Note: Descriptions are shown in the official language in which they were submitted.
PLASTIC VOID CONSTRUCTION UNIT
BACKGROUND
1. Field of the Invention
[0001] The present application relates generally to construction products, and
in
particular to an apparatus for a water proof component void form, formed from
a single
sheet member, to create space between concrete structures and expansive soil
for the
passage of plumbing lines, electrical lines and other utility conduit lines.
2. Description of Related Art
[0002] A plurality of structures are built on and in expansive soils. Most
buildings require
one or more plumbing lines to provide clean water and remove waste water.
Unprotected
plumbing lines in the ground are subject to stresses from expansive soil.
Often the
stresses are great enough to break the pipes, push plumbing lines through the
slab,
damage other plumbing apparatuses or even cause damage to adjacent structures.
Once
this occurs, the lines leak and can cause excessive saturation under a
foundation. This
saturation may lead to foundation cracking and further soil expansion. It is
often desired
to isolate plumbing lines from direct contact with expansive soil in order to
minimize
potential damages. This is not always easy.
[0003] A few different types of methods have been developed. For example, one
type
of method involves the use of a metal wire mesh formed into a volumetric
shape. The
idea being that as the soil pushes on the wire mesh, the mesh will deform or
the soil will
push through the mesh. While in theory this may work, it is often not feasible
and has
many disadvantages. Metal cages are difficult to manipulate and contour to the
path of
the plumbing. Additionally, cutting and shaping the mesh can be very difficult
and time
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consuming. Cut wires are sharp and can lead to injuries. Likewise, soil passes
easily
through the gaps in the mesh.
[0004] Although great strides have been made with respect to protecting
underground
plumbing lines from expansive soil, considerable shortcomings remain. A new
type of
system is needed that prevents damage to buildings, plumbing lines and other
conduit
from soil expansion.
SUMMARY
[0005] In an aspect, there is provided a construction unit for the formation
of a void
space, comprising: a plurality of panels aligned adjacent one another, the
plurality of
panels having a lower surface and an upper surface, the upper surface being
scored
along a score line and the lower surface being uncut; a plurality of flutes
defined within
the plurality of panels between the upper surface and the lower surface, the
plurality of
panels folded at the score line about the lower surface; a support extending
internally
within the flutes of a singular panel of the plurality of panels, the support
extending across
the void space passing within the flutes on opposing ends of the singular
panel of the
plurality of panels; and a connector configured to interlock the plurality of
panels together,
the connector passing internally within the flutes of adjacent panels of the
plurality of
panels; wherein the void space is formed for the protection of utility lines
from soil
expansion.
[0006] In another aspect, there is provided a method of protecting utility
lines from the
effects of expansive soil, comprising: obtaining a first panel member; scoring
the first
panel member across a plurality of internal flutes to create a folding joint,
the scoring
configured to cut an upper surface of the first panel member, a lower surface
of the first
panel member being unscored; folding over a portion of the first panel member
about the
folding joint to form a defined central volume; inserting a support between
opposing ends
of the first panel member through the flutes, the support extending across the
void space;
abutting a secondary panel member adjacent the first panel member; coupling
the panel
members together with one or more connectors; and aligning the panel members
so as
to create a route; wherein the route defines a void space for the passage of
the utility
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lines.
DESCRIPTION OF THE DRAWINGS
[0007] The novel features believed characteristic of the application are set
forth in the
appended claims. However, the application itself, as well as a preferred mode
of use,
and further objectives and advantages thereof, will best be understood by
reference to
the following detailed description when read in conjunction with the
accompanying
drawings, wherein:
[0008] Figure 1 is a perspective view of a plumbing void construction unit
according to
an embodiment of the present application;
[0009] Figure 2 is an exemplary front view looking down the length of the
plumbing void
construction unit of Figure 1 in finished form;
[00010] Figures 3-22 are exemplary perspective views illustrating the method
of
construction of the plumbing void construction unit of Figure 1.
[00011] Figure 23 is a perspective view of an alternate embodiment of the
plumbing void
construction unit of Figure 1.
[0010] Figure 24 is an exemplary front view of the plumbing void construction
unit of
Figure 23;
[0011] Figure 25 is a perspective view of a panel member in the plumbing void
construction unit of Figure 23, prior to assembly.
[0012] Figure 26 is an enlarged view of a series of flutes within the panel
member of
Figure 25.
[0013] Figure 27 is a front view of the panel member of Figure 25 formed to
define a
void space.
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[0014] Figure 28 is a perspective view of an attachment member within the
plumbing
void construction unit of Figure 23 joining two adjacent panel members.
[0015] While the device and method of the present application is susceptible
to various
modifications and alternative forms, specific embodiments thereof have been
shown by
way of example in the drawings and are herein described in detail. It should
be
understood, however, that the description herein of specific embodiments is
not intended
to limit the application to the particular embodiment disclosed, but on the
contrary, the
intention is to cover all modifications, equivalents, and alternatives falling
within the spirit
and scope of the process of the present application as defined by the appended
claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] Illustrative embodiments of the preferred embodiment are described
below. In
the interest of clarity, not all features of an actual implementation are
described in this
specification. It will of course be appreciated that in the development of any
such actual
embodiment, numerous implementation-specific decisions must be made to achieve
the
developer's specific goals, such as compliance with system-related and
business-related
constraints, which will vary from one implementation to another. Moreover, it
will be
appreciated that such a development effort might be complex and time-consuming
but
would nevertheless be a routine undertaking for those of ordinary skill in the
art having
the benefit of this disclosure.
[0017] In the specification, reference may be made to the spatial
relationships between
various components and to the spatial orientation of various aspects of
components as
the devices are depicted in the attached drawings. However, as will be
recognized by
those skilled in the art after a complete reading of the present application,
the devices,
members, apparatuses, etc. described herein may be positioned in any desired
orientation. Thus, the use of terms to describe a spatial relationship between
various
components or to describe the spatial orientation of aspects of such
components should
be understood to describe a relative relationship between the components or a
spatial
orientation of aspects of such components, respectively, as the device
described herein
may be oriented in any desired direction.
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[0018] The apparatus and method in accordance with the present application
overcomes one or more of the above-discussed problems commonly associated with
underground plumbing lines, electrical lines and other conduit. Specifically,
the unit of
the present application is configured to eliminate costly damage to buildings
and broken
plumbing under, and above, concrete slabs due to the effects of expansive
soil. In
particular, the unit of the present application is configured to provide a
void space within
the ground that is formed from a single panel member scored along selected
surfaces to
produce a desired shape and size. The unit of the present application is
configured to
provide temporary support to under-slab plumbing and suspend lateral pipes in
a
protected containment void area. The unit is easily customizable and can
adjust to
changes in plumbing routes. These and other unique features of the device are
discussed
below and illustrated in the accompanying drawings.
[0019] The apparatus and method will be understood, both as to its structure
and
operation, from the accompanying drawings, taken in conjunction with the
accompanying
description. Several embodiments of the device may be presented herein. It
should be
understood that various components, parts, and features of the different
embodiments
may be combined together and/or interchanged with one another, all of which
are within
the scope of the present application, even though not all variations and
particular
embodiments are shown in the drawings. It should also be understood that the
mixing
and matching of features, elements, and/or functions between various
embodiments is
expressly contemplated herein so that one of ordinary skill in the art would
appreciate
from this disclosure that the features, elements, and/or functions of one
embodiment may
be incorporated into another embodiment as appropriate, unless otherwise
described.
[0020] The apparatus of the present application includes a unit having a
plurality of
members that when used in combination, creates a self-contained void space for
the safe
routing of plumbing lines, electrical lines and other conduit underground. In
one
embodiment the unit includes a plurality of selectively arrayed panel sections
coupled
together to form a routing path. In a secondary embodiment the routing of the
void space
is formed from the scoring of single panel members along a top surface to form
the
desired shape.
Neighboring panel sections are supported with a plurality of
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braces/connectors for stability. Additional panels may be added over the top
of the panel
sections so as to enclose the space and seal gaps between panel sections. Pipe
is laid
within the space and elevated as necessary to ensure proper drainage.
Elevation is
secured through the use of a clevis bracket and threaded rod configured to
extend out
through the space and panel sections. A fastener and washer combination is
used to
provide temporary support for the pipe, being supported by the
braces/connectors. By
modifying the panel sections, routes may be customized to accommodate plumbing
needs. Additional features and functions of the device are illustrated and
discussed
below.
[0021] Referring now to the drawings wherein like reference characters
identify
corresponding or similar elements in form and function throughout the several
views.
Figure 1 illustrates a sample configuration for a plumbing void construction
unit 101
according to the present application. Unit 101 is depicted below ground level
within a
trench, wherein the wall of the trench closest in the view is removed for
clarity purposes.
Unit 101 is configured to provide a modular and fully customizable routing
void space
below ground level in which to run any number of utility lines, such as
plumbing lines,
electrical lines, gas lines and so forth. Unit 101 is configured to provide a
fully enclosed
space designed to withstand soil pressures. Unit 101 is also configured to
protect the
utility lines from expansive soil movements.
[0022] Referring now also to Figure 2 in the drawings, a front view looking
down the
length of unit 101 is illustrated. Unit 101 includes a plurality of side
panels 103 coupled
together through one or more braces / connectors 105. The combination of
panels 103
in communication with one another form a channel for the laying of piping. It
is understood
that any type of lines may be run within the void space generated by unit 101.
For
purposes of explanation, reference will be given to that of plumbing lines and
associated
piping. Unit 101 further includes a top cap configured to overlap the side
panels and
enclose the void space from the backfill and soil. The side panels 103 and top
cap 107
are configured to resist inward movement of the soil into the void space.
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[0023] As seen in Figure 2, unit 101 is located within the ground and
surrounded by
backfill or soil when fully assembled. Initially unit 101 is located within a
trench for
assembly purposes. A hanger 109 and rod 111 are also shown for supporting the
plumbing lines. Unit 101 may further include fastener system 113 to provide
support for
hanger 109 and rod 111 prior to being fully secured by the substrate above
ground. The
other depicted portions of Figure 2 illustrate contextual references and show
an
exemplary manner in which unit 101 may be utilized in a more specific
application. As
seen, unit 101 is located within the ground and rod 111 protrudes forth out of
the ground
into a substrate 115 such as concrete. A void producing structure 117 may be
utilized
between the substrate and the ground.
[0024] Referring now also to Figures 3-22 in the drawings, the method of use
and
components of unit 101 are illustrated. As stated previously, unit 101 is
configured to
create and maintain a contained void space separating underground plumbing
lines,
electrical lines and other conduit from expansive soil which may cause damage
to the
lines and adjacent structures. Unit 101 temporarily provides support for under-
slab
plumbing by suspending them off the ground. A void space area is provided in
which
expansive soils may expand without damaging plumbing lines. As seen in Figure
1, unit
101 is located in a trench (see also Figure 3) and is used to surround the
plumbing lines.
The inner wall of the trench is not show in order to visually display unit 101
(see Figures
4-20). The sequential alignment of panels 103 are shown. It is understood that
the
various members and parts of unit 101 are customizable to permit routing
having any
number of bends, changes in elevation, and more than one plumbing pipe,
electrical line
or conduit contained within. It is recommended that the trench be wider than
the
necessary void space area in order to have room for adjusting the sections
when needed.
This also applies to the depth of the trench in the case that a granular
material is selected
as a bottom layer.
[0025] In Figure 4 two side panels 103 are illustrated within the trench. The
panels 103
are placed at the base of the trench and are located in a side by side manner
being
separated by a gap. The gap is determined by the needed spacing requirements
of the
project these are used in conjunction for. Gap distances could be 24 inches or
18 inches
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for example. Panels 103 can be manufactured and used in various manners and
forms.
A top view of panel 103 is illustrated in Figure 6. As seen, panel 103 is
preferably formed
as a ribbed plastic panel. The plastic material has perpendicular supports 119
connecting
the exterior surfaces/faces 121 in order to form a supportive sheet/panel.
Ideally, panel
103 is a solid member without perforations or holes along its main surfaces
121. This
prevents soil from passing through the panel. A conceivable material would be
polypropylene plastic. Panels 103 may be found in different sizing. A common
sizing
may be that of: height approximately 18" to 36"; width approximately 12" to
24"; and length
approximately 48" for example. In these depictions, panels 103 are parallel to
one
another. It is understood that some instances may necessitate the angling of
the panels
103 in a non-parallel orientation.
[0026] Panels 103 are coupled together via connectors 105. Connectors 105 are
configured to interlock the plurality of panels 103 together. Panels 103 will
be aligned
opposite one another, as seen in Figures 4 and 5, and also in an abutting
fashion along
the same relative line, as seen starting in Figure 9. Therefore connectors 105
are used
to couple panels 103 together in both situations. Connectors 105 can be seen
in
communication with panels 103 in Figure 5.
[0027] Figures 7A and 7B illustrated two basic types of connectors 105.
Connector 105a
is illustrated in Figure 7A. Connector 105b is illustrated in Figure 7B. Each
connector
has a plurality of legs 123a/b and a bridge portion 125a/b. Bridge portion
125a/b is
configured to extend between legs 123a/b. Its length may be any that is
necessary to
accommodate the spacing of panels 103. In particular, connector 105a is
configured to
couple abutting panels 103. Given that these panels abut one another, bridge
portion
125a is relatively small and almost insignificant. Connector 105b is
configured to extend
between opposing panels across from one another and provide lateral support
from the
forces incurred through soil expansion. In this instance, bridge portion 125b
is lengthened
accordingly. Both types of connectors are seen in Figure 5. It is important to
note that
legs 123a/b are configured and sized so as to translate within slots 127 (see
Figure 6)
formed between surfaces 121 and supports 119. Other manners of coupling are
considered, and in no way are connectors 105 limited to this particular manner
of
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coupling. An example of connectors 105 could be rebar selectively bent, cut,
and/or
welded into shape.
[0028] In Figure 8, the connected section of panels 103 shown in Figure 5 is
flipped over
and aligned within the trench. An advantage of unit 101 is that it is ideally
suited for
simplified and easy construction, and can adapt to any routing configurations.
In the
flipped orientation, connectors 105 are located along the bottom of the panel
sections.
The constructing of them first with the connectors at the top and then
flipping it over is
found to be the simplest manner of construction. In Figure 9, a second panel
section unit
is constructed and connected to the first panel section unit. The second unit
abuts the
first panel section unit. These panel sections are coupled to corresponding
connectors
105a, both at the top and the bottom at this stage of construction so as to
maintain their
relative alignment during the remaining construction process. This same
process is
applicable for the constructing of all other panel sections.
[0029] As stated previously, panels 103 are configured to adapt to different
routing
paths, where the paths do not necessarily follow a straight line. Figures 10
and 11
illustrates a panel section that incorporates a "T" in the routing. Panel 103
is configured
to accept scoring along surfaces 121. When scored along the slots 127 of the
ribbing
through only a single face 121, the remaining face 121 acts as a pivot point
or folding joint
to allow the face 121 to be angled as desired. In the depicted example, the
face is
oriented to form a perpendicular routing. Corresponding panels 103b are found
opposite
each other at the "T" intersection.
[0030] Finally in Figure 12, another panel section is included to form the
initial routing.
At this stage, when the routing is completed, utility lines may be added (see
Figure 13).
These lines are run/placed within the gap between panel sections. Naturally,
the type of
utility lines may dictate the how, where, and in what manner they are located
within the
gap. For purposes of explanation, unit 101 is shown with plumbing lines. Unit
101 may
include a hanger 109 and a threaded rod 111 for the locating of plumbing
lines. Hanger
109 and corresponding rods 111 are spaced as needed along the length of the
plumbing
lines. An exemplary distance of spacing may be that of four feet.
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[0031] Corresponding connectors 105 are located along the top surface of
panels
103/103b in a manner and spacing similar to that described previously (see
Figure 14).
Ideally it is conceived that the spacing would be approximately 12" on center,
however
the precise spacing requirements may depend on design constraints and
environmental
considerations. At this stage, connectors 105 are located along the top
surface and the
bottom surfaces of panels 103. They are also located at the abutting ends of
each panel.
By laying the utility lines prior to locating the top layer of connectors, it
is easier for a
worker to maneuver and operate.
[0032] The plumbing lines are needing to be located and/or suspended within
the gap
of panels 103. Additional connectors 105c are located across panels 103 and on
either
side of rod 111 (see Figures 15 and 16). Connectors 105c are similar in form
and function
to that of connectors 105b. System 113 is in threaded communication with rod
111 and
is configured to rest on top of connectors 105c. The elevation of hanger 109
at each rod
111 is set by adjusting the amount of rod 111 that is threaded above and below
system
113. Therefore, by extending more of rod 111 above panels 103, less is left
within the
gap. Although is it known that system 113 may take many types of forms, a
simplistic
configuration would be that of a single nut fastener and a washer. The washer
would be
configured to extend out away from rod 111 sufficiently to overlap connectors
105c. The
fastener would permit the relative adjustment of rod 111, with the washers
supporting the
weight of the plumbing lines across connectors 105c. System 113 is configured
to
temporarily locate and support the plumbing lines until the top end of rod 111
is secured
within the substrate. Manipulation of each rod 111 within the routing allows
workers to
set a proper slope in the plumbing lines. Another feature to note is the use
of connector
105d. Connector 105d is similar in form and function to that of connectors
105b except
that the bridge portion is extended to permit a non-perpendicular alignment to
panels 103.
[0033] Upon completion of unit 101, the soil will be backfilled against panels
103. Unit
101 may further include a retainer spacer 129 in communication with parallel
panels on
directly opposing sides of the gap (see Figure 17). Spacer 129 is configured
to provide
additional lateral support against stress induced flexure of panels 103 from
the backfill of
soil and potential subsequent expansion of said soil. Spacer 129 is made of
similar
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material and structure as that of panel 103. Slots similar to slots 127 are
present and
configured to accept one or more connectors. Spacer 129 is adhered to an
interior
surface 121 of panels 103. A connector similar to that of connectors 105b are
inserted
into spacers 129 on corresponding sides of panels 103 (across the gap).
Spacers 129
are typically installed after the locating of the utility lines so as not to
interfere or cause an
obstruction. The particular shape of spacers 129 are not herein limited to
that which is
depicted.
[0034] In Figure 18, unit 101 is illustrated with the inclusion of a top cap
107. Cap 107
is configured to overlay across the tops of panels 103/103b. Cap 107 extends
between
rods 111, such that rods 111 pass beyond cap 107 without the need to puncture
cap 107.
Cap 107 is formed by taking a panel 103 and aligning the slots within the
panel in a
crosswise (side to side) orientation. Cap 107 may be scored in a manner to
allow a
portion of cap 107 to fold over and along the exterior surface 121 of both
panels 103.
Connectors 105e are included over the top of cap 107 and are configured to
pass through
a portion of the scored flap sections. If the slot orientation is crosswise,
the slots would
be oriented in a vertical manner ready to accept connectors 105e. Connectors
105e are
similar in form and function to that of connectors 105b. At intersection
points, it may be
necessary to trim portions of cap 107 to accommodate the inclusion of route
branches.
Figure 19 shows the inclusion of an end cap 131 adjacent panels 103b. End caps
131
are used to seal off open ends of each route to prevent soil from entering the
void space.
[0035] In particular to Figure 20, a seam pad is illustrated. Unit 101 may
further include
the use of a seam pad 133. Pads 133 pass around rods 111 and overlap the
joints of
caps 107. Additionally, pads 133 are trimmed to wrap around any piping that
may extend
above caps 107. In Figure 21, once unit 101 is constructed, the soil is
backfilled into the
trench. The soil covers a portion of unit 101. Ideally in most circumstances
it is conceived
that the backfill of soil will cover all of unit 101 except the extension of
rods 111, which
will rise above the soil surface (see Figure 22).
[0036] Referring again to Figure 2 in the drawings, rod 111 extends above the
surface
of the soil and is configured to couple to or within the substrate 115. The
substrate
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provides the final secure holding of rod 111 and therefore the plumbing lines
within the
void space located between panels 103 and cap 107. System 113 is still
operative at this
time. System 113 is configured to flex under stresses induced by soil
expansion so as to
minimize the transfer of stress loads to the plumbing line. As soil expands,
it may shift
unit 101. System 113 is configured to traverse along the tops of connectors
105c with
lateral load shifts. Additionally, the washer is configured to flex or bend as
soil induces a
vertical load upwards on unit 101. The composition of the washer is such that
flexure is
induces under particular loading. Under extreme conditions, the flexure of
system 113 is
sufficient to result in the washer passing between connectors 105c. This
avoids rod 111
being loaded in a manner that would alter the slope of the plumbing lines.
[0037] Referring now also to Figures 23 and 24 in the drawings, an alternative
embodiment of the plumbing void construction unit 101 is provided. Figure 23
illustrates
an alternative embodiment noted as being plumbing void construction unit 201.
Unit 201
is similar in form and function to that of unit 101 except as herein
indicated. As seen in
Figure 23, a sample configuration for a plumbing void construction unit 201 is
shown.
Unit 201 is configured to be located below ground level within a trench. Unit
201 is
configured to provide a modular and fully customizable routing void space
below ground
level in which to run any number of utility lines, such as plumbing lines,
electrical lines,
gas lines and so forth. Unit 201 is configured to provide a fully enclosed
space designed
to withstand soil pressures. Unit 201 is also configured to protect the
utility lines from
expansive soil movements.
[0038] In Figure 24, a front view looking down the length of unit 201 is
illustrated. Unit
201 is formed and combined with other units to generate a routing or run. Unit
201
includes a singular panel member 203 which is used to form the top portion 204
and side
portion 206 of the routing. Top portion 204 and side portions 206 form a
continuous
surface extending along the interior of the void space. Neighboring panel
members 203
are coupled together through one or more braces / connectors 207. A series or
plurality
of lower supports 205 are configured to engage side portions 206 to maintain
rigidity of
the structure from the side forces as backfill is introduced into the trench.
The
combination of panels 203 in communication with one another form a channel for
the
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laying of piping. It is understood that any type of lines may be run within
the void space
generated by unit 201. For purposes of explanation, reference will be given to
that of
plumbing lines and associated piping.
[0039] Unit 201 further includes a seam pad 209 is included to cover the gap
between
neighboring panel members 203 along the top portion 204. These may be secured
to top
portion 204 with one or more fasteners 211 that either puncture through pad
209 or lay
across pad 209. The panels 203 along with supports 205 and seam pad 209 are
configured to resist inward movement of the soil into the void space. A seam
pad 209 is
also included to cover the gap between neighboring panels 103 along the top of
the
panels. The seam pad 209 may be secured to the top surface via any number of
fasteners, As an alternative to fasteners 211, adhesives or other boding
agents may be
used to secure seam pad 209 to panel 203. Seam pad 209 is made from a similar
material
to that of panel 203.
[0040] As seen in Figure 24, panel member 203 is located within the ground and
surrounded by backfill or soil when fully assembled. Initially unit 201 is
located within a
trench for assembly purposes. Support 205 is shown extending beneath portions
206 as
it extends between the pair of portions 206. Supports 205 are similar to that
of connector
105b in unit 101. A horizontal section of support 205 extends between portions
206 while
a relatively vertical section extends upward and passes internally through the
opposing
portions 206. Support 205 prevents portions 206 from collapsing into the
central defined
void space. Supports 205 may be a metallic rigid member such as a rebar of
appropriate
sizing.
[0041] Also seen in Figure 24 is that panel members 203 have an interior
surface 213
that extends continuously from each portion 206 to top portion 204. It is
understood that
unit 201 may include the use of hanger 109, rod 111, and fastener system 113
as noted
with unit 101 for purposes of routing the utility lines within the void space.
[0042] Referring now also to Figures 25 and 26 in the drawings. Panel members
203
are formed from a product comprised of polypropylene plastic arrayed in a
sheet of
various sizing. Panels 203 may be found in different sizing sufficient to
produce a void
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structure ranging from a height of portions 206 being that of 12-18 inches and
width along
top portion 204 being approximately 18-36 inches for example. Each panel
member 203
is ideally in length approximately 48" for example. Panels 203 are
manufactured as a
ribbed plastic panel having a series of aligned flutes 213 that run the
length/width of the
panel.
[0043] As seen in Figure 25, unit 201 is a unique product that is designed to
be
constructed of a limited number of components and yet be configured to
withstand all
lateral and vertical pressures that are applied to it when buried during a
backfill process.
The minimal number of components allow unit 201 to be easily transported in a
broken
down condition to save space and increase portability. Unit 201 is depicted in
a manner
wherein the panel 203 is scored and folded partially to form a three-sided
channel.
Supports 205 are engaged within the panel 203 to maintain the orientation of
portions
206. Multiple panel sections may be combined together.
[0044] Each panel 203 is provided and shipped to the site as a flat sheet of
material
(see Figure 25). Panel 203 has an upper surface 214 and a lower surface 216.
Panel
member 203 is arrayed with a series of flutes 215 (see Figure 26) that have a
defined
orientation and are formed between surfaces 214 and 216. Each flute 215 is
linear and
is defined by the inclusion of perpendicular walls 217 connecting the exterior
surfaces
214 and 216. In order to form the void structure with a top portion and side
portions, an
operator scores upper surface 214 of panel 203 so as to cut through surface
214 and at
least a portion of walls 217. Lower surface 216 is retained without cutting.
Score lines
219 are configured to run across flutes 215 in a perpendicular manner such
that when
folded, the flutes 215 are exposed. Use of two score lines permits panel 203
to be formed
into a U-shaped structure having 2 side portions and a top portion. Lower
surface 216
retains the connection between portion 206 and top portion 204. Interior
surface 213 is
the retained lower surface 216 after scoring is performed. It is understood
that the
location of score lines 219 are chosen in accordance with the sizing needs of
the void
space. This location also affects the sizing of portions 204 and 206.
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[0045] Figure 26 provides an enlarged view of the flutes 215 of panel Each
flute 215 is
a hollowed channel that runs the full dimension of panel 203. These flutes 215
add rigidity
and also help to minimize weight and material. In order to maintain its
orientation in the
U-shape, a number of supports 205 are located beneath and through the sides of
panel
203. Supports 205 are configured to pass internally through flutes 215. The
support
members 205 extend upwards a selected distance into the flutes 215 of each
portion 206.
There is no restriction on the specific amount of length of support member 205
that needs
to be inserted into the side portions 206. It is important that the size of
support members
205 be sized sufficiently small enough that they fit within the flutes 215
without
compromising the structure of the panels. Some resistance will be ideally
created
between them. Frictional resistance helps to maintain the position of the
support
members such that they do not fall out of the panel's flutes.
[0046] Referring now also to Figure 27 in the drawings, a front view of unit
201 is
depicted with panel 203 formed in the U-shaped structure. Supports 205 are
seen at the
bottom between portions 206. Upper surface 214 is shown scored or cut with
lower
surface 216 uncut and holding portions 204 and 206 together, similar to a
membrane.
[0047] Referring now also to Figure 28 in the drawings, a perspective view of
two
neighboring panel members 203 are illustrated. Connectors 207 are inserted
along the
vertical sides of panel 203 adjacent the respective edges of the neighboring
panels.
These are inserted through flutes 215 similarly to that of supports 205.
Connectors 207
are similar in form and function to connectors 105a/105b. As noted previously,
neighboring units 201 may be aligned adjacent one another to create additional
length.
Connectors 207 are used and inserted into the vertical flutes 215 of the panel
sides of
neighboring units. Each connector 207 includes a plurality of vertical members
and a
cross member there between. These are also U-shaped. The cross member portion
may
be created via different methods. It is not imperative that the connector 207
remains flush
with the top of panel 203.
[0048] In operation, the method of constructing is simplified over that of
unit 101. Panels
203 are scored as needed across flutes 215 and folded about lower surface 216.
This
CA 3023745 2019-11-22
folding exposes flutes 215 for communication with connectors 207. Supports 205
are
inserted into the flutes at the ends of portions 206. A series of panels 203
are aligned to
form the routing and are coupled with connectors 207. Seam pads 209 are
optionally
located to cover the gaps between panels 203. It is understood that the
hanger, rods,
and fasteners system described with respect to unit 101 is equally usable with
respect to
and included optionally within unit 201. As the method of use and components
are similar
in form and function between units 201 and 101, further depiction and
description was not
made for unit 201.
[0049] It is common for plumbers or tradesman to provide their own supports
for
supporting and suspending plumbing, conduit, and other "lines" within the void
space of
unit 201. Unit 201 is configured to permit the selective passage of utility
support devices
through panel 203 in order to properly route utility lines. These support
devices may
include threaded rods holding brackets or clevises. These may be secured to
panel 103
and/or also to any foundation above unit 201 and the soil.
[0050] One important feature worth noting at this stage is that, when fully
constructed,
unit 201 is likely to include portions along its constructed length that are
below a concrete
footing or slab. Often space exists between unit 201 and the slab eventually
poured
above. Locating the support devices in the foundation anchors them to a
particular
location and ensures the location and elevation of the utility lines. In the
event of heaving
or other soil expansion, such support devices could pull through panel 203 as
it moves,
but the lines remain constant as a result of the foundation anchoring it.
[0051] e current application has many advantages over the prior art including
at least
the following: 1) simplified packaging and transportation; 2) simplified
customization; 3)
prevents slab leak damage; (4) provides an area into which soil can expand;
(5)
temporarily supports under-slab plumbing; (6) secures and suspends lateral
pipes; (7)
provides containment; and (8) eliminates potential damage to pipes, electrical
lines,
conduit, other plumbing apparatuses and adjacent structures.
[0052] The particular embodiments disclosed above are illustrative only and
are not
intended to be exhaustive or to limit the invention to the precise form
disclosed, as the
16
CA 3023745 2019-11-22
embodiments may be modified and practiced in different but equivalent manners
apparent
to those skilled in the art having the benefit of the teachings herein. It is
therefore evident
that the particular embodiments disclosed above may be altered or modified,
and all such
variations are considered within the scope and spirit of the application.
Accordingly, the
protection sought herein is as set forth in the description. It is apparent
that an application
with significant advantages has been described and illustrated. Although the
present
application is shown in a limited number of forms, it is not limited to just
these forms, but
is amenable to various changes and modifications without departing from the
spirit
thereof.
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