Note: Descriptions are shown in the official language in which they were submitted.
CA 02952389 2016-12-21
TRENCH DRAIN WITH OVERMOLDED FRAME
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based on and claims priority to
U.S. Provisional Patent Application No. 62/271,078, filed
December 22, 2015, the contents of which are incorporated herein
by reference in its entirety for all purposes.
TECHNICAL FIELD
[0002] This application relates to modular trench drains used
to transport liquid to a drainage sewer.
BACKGROUND
[0003] Trench drains are U-shaped or V-shaped troughs for the
collection of liquid, such as rainwater, and can be used to
transport the collected water to a sewer or other drainage
point. Trench drains are commonly installed in the ground and
secured in concrete. In most cases, trench drains also include
a grate to prevent large debris from entering the water-
conveying channel and to prevent people from stepping or falling
into them.
[0004] Historically, concrete trench drain systems used
forms. The forms were placed in a ditch dug in the ground.
Concrete was then poured around the forms, which were removed
after the concrete has set. Trench drain systems made in
accordance with this method or similar methods result in
relatively expensive systems due to the cost of installing and
removing the forms.
[0005] Many of the expenses associated with these prior art
trench drain systems have been overcome by the advent of
polymeric trench drains, which can be left in place after the
concrete has been poured in place. These polymeric trench
QB\43032020.1 - 1 -
156214.00527
CA 02952389 2016-12-21
drains perform two functions. First, the polymeric channel acts
as a form for casting the concrete. Second, the polymeric
channel acts as a liner such that the water initially comes in
contact with the polymeric channel and not in direct contact
with the concrete. The manufacture and transportation costs
associated with this type of trench drain is significantly less
than the other types of trench drains.
[0006] However, trench drain systems made of polymeric
channels have problems not associated with the other types of
trench drain systems, namely buckling due to the expansion of
the trench drains. This typically occurs when the trench drains
are installed in colder weather. They then expand in hotter
weather due to the polymeric materials' high coefficient of
expansion. The embedding concrete prevents the trench drains
from expanding in a longitudinal direction. Therefore, the
trench drains buckle to compensate for this expansion. Further,
the trench drains can deform during installation when wet
concrete is poured around the periphery of the trench drains.
This is due to the pressure of wet concrete against the trench
drain walls.
[0007] Furthermore, as in all of the above trench drain
systems, installing the polymeric trench drains require a
substantial amount of hardware, such as nuts and bolts, which
adds not only to the cost, but can also result in delays, should
the installer run out of this hardware.
SUMMARY
[0008] Various improvements to trench drains are described
herein including an improvement relating to the overmolding of
metal rails. It will be appreciated that the various
improvements could potentially be used separate from one another
or in various combinations and permutations with one another.
QB\43032020.1 - 2 -
158214.00527
CA 02952389 2016-12-21
[0009] According to one aspect, a trench drain includes an
open-faced channel having spaced-apart sidewalls connected to a
bottom wall and extending between a pair of opposing axial ends.
The open-faced channel comprises a polymeric material. The
trench drain further includes an integral metal frame having an
upper lip portion adapted to support a grate and having a lower
embedded portion which is molded into at least one of the
spaced-apart sidewalls to secure the integral metal frame to the
open-faced channel.
[0010] In some forms, the integral metal frame may include a
pair of opposing axial ends and may further include an anchor
feature disposed proximate one of the pair of opposing axial
ends. The anchor feature may be molded into the polymeric
material of the open-faced channel to positionally fix the axial
ends of the integral metal frame on which the anchor feature is
positioned relative to a respective one of the pair of opposing
axial ends of the open-faced channel. During molding, the
polymeric material may flows into and/or engages the anchor
feature such that, upon cooling, the anchor feature serves as an
anchor point for the integral metal frame relative to the
sidewall. Because as the integral metal frame and the open-
faced channel differentially shrink during cooling, a
dimensional shrinkage difference in an axial direction between
the integral metal frame and the open-faced channel may then be
expressed only on the respective axial ends of the frame and
channel not having the anchor feature. In some forms, the
anchor feature may be a frame aperture and, during molding, the
polymeric material flows into and fills the frame aperture
creating a sidewall protrusion. In other forms, the anchor
feature may be a frame notch having an axially-facing wall that
is embedded in the polymeric material of the open-faced channel.
Still yet, in other forms, the anchor feature may include
QB\43032020.1 - 3 -
158214.00527
CA 02952389 2016-12-21
multiple features such as, for example, a frame aperture and a
frame notch. It is contemplated that if there is one or more
anchor features, that each anchor feature may have a surface
that is at least partially facing an axial direction to anchor
the end of the integral metal frame relative to the sidewall.
[0011] In some forms, the integral metal frame may further
include an intermediate section connecting the upper lip portion
to the lower embedded portion. The intermediate section may
have at least one exposed surface which is not at an axial end
of the integral metal frame and that is not covered by the
polymeric material of the open-faced channel. Put another way,
the intermediate section may separate inner and outer
environments having an inwardly facing surface that defines a
portion of the inner channel and outwardly facing surface that
is adapted for being cast in concrete or the like. In some
forms, the upper lip portion, the intermediate section, and an
upper edge of each sidewall may collectively form an outer
recess. The outer recess may also be further defined by one or
more vertically extending side ribs on the outside of the open-
faced channel. The outer recess may be configured to receive
concrete.
[0012] In some forms, the lower embedded portion may be an
embedded angle including both a horizontal and vertical section
molded into the sidewall. The embedded angle may forms a right
angle that helps to secure the embedded angle in the polymeric
material. To help accommodate the molding of the lower embedded
portion in the polymeric material, an upper extent of each
sidewall is thickened relative to a lower extend of each
sidewall to provide a sufficient thickness of polymeric material
to hold the embedded angle of the integral metal frame within
the corresponding sidewall (or whatever geometry the lower
embedded portion takes).
QB\43032020.1 - 4 -
158214.00527
CA 02952389 2016-12-21
[0013] In some forms, the polymeric material may be a resin
containing at least one of a fiberglass, nylon, and a
polyethylene. In some forms, the polymeric material may include
polyethylene and/or polypropylene.
[0014] In some forms, an integral metal frame may each be
molded into a respective one of the spaced-apart sidewalls.
[0015] These and still other advantages of the invention will
be apparent from the detailed description and drawings. What
follows is merely a description of some preferred embodiments of
the present invention. To assess the full scope of the
invention, the claims should be looked to as these preferred
embodiments are not intended to be the only embodiments within
the scope of the claims.
BRIEF DESCRIPTION OF THE FIGURES
[0016] FIG. 1 is a top perspective view of a trench drain;
[0017] FIG. 2 is a partial cross-sectional view of the trench
drain shown in FIG. 1;
[0018] FIG. 3 is a perspective view of a pair of exploded
sections of a trench drain and a gasket used that can be slid
into one another to form a connection therebetween;
[0019] FIG. 4 is a top perspective view of a rebar clip
attachment mechanism on a lateral side of a trench drain;
[0020] FIG. 5 is a top perspective view of an alternative
embodiment of a rebar clip attachment mechanism;
[0021] FIG. 6A is a bottom perspective view of a spacer block
for lateral placement across the trench drain;
[0022] FIG. 6B is a top perspective view of a spacer block of
FIG. 6A;
[0023] FIG. 7 is a top perspective views of the insertion
steps of a spacer block into a trench drain;
QB\43032020.1 - 5 -
158214.00527
CA 02952389 2016-12-21
[0024] FIG. 8 is a partial cross-sectional view of the trench
drain showing the spacer block shown of FIG. 7;
[0025] FIG. 9 is a partial cross-sectional view of a toggle
bolt for securing a grate to a spacer block;
[0026] FIG. 10 is a partial cross-sectional view of a push
pin for securing a grate to a spacer block;
[0027] FIG. 11 is a top perspective view of a trench drain
cover for a grate;
[0028] FIG. 12 is a top perspective view of a catch basin for
use with a trench drain system;
[0029] FIG. 13 is a top plan view of the catch basin of FIG.
12;
[0030] FIG. 14 is a top perspective view of a catch basin
with metal rails;
[0031] FIG. 15 is a top perspective view of a catch basin
with a removed side wall section;
[0032] FIG. 16 is a top perspective view of another trench
drain;
[0033] FIG. 17 is a front elevational view of the trench
drain shown in FIG. 16;
[0034] FIG. 18 is a partial cross-sectional view of the
trench drain shown in FIG. 16;
[0035] FIG. 19 is a detail view of a rear end of a metal
frame of the trench drain of FIG. 16; and
[0036] FIG. 20 is a detail view similar to FIG. 19, shown
without the metal frame installed on the trench drain.
DETAILED DESCRIPTION
[0037] FIGS. 1-3 show a U-shaped trench drain 10. In some
forms, the trench drain 10 is made of a polymeric or plastic
material, such as a resin containing fiberglass, nylon, or a
polyethylene and formed in lengths of eighty inches. The trench
QB\43032020.1 - 6 -
158214.00527
CA 02952389 2016-12-21
drain 10 weighs considerably less than a comparable concrete or
metal trench drain. In general, more polymeric trench drains can
be transported per truckload than concrete or metal trench
drains because of their light weight.
[0038] The trench drain 10 includes a pair of spaced apart
sidewalls 12 connected to a U-shaped bottom wall 14 and define
an open-faced channel 15. The sidewalls 12 can either be
straight or angled. Likewise, the bottom wall 14 can either be
flat, round, or angled so that water or other liquids can be
directed from one end to another. In any event, the particular
geometry of the trench drain 10 and channel can deviate from
that illustrated.
[0039] The trench drain 10 includes a first end or male end
16 and a second end or female end 18 that can be used to connect
sections of the trench drain 10 together as best illustrated in
FIG. 3. The male end 16 includes a portion of the walls 12 and
14 and the female end 18 defines a recessed portion adapted to
matingly receive the male end 16 of an adjacent trench drain. As
best illustrated in FIG. 3, a gasket 19 may be seated in the
female end 18 of one segment of a trench drain before the
reception of the male end 16 of another segment of a trench
drain and this gasket 19 can help prevent leaking of fluids
between the different sections of the trench drain 10 and
accommodate some dimensional adjustment or flexure of the
separate drain sections relative to one another.
[0040] Returning now to FIG. 1, a plurality of ribs 20 are
integrally formed in the walls 12 and 14 and are spaced along
the length of the trench drain 10. The ribs 20 add structural
strength to the trench drain 10. A plurality of support ribs 24
(which support rebar clips 26) are also integrally formed in the
walls 12 and 14 and are spaced along the length of the trench
drain 10. An L-shaped lip 22 is defined at upper ends of
Q18\43032020.1 - 7 -
158214.00527
CA 02952389 2016-12-21
respective sidewalls 12. The lips 22 define recesses 23 for
receiving a grate 112 (as will be best illustrated in FIG. 11).
[0041] With specific reference to FIG. 2, the sidewalls 12
which may be comprised of high-density polyethylene (HDPE) are
molded over an elongated metal frame 56 traversing the axial
length of the trench drain 10. The metal frame 56 includes a
first vertical wall 58 and a horizontal wall 60 forming lips 22
or an upper lip portion and a second vertical wall 62 embedded
within the sidewalls 12 forms a lower embedded portion.
[0042] The metal frame 56 provides significantly improved
stability of trench drain 10, thereby allowing longer lengths of
the trench drain 10 to be transported long distances without
being damaged or deformed during shipping. Being able to
transport long lengths of the trench drains 10 (e.g., 80 inch
lengths) is especially useful in large industrial applications
requiring a significant amount of the trench drains 10 (e.g.,
gas stations, stadiums, etc.).
[0043] The metal frame 56 additionally provides substantial
reinforcement along the length of the trench drain 10 thereby
minimizing any deformation of the trench drain 10 during
installation when the concrete is poured into the trench. The
metal frame 56 further provides a clean edge after the concrete
is poured and enhances structural support for the trench grates
112 as best illustrated in FIG. 11.
[0044] It should be appreciated that, while the metal frame
56 is illustrated in FIGS. 1-3 as being molded into the body of
the trench drain, the metal frame could potentially be assembled
to or connected to the polymeric body in a number of other ways
while achieving the same or similar benefits to those described
herein. For example, rather than molding the metal frame 56
into the sidewalls 12 of the trench drain 10, the metal frame
could be otherwise assembled to the polymeric body of the trench
413\43032020.1 - 8 -
158214.00527
CA 02952389 2016-12-21
drain by fastening (e.g., using threaded screws or other types
of fasteners), by snap fit (e.g., designing the frame and body
to have interlocking clip features or features the mechanically
engage one another), by adhesion (e.g., using adhesive or epoxy
to join the metal frame to the polymeric body, although it is
noted that such adhesive joining can be difficult given the
types of materials involved), slotted engagement (e.g., sliding
the metal frame into a slot formed in the body or vise-versa) or
such other joining techniques.
[0045] Turning now to FIG. 4, detail of the U-shaped rebar
clip 26 is illustrated showing the attachment of the rebar clip
26 to a rebar support 42. The U-shaped rebar clip 26 includes a
first section 34 opposite a second section 36 and a rebar clip
engagement surface 38 defining an annular hole 40 passing
therethrough. The rebar support 42 passes through the hole 40
and is frictionally held in place against the rebar clip
engagement surface 38 with a fastening tool 44 when the
fastening tool 44 is used to draw the first section 34 and the
second section 36 together. The fastening tool 44 is
manufactured using a glass filled composite or metal materials
and includes a threaded end 46 and an L-shaped toggle arm 48.
The threaded end 46 of the fastening tool 44 is received through
a first hole 50 in the second section 36 and into a second hole
52 in the first section 34. It is contemplated that the tool 44
could be pre-assembled to the trench drain 10 or installed by
the installer during installation. With the tool 44 generally in
place, the L-shaped toggle arm 48 can be rotated approximately
180 degrees in a clockwise direction to drive the threaded end
46 through a first hole 50 in the second section 36 and into a
second hole 52 in the first section 34, thereby drawing the
sections 34 and 36 towards one another to close the gap
therebetween and secure in position trench drain 10 to rebar
QB\43032020.1 - 9 -
158214.00527
CA 02952389 2016-12-21
support 42. The diameter of the holes 50 and 52 are smaller
than a flange or headed portion 54 of the threaded end 46 of the
fastening tool 44 and thus the flange can draw the sections 34
and 36 together as the fastening tool 44 is tightened.
[0046] After the trench drain 10 has been positioned in the
trench and attached to the rebar support 42 by the rebar clips
26, the drain 10 may still be vertically adjusted by rotating
the toggle arm 48 in a counter-clockwise direction by
approximately 180 degrees to slight remove the threaded end 46
from the holes 50 and 52 and remove the clamping force applied
by the clip 26 on the rebar support 42, thereby temporarily
allowing movement of the rebar clip 26 along the rebar support
42, moving the trench drain to a desired position, and then
refastening the rebar clips onto the rebar 42 by rotating the
toggle arm 48 in a clockwise direction again.
[0047] It should be appreciated that the L-shape of the
toggle arm 48 offers easy and reversible tightening or loosening
of the clips 26 to the rebar support 42. Moreover, the tool 44
has a low profile and does not require much space to the lateral
sides of the trench drain 10 to use. Thus, difficulty of using
a power tool to drive a fastener on a lateral side of the trench
drain 10 can be avoided. It should further be appreciated that,
later during installation of the trench drain 10, the fastening
tool 44 can be cast right into the surrounding concrete with the
trench drain 10.
[0048] FIG. 5 shows an alternative embodiment of a rebar clip
63 that includes a top cap 64, a base 66 and a tapered cone
portion 72. A slot 68 formed in the top cap 64 mates with an
extension 70 formed in the base 66. Opposite the base 66 is the
cone portion 72 that includes a first arced arm 74 and a second
arced arm 76 which partially angularly surround the rebar
support 42 and have a slight gap therebetween their respective
QB\43032020.1 - 10 -
158214.00527
CA 02952389 2016-12-21
ends permitting their flexure towards another. A vertical
surface 78 of the first arced arm 74 and the second arced arm 76
is tapered and the top cap 64 matingly fits over the tapered
cone portion 72 to secure the base 66 onto the rebar 42 and
compress the arced arms 74 and 76 towards one another.
[0049] The top cap 64 is further affixed to the base 66 with
a screw 80 that is threaded from the top surface of the cap 64
through a first hole 82 in the cap 64 and a second hole 84 in
the base 66. During installation, the top mounting of the screw
80 (as opposed to a lateral approach) is easily accessed to
allow convenient repositioning of the trench drain 10 secured to
the rebar 42. The top cap 64 is preferably made of a rigid
material and the base 66 is preferably made of high-density
polyethylene.
[0050] FIGS. 6A and 6B show spacer blocks 86 that, as shown
in FIGS. 7 and 8, are adapted to be received in a plurality of
opposing pairs of recesses 88 defined between the sidewalls 12
of the trench drain 10 and the metal frames 56. These spacer
blocks 86 provide widthwise extending cross-supports that keep
the sidewalls 12 evenly spaced apart over the length of the
trench drain 10 and further provide a point for attachment for a
grate 112 using a fastener in a hole 90.
[0051] As best illustrated in FIGS. 6A and 6B, each spacer
block 86 can be made of a glass filled composite and has an
upward-facing longitudinal slot 92 that receives a downturned
portion 94 of the metal frame 56. The blocks 86 have an
integrally formed spring clip 96 that locks the spacer block 86
in place by applying downward pressure against a bottom surface
98 of the recess 88 thereby biasing upward-facing longitudinal
slot 92 into the downturned portion 94 of the metal frame 56.
QB\43032020.1 - 11 -
158214.00527
CA 02952389 2016-12-21
[0052] With respect to FIG. 7, it is illustrated how the
spacer block 86 can be twisted into place to secure the spacer
block 86 into the opposing pairs of recesses 88.
[0053] With additional reference to the detailed view of FIG.
8, to secure the spacer block 86 in place in the recesses 88,
downward pressure is applied on the spacer block 86 against the
bias of the spring clip 96 to allow enough clearance to
disengage the downturned portion 94 of the metal frame 56 from
the slot 92 and twisting the spacer block in a counter-clockwise
direction to remove it from the recess 88. As noted above, the
spacer block 86 also prevents deformation and collapse of the
trench drain 10 when the trench drain 10 is shipped to a job
site for installation.
[0054] FIG. 9 shows an improved quarter turn toggle bolt 100
with a pair of wings 102 that is received in the bolt hole 90 of
the spacer block 86 to lock the grate 112 in place. The toggle
bolt 100 has a spring 101 that biases a bolt head 103 in an
upward direction away from the grate 112. The head is depressed
and the bolt head is rotated a quarter turn to disengage the
wings 102 from the bottom surface of the spacer block 86 thereby
releasing the bolt 100 securing the grate 112 on the trench
drain 10.
[0055] FIG. 10 shows an alternative embodiment to lock the
grate 112 in place on the trench drain 10 by providing a push-
pin locking mechanism 104 received within a body portion 106
wherein the body portion 106 is installed in the spacer bar 86.
In the open position, the grate 112 is easily inserted or
removed because the diameter of a hole 105 in the grate 112 is
larger than a movable top portion 108 of the body 106. To lock
the grate 112 in place, the push-pin locking mechanism is
depressed causing an engagement surface 109 of the top portion
108 to mate within a recess 110 thereby increasing the diameter
Q13\43032020.1 - 12 -
158214.00527
CA 02952389 2016-12-21
of the top portion 108 so that it is larger than the diameter of
the hole 105 in the grate 112. The grate 112 is removed by
pulling the push-pin locking mechanism 104 away from the grate
112 to disengage the engagement surface 109 of the top portion
108 from the recess 110.
[0056] In either fastener design, with the grate 112 removed,
this spacer block 86 is easily removed to allow cleaning of the
trench drain 10.
[0057] Turning now to FIG. 11, a grate cover 114 is shown
that fits over the exposed top surface of the grate 112. The
grate cover 114 is preferably manufactured from an inexpensive
plastic and thrown away after the concrete is poured into the
trench. The grate cover 114 protects the trench drain 10 and
the grate 112 from accidental debris and concrete being spilled
thereupon during the pouring of the concrete during the
installation of the trench drain 10.
[0058] FIGS. 12-15 show a catch basin trench drain module 116
that includes a catch basin 118, a pair of molded female ends
18, and integral rebar clips 26. A top edge 120 of the catch
basin trench drain module 116 can be cut to match the size of
the opening of the mating male ends 16 of the trench drains 10.
As best illustrated in FIG. 14, a set of metal rails 122 can be
affixed to a top edge 124 of the catch basin 116 which has been
already cut using a plurality of screws 126 inserted into a hole
128 in the top edge 124 and a hole 130 in the top edge 124 of
the catch basin 116. A metal insert 132 is inserted into a
recess 134 and adapted to receive the spacer block 86. As best
shown in FIG. 15, excessive sidewall material 131 is cut to
accommodate the size of the mating male ends 16 of the trench
drains 10. Alternatively, the excessive sidewall material 131
is perforated at predetermined intervals to allow portions of
the sidewalls 12 to be snapped off along the perforations to
Q13\43032020.1 - 13 -
158214.00527
CA 02952389 2016-12-21
match the size of the opening of the mating male ends 16 of the
trench drains 10.
[0059] FIGS. 16-20 show another embodiment of a U-shaped
trench drain 210. The trench drain 210 is similar to the trench
drain 10 and, as such, like features will be labeled with like
numbers in the 200 series (e.g., sidewalls 12 and sidewalls 212,
metal frame 56 and metal frame 256, etc.). A description of the
trench drain 210 will be provided below which will, in part,
highlight differences between the trench drain 10 and the trench
drain 210.
[0060] In some forms, the trench drain 210 is made of a
polymeric or plastic material, such as a resin containing
fiberglass, nylon, or a polyethylene and formed in lengths of
eighty inches. In some other forms, the trench drain 210 is
made of high density polyethylene (HDPE), polypropylene (PP), or
any other suitable material. Being made of a polymeric or
plastic material, the trench drain 210 weighs considerably less
than a comparable concrete or metal trench drain. As such, in
general, more polymeric trench drains can be transported per
truckload than concrete or metal trench drains because of their
light weight.
[0061] The trench drain 210 includes a pair of spaced apart
sidewalls 212 connected to a U-shaped bottom wall 214 and
defines an open-faced channel 215. The sidewalls 212 can either
be straight or angled. Likewise, the bottom wall 214 can either
be flat, round, or angled so that water or other liquids can be
directed from one end to another. In any event, the particular
geometry of the trench drain 210 and channel can deviate from
that illustrated.
[0062] The trench drain 210 includes a first axial end 216
and a second axial end 218 that can be configured to connect
sections of the trench drain 210 together, similar to the first
QB\43032020.1 - 14 -
158214.00527
CA 02952389 2016-12-21
end 16 and the second end 18 of the trench drain 10, or using
alterative mechanisms.
[00631 As shown in FIG. 16, a plurality of ribs 220 are
integrally formed in the walls 212 and 214 and are spaced along
the length of the trench drain 210. The ribs 220 add structural
strength to the trench drain 210. A plurality of support ribs
224 (which support rebar clips, not shown, in FIG. 16, but which
may be similar to the clips in the first embodiment, for
example) are also integrally formed in the walls 212 and 214 and
are spaced along the length of the trench drain 210. An L-
shaped lip 222 is defined at an upper ends of each respective
sidewalls 212. The lips 222 define recesses 223 for receiving a
grate, similar to the lips 22 of the trench drain 10.
[0064] Referring now to FIGS. 16 through 18, the sidewalls
212, which are preferably comprised of HDPE or PP, are molded
over an elongated, integral metal frame 256 traversing the axial
length of the trench drain 210. Each metal frame 256 extends
from a first frame axial end 255 disposed adjacent to the first
axial end 216 of the channel 215 of the trench drain 210 to a
second frame axial end 257 disposed adjacent to the second axial
end 218 of the channel 215 of the trench drain 210.
Additionally, each metal frame 256 includes a first vertical
wall 258 and a first horizontal wall 260 forming lips 222 in an
upper lip portion of the frame 256 and a second vertical wall
262 providing an intermediate portion of the frame 256 that
extends to a lower embedded portion.
[0065] Unlike the metal frames 56, the second vertical walls
262 of the metal frames 256 (or the intermediate portion) are
not fully embedded within the sidewalls 212. Instead, the
second vertical walls 262 are only slightly inset into the
sidewalls 212 within the open faced channel 215, such that each
second vertical wall 262 is flush with the corresponding
QB\43032020.1 - 15 -
158214.00527
CA 02952389 2016-12-21
sidewall 212 within the open faced channel 215. This leaves
one non-axial surface non-contacted by the polymeric material of
the channel 215.
[0066] Additionally, each metal frame 256 further includes a
second horizontal wall 265, extending from a lower end of the
corresponding second vertical wall 262, and a third vertical
wall 267 which, as illustrated define the lower embedded
portion. Each second horizontal wall 265 further extends
horizontally into the corresponding sidewall 212 and each third
vertical wall 267 extends downwardly from an embedded end of the
corresponding second horizontal wall 265. As such, the second
horizontal walls 265 and the third vertical walls 267 are
embedded within the sidewalls 212 to define the lower embedded
portion, forming embedded right angles 269, which secure the
metal frames 256 within the sidewalls 212. The embedded right
angles 269 further aid in preventing the metal frames 256 from
being inadvertently pulled out from the sidewalls 212 during
transport.
[0067] Similar to the metal frame 56, the metal frame 256
provides significantly improved stability of trench drain 210,
thereby allowing longer lengths of the trench drain 210 to be
transported long distances without being damaged or deformed
during shipping. Being able to transport long lengths of the
trench drains 210 (e.g., 80 inch lengths) is especially useful
in large industrial applications requiring a significant amount
of the trench drains 210 (e.g., gas stations, stadiums, etc.).
[0068] The metal frame 256 additionally provides substantial
reinforcement along the length of the trench drain 210 thereby
minimizing any deformation of the trench drain 210 during
installation when the concrete is poured into the trench. The
metal frame 256 further provides a clean edge after the concrete
is poured and enhances structural support for the trench grates.
QB\43032020.1 - 16 -
158214.00527
CA 02952389 2016-12-21
[0069] Referring now to FIG. 18, the first horizontal wall
258, the second vertical wall 262, and an upper edge 271 of each
sidewall 212 collectively form an outer recess 273. Each outer
recess 273 is configured to receive concrete during
installation. As such, once the concrete has set, any grate
received by the recesses 223 is supported by the first
horizontal walls 260, which are further directly supported by
concrete. Additionally, each sidewall 212 of the channel 215 is
thickened proximate the upper edge 271 to provide sufficient
material to hold the corresponding metal frame 256 within the
sidewall 212.
[0070] Referring now to FIGS. 19 and 20, the second frame end
257 of one of the metal frames 256 is shown molded into the
second end 218 of the sidewalls of the channel of the trench
drain 210 at one or more anchor features (shown with the frame
256 in place in FIG. 19 and with the frame 256 omitted in FIG.
20 to show only the molded portion of the channel).
Additionally, a frame notch 275 is formed in the second vertical
wall 262 at the second frame end 257 which is axially offset
from the axial end of the sidewall of the channel.
[0071] While the sidewalls 212 are molded over the metal
frames 256, the polymeric or plastic material flows into and
fills the frame aperture 273, forming a sidewall protrusion 277,
and also flows around the frame notch 275, engaging these
anchoring features and fixing the axial end of the frame 256 at
this anchoring point in the sidewall of the channel. Notably,
after the molded polymeric or plastic material forms the
sidewalls 212 and begins to cool, the sidewalls 212 tend to
shrink more than the metal frames 256 due to a higher
coefficient of thermal expansion of the polymeric or plastic
material as compared to the coefficient of thermal expansion of
the metal. As such, the frame aperture 273 and the frame notch
QB\43032020.1 - 17 -
158214.00527
CA 02952389 2016-12-21
275 provide anchor points, such that the plastic material
shrinks in a single direction from the first end 215 of the
trench drain 210 towards the second end 218 of the trench 210.
With the frame 256 being fixed or staked at one axial end of the
trench, this means that all of the dimension difference as the
result of differential shrinking occurs at the non-fixed axial
end. Accordingly, the entire difference as the result of
differential shrinkage occurs at that one side, which can be cut
at that axial end, and that end only.
[0072] It should be appreciated that various other
modifications and variations to the preferred embodiments can be
made within the spirit and scope of the invention. Therefore,
the invention should not be limited to the described embodiments.
To ascertain the full scope of the invention, the following
claims should be referenced.
QB\43032020.1 - 18 -
158214.00527
