located relative to the
received locking lug
-38-
CA 02875433 2014-12-19
68, 70 so as to be located in a radial plane passing between two adjacent
first ridges 46 when one
of the locking lugs 68, 70 is received between two first ridges 46, and
preferably located in the
middle of two such adjacent first ridges. The pilot hole(s) 212 may also
advantageously located
relative to the received locking lug 68, 70 so as to be located in a radial
plane passing between
two adjacent second ridges 48 when one of the locking lugs 68, 70 is received
between two first
ridges 46, and preferably located in the middle of two such adjacent first
ridges.
[00148] Referring to Figs. 40-41, the extension tube 60 may have stiffening
ribs in order to
increase the strength of the passage tube assembly. The tube 60 may thus have
circumferential
ring stiffening rings 220 located along the axial length of the tube 60, or it
may have longitudinal
stiffeners 222 extending parallel to the longitudinal axis 16 along the axial
length of the outer
surface of the tube 60. The stiffeners 220, 222 extend outward from the
exterior or outer surface
of tube 60 and may extend radially outward and are preferably of the same
cross-sectional shape.
The stiffeners 220, 222 may have various cross-sectional shapes but preferably
a cross-sectional
shape is selected that allow the stiffeners 220, 222 to be molded by a two-
part mold with a
vertical mold separation line.
[00149] Depending on the strength desired for the tube 60, the stiffeners 220,
222 may have
various shapes and various numbers of rings or stiffeners. For stiffening
rings 220, the cross-
section is smaller at the outermost end and wider at the innermost end which
joins the outer
surface of the tube and shapes having slightly rectangular cross-sections or
semi-circular cross
sectional shapes are believed desirable, and the cross-sectional shapes are
preferably solid.
[00150]
For longitudinal stiffeners 222 the orientation of the stiffeners preferably
alters to
accommodate a two part mold, with each longitudinal stiffener or stiffening
rib 224 having a
height extending along an axis parallel to the axis 144 (Fig. 41) along which
the mold is
withdrawn, with the molds separating along mold separating line 225. Thus, as
seen in Fig. 41,
the longitudinal stiffeners 222 on opposing sides of bosses 214 are almost
radial in orientation
while the rigs 90 degrees thereto are radial in orientation, but the ribs in-
between become more
tangential or inclined since the rib height is parallel to the axis 224. The
depicted ribs 224 thus
have a varying actual height but preferably do not extend outward beyond the
radial outward
diameter of the flange having internal threads 66. The longitudinal ribs 224
may be about .1 inch
to 1/8 inch wide with the height varying as described. On the inside of the
extension tube 60 of
Fig. 41 are shown some slightly raised longitudinal bosses 226 that are added
for molding
-39-
CA 02875433 2014-12-19
convenience. The bosses 226 are about .02 inches high for a tube 60 that is
about 4.5 to 5 inches
in diameter as shown in Figs. 40-41.
[00151] The stiffeners 220, 222 allow greater load to be carried along the
axis 16 and to
accommodate that increased load the various threads 16, 35, 64, 66 may be
buttress threads, or
ACME threads or other type of power threads in order to carry the increases
axial forces without
shearing off or breaking the threaded connections among the parts. The threads
are preferably
integrally molded with the various parts (base 12, tube 36, tube 60) and are
thus of the same type
of material, preferably plastic, as the various parts. But the threads 16, 35,
64, 66 could be made
of metal and either over-molded into parts made of plastic such as base 12,
tube 36 or tube 60, or
otherwise secured in the plastic part. There are thus provided circumferential
stiffening ribs 220
or longitudinal stiffening ribs 222 to strengthen the extension tube 60.
[00152] Although these inventions have been disclosed in the context of
certain preferred
embodiments and examples, it will be understood by those skilled in the art
that the present
inventions extend beyond the specifically disclosed embodiments to other
alternative
embodiments and/or uses of the inventions and obvious, modifications and
equivalents thereof.
In addition, while several variations of the inventions have been shown and
described in detail,
other modifications, which are within the scope of these inventions, will be
readily apparent to
those of skill in the art based upon this disclosure. It is also contemplated
that various
combination or sub-combinations of the specific features and aspects of the
embodiments may be
made and still fall within the scope of the inventions. It should be
understood that various
features and aspects of the disclosed embodiments can be combined with or
substituted for one
another in order to form varying modes of the disclosed inventions. Thus, it
is intended that the
scope of at least some of the present inventions herein disclosed should not
be limited by the
particular disclosed embodiments described above.
-40-
