Note: Descriptions are shown in the official language in which they were submitted.
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Foldable and/or Collapsible Plastic/Composite Utility Enclosure
Field of the Invention
The invention relates to underground utility enclosures for providing
protection for below
ground devices such as water meters, valves, telecom hardware, and the like
and, more particularly,
to a foldable and/or collapsible plastic/composite utility enclosure.
Background of the Invention
Utility enclosures are used to protect buried meters, valves, and telecom
hardware and need
to be capable of withstanding heavy loads that may be placed on the cover of
the utility enclosure.
Concrete utility enclosures are commonly used in or near roadways and
driveways since they are
heavy duty and are capable of withstanding heavy loads placed on the cover.
Concrete utility
enclosures are formed by a wall of concrete that extends around the utility. A
lip extends about the
top of the utility enclosure in the interior of the utility enclosure. The
cover of the utility enclosure
fits into the interior of the utility enclosure and rests on the lip. The
concrete lip provides sufficient
support to the cover to enable the utility enclosure to withstand the force of
heavy loads.
Concrete utility enclosures present some disadvantages, however. Concrete
utility
enclosures are difficult to transport and install. They are bulky and take up
space. During transport,
concrete utility enclosures are prone to being chipped, and significant
amounts of concrete utility
enclosures become non-usable because of damage incurred in transport.
Installation of concrete
utility enclosures is difficult because of the weight of the utility
enclosures. Installation of a
concrete utility enclosure generally requires the effort of two people because
the utility enclosures
weigh in excess of two hundred pounds each. The weight of the concrete utility
enclosures also
presents some danger of physical injury to the persons installing the utility
enclosure
Plastic utility enclosures are known. U.S. Patent No. 5,333,750 discloses a
plastic utility
enclosure that is durable, lightweight, and capable of being located in
roadways or driveways and
withstanding heavy loads. However, plastic utility enclosures also are bulky
and take up space
during transportation. What is needed is a foldable utility enclosure that
takes up reduced space
when folded.
Summary of the Invention
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This invention is a foldable plastic/composite utility enclosure having a
first side, a second
side opposite the first side, a third side, and a fourth side opposite the
third side. Each of the sides
has a first end and a second opposite end. The first end of the first side is
connected to the first end
of the third side by means of a first hinge. The second opposite end of the
second side is connected
to the second opposite end of the third side by means of a second hinge. The
second opposite end
of the first side is connected to the second opposite end of the fourth side
by means of a third hinge.
The first end of the second side is connected to the first end of the fourth
side by means of a fourth
hinge.
The third side is constructed to rotate on the first and second hinges only
away from the
first side. The fourth side is constructed to rotate on the third and fourth
hinges only towards the
first side. The third side and the fourth side are constructed to rotate until
the first side engages the
second side and the foldable plastic/composite utility enclosure is in a
folded configuration. The
folded plastic/composite utility enclosure when in a folded configuration has
only 15 to 20 percent
of the thickness compared to an unfolded configuration.
The first end of the first side and the first end of the second side are
curved. The first end
of the third side is positioned slideably over the first end of the first side
and the first end of the
fourth side is positioned slideably over the first end of the second side. The
second opposite end
of the first side abuts against the second opposite end of the fourth side and
the second opposite
end of the third side abuts against the second opposite end of the second
side. The second opposite
ends are angled.
Each hinge consists of hinge members wherein each hinge member is positioned
in a
housing. The housing has an open interior to help anchor the housing in the
ground. Each edge of
each side has a plurality of spaced-apart hinge members wherein hinge members
on one side
engage the hinge members on another side to form the hinge. One or more of the
hinges may have
a reversibly insertable locking pin that prevents the sides from rotating on
the hinges and prevents
the foldable plastic/composite utility enclosure from folding.
The foldable and/or collapsible plastic/composite utility enclosure of this
invention can be
made of any type of plastic or composite, preferably plastic imbedded with
fibers such as carbon
fibers, glass fibers, or ceramic fibers or imbedded with particles such as
glass particles. The use of
plastic/composite and various openings or cutouts makes the utility enclosure
light weight. The
hinges allow the utility enclosure to be folded flat for storage and
transportation. The pairs of sides
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are symmetrical which facilitates manufacturing. The foldable
plastic/composite utility enclosure
is ideal for housing underground utilities. However, it can be used to house
or contain any desired
device.
A preferred embodiment of a lid for the utility enclosure has a front end, a
rear end, a right
side, a left side, a top lid portion, and a bottom, defining an interior.
First reinforcement ribs are
on an interior surface of the top lid portion. Metal bars are embedded in the
first reinforcement
ribs. The lid is made, preferably, of glass fiber-reinforced polypropylene.
The first reinforcement ribs form a lattice-type structure, with second
reinforcement ribs
mounted in spaces formed by the lattice type structure. The metal bars are
positioned in the first
reinforcement ribs near a bottom of the first reinforcement ribs and are
spaced above the bottom
of the first reinforcement ribs. The top lid portion has a recess with a lift
pin therein. A lifting tool
can be inserted into the recess and under the lift pin to lift the lid off a
utility enclosure. The top
lid portion may have bolt holes to bolt the lid to the utility enclosure. The
lid is constructed to
withstand up to 33,750 pounds of force without breaking or being deformed.
Brief Description of the Drawings
FIG. 1 is a top, front, perspective view of the utility enclosure of the
present invention.
FIG. 2A is perspective view from an exterior surface of a first side the
utility enclosure.
FIG. 2B is a perspective view from an interior surface of the first side.
FIG. 3A is perspective view from an exterior surface of a third side.
FIG. 3B is a perspective view from an interior surface of the third side.
FIG. 4 is a top, interior surface view of the second side of the utility
enclosure.
FIG. 5 is a top, interior surface view of the third side of the utility
enclosure.
FIG. 6 is a top, exterior surface view of the first side of the utility
enclosure.
FIG. 7A is a top perspective view of the utility enclosure laying with its
first side on a
horizontal plane in an unfolded configuration.
FIG. 7B shows the utility enclosure of FIG. 7A in a semi-folded configuration.
FIG. 7C shows the utility enclosure of FIG. 7A in a completely folded
configuration.
FIG. 8A shows an enlarged top view of an end of a second side and an end of
the third side
in an unfolded configuration.
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FIG. 8B show an enlarged top view of the end of the second side and an end of
a fourth
side in an unfolded configuration.
FIGs. 9A and 9B show the same views as 8A and 8B but with the utility
enclosure in a
semi-folded configuration.
FIGs. 10A and 10B show the same views 8A md 8B but with the utility enclosure
in a
completely folded configuration.
FIG. 11 shows a top perspective view of the utility enclosure with a top cover
inserted in a
top end of the utility enclosure.
FIG. 12 shows a top perspective view of the top cover having an opening with a
door.
FIG. 13 shows a bottom perspective view of the utility enclosure with a bottom
cover
attached reversibly to a bottom end of the utility enclosure.
FIG. 14 shows a perspective view of corner with a hinge connecting two sides,
with a
locking pin inserted through the hinge members to prevent rotation of the
sides on the hinge and
to prevent folding of the foldable plastic utility enclosure.
FIG. 15 shows a top view of a preferred embodiment of a lid for the utility
enclosure of the
present invention.
FIG. 16 shows a bottom view of the lid
FIG. 17 shows a rear, bottom, perspective view of the lid.
FIG. 18 shows a front-end view of the lid.
FIG. 19 shows a rear, top, perspective, sectional view of the lid.
FIG. 20 shows a bottom perspective sectional view of the lid.
FIG. 21 shows an enlarged view of rebar positioned in a large reinforcement
rib of the lid.
FIG. 22 illustrates a testing device for measuring the load strength of the
lid as described
in ANSI/SCTE 77.
Detailed Description of the Invention
While the following description details the preferred embodiments of the
present invention,
it is to be understood that the invention is not limited in its application to
the details of arrangement
of the parts or the illustrations disclosed herein, since the invention is
capable of other
embodiments and of being practiced in various ways.
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FIG. 1 is a top, front, perspective view of the utility enclosure 10 of the
present invention.
The utility enclosure 10 is rectangular and has a first side 11, a second side
12 opposite the first
side 11, a third side 13, and a fourth side 14 opposite the third side 13. The
first side 11 and the
second side 12 form a first pair of sides and the third side 13 and the second
side 14 form a second
pair of sides. The utility enclosure 10 has a top end 15, a bottom end 16, and
an interior 17. An
interior ledge 18 is formed on each side in the interior 17 near the top end
15 to support a cover
(see FIGs. 11 and 12) or an extension enclosure 80 (See FIG. 16). The edges of
each side 11, 12,
13, and 14 are joined together with hinges 20, 21, 22, and 23 to form the
rectangular utility
enclosure 10, with a hinge in each corner of the rectangle. The hinges 20, 21,
22, and 23 are made
up of hinge members 24. Each hinge member 24 has a central hole 25 (see FIGs.
2A and 2B) for
the insertion of a hinge pin 26 to form the hinge, as is known in the art. The
hinge members 24 are
formed in open hollow housings 27, the housings 27 having interiors 28.
First side 11 has a first end 30 and a second opposite end 31. The second side
12 has a first
end 32 and a second opposite end 33. The third side 13 has a first end 34 and
a second opposite
end 35. The fourth side 14 has a first end 36 and a second opposite end 37.
The first ends 30 and
32 of the sides 11 and 12 (first pair of sides) form curved comers which end
with curved extensions
38. The second opposite ends 31 and 33 of sides 11 and 12 are also curved and
form acute angles
39. The first ends 34 and 36 of sides 13 and 14 (second pair of sides) and the
second opposite ends
35 and 37 of sides 13 and 14 form obtuse angles 40. The first ends 34 and 36
of the sides 13 and
14 fit over the curved extensions 38 of sides 11 and 12 and the first ends 34
and 36 may be slightly
curved to match the curved extensions 38. The second opposite end 35 of the
third side 13 forms
an obtuse angle 40 between an interior surface 45 (see FIG. 3B) of the third
side 13 and an interior
surface 42 (see FIG. 2B) of the first side 11. The obtuse angle 40 extends
from the top end 15 of
the utility enclosure 10 to the bottom end 16 of the utility enclosure 10. The
second opposite end
37 of the fourth side 14 forms an acute angle 39 between an interior surface
45A of the fourth side
14 and an interior surface 42 of the first side 11 and the acute angle 39
extends from the top end
15 of the utility enclosure 10 to the bottom end 16 of the utility enclosure
10. The angled edges of
the second opposite ends 35 and 37 of sides 13 and 14 abut the angled edges of
the ends 31 and 33
of the sides 11 and 12. The sides 11, 12, 13, and 14 may have openings 19 to
accommodate wires,
pipes, tubing, and the like.
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FIG. 2A is perspective view from an exterior surface 41 of the first side 11,
separated from
the utility enclosure 10, and FIG. 2B is a perspective view from an interior
surface 42 of the first
side 11. The hinge members 24, the housings 27, and the interiors 28 can be
seen in more detail.
Grooves or spaces 43 between the hinge members 24 accommodate the housings 27
of the hinge
members 24 that engage the first side 11 to complete the formation of the
hinges 23.
FIG. 3A is perspective view from an exterior surface 44 of the third side 13
separated from
the utility enclosure 10 and FIG. 3B is a perspective view from an interior
surface 45. The hinge
members 24, the housings 27, and the interiors 28 can be seen in more detail.
FIGs. 3A and 3B
further show latches 46 which lock the third side 13 to the first side 11 to
prevent the utility
enclosure 10 from folding. Grooves 47 between the hinge members 24 accommodate
the housings
27 of the hinge members 24 that engage the third side 13 to complete the
formation of the hinges
20, 21, 22, 23.
The housings 27 strengthen the hinges 20, 21, 22, 23 and protect them from
external forces.
When the utility enclosure 10 is placed in the ground to protect an
underground device, soil, rocks,
and cement can fill the interiors 28 of the housings 27 which will prevent the
utility enclosure 10
from moving or folding. The first side 11 and the second side 12 are identical
to each other and
the third side 13 and the fourth side 14 are identical to each other with
regard to hinging and folding
features.
FIG. 4 is a top, interior surface view of the second side 12. FIG. 5 is a top,
interior surface
view of the third side 13. FIG. 6 is a top, exterior surface view of the first
side 11. The utility
enclosure 10 is formed by inserting the housings 27 on end 35 of the third
side 13 in between the
housings 27 on end 31 of the second side 12 and inserting the housings 27 on
end 34 of the third
side 13 in between the housings 27 on end 30 of the first side 11. The pins 26
are then inserted
through the holes 25 to form the hinges 20, 21, 22, 23. The fourth side 14 is
added to sides 11 and
12 in the same way to complete the assembly of the utility enclosure 10.
FIG. 7A is a top perspective view of the utility enclosure 10 laying with its
first side 11 on
a horizontal plane, shown by double arrow 50. The utility enclosure 10 is in
an unfolded
configuration. FIG. 7B shows the utility enclosure 10 in a semi-folded
configuration. FIG. 7C
shows the utility enclosure 10 in a completely folded configuration. As the
second side 13 is rotated
away from the first side 11 the fourth side 14 is rotated towards the first
side 11. The second side
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12 moves inward towards the first side 11. In the folded configuration the
utility enclosure 10 has
about 15% to 25% of the thickness, compared to the unfolded configuration,
preferably about 20%.
FIG. 8A shows an enlarged top view of the end 33 of the second side 12 and the
end 35 of
the third side 13 in an unfolded configuration. FIG. 8B shows an enlarged top
view of the end 32
of the second side 12 and the end 36 of the fourth side 14 in an unfolded
position. The utility
enclosure 10 cannot fold in a direction opposite to that shown in FIGS. 9A,
9B, 10A, and 10C,
because the end 35 of side 13 abuts the end 33 of side 12, shown by arrow 51,
at an angle relative
to sides 12 and 13. The end 35 of side 13 cannot move around the end 33 of
side 12. However, the
end 36 of side 14 can move around end 32 of side 12, as shown in FIGS. 9A, 9B,
10A, and 10C,
because end 36 overlaps end 32, shown by arrow 52.
FIGs. 9A and 9B show the same views as FIGs. 8A and 8B but with the utility
enclosure
10 in a semi-folded configuration. Arrow 53 in FIG. 9A shows the extent to
which end 35 of side
13 has moved away from end 33 of side 12. Arrow 54 in FIG. 9B shows the extent
to which end
36 of side 14 has moved over and around the curved extension 38 of end 32 of
side 12. FIGs. 10A
and 10B show the same views as FIGs. 8A and 8B but with the utility enclosure
10 in a completely
folded configuration with the first side 11 engaging the second side 12. The
folding of the utility
enclosure 10 is reversible and the utility enclosure 10 can be restored to its
unfolded configuration
by pulling the first side 11 and the second side 12 apart.
FIG. 11 shows a top perspective view of the utility enclosure 10 with a top
cover 60 inserted
in the top end 15. The top cover 60 can have handles or openings for removing
the cover 60. FIG.
12 shows a top perspective view of a top cover 61 having an opening 62 with a
door 63. The
interior 17 of the utility enclosure 10 can be viewed and accessed by raising
the door 63.
FIG. 13 shows a bottom perspective view of the utility enclosure 10 with a
bottom cover
64 attached reversibly to the bottom end 16 by methods known in the art. The
use of a bottom
cover 64 allows the utility enclosure 10 to be used as any type of utility
enclosure for any type of
articles.
FIG. 14 shows a perspective view of corner with a hinge connecting two sides,
with a
locking pin 70 inserted through the hinge members 24 to prevent rotation of
the sides on the hinge
and to prevent folding of the foldable plastic/composite utility enclosure. An
insertion hole 71 is
on the top end 15 to insert the locking pin 70. Each hinge member 24 has an
upper groove 72 and
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a bottom groove 73 through which the locking pin 70 passes. The locking pin 70
can be retained
in an opening 74 in the bottom hinge member.
Top covers or lids for utility enclosures, under certain circumstances, may
require
sufficient reinforcement so that they may withstand several thousand pounds of
pressure. To
achieve sufficient reinforcement the lid may be made with strong plastic
material, have a suitable
thickness, and contain rebar, FIG. 15 shows a top view of a preferred
embodiment of a lid 100 for
the utility enclosure of the present invention. The lid 100 has a front end
101, and a rear end 102,
a right side 103, a left side 104, and a top lid portion 105, defining an
interior 113 (see FIG. 16).
There are two recesses 106 on the top lid portion 105. Within the recess 106
is a lift pin 107. A
lifting tool can be inserted into the recess 106 and under the lift pin 107 to
lift the lid 100 off a
utility enclosure. Each side 103 and 104 has bolt holes 108 for bolting the
lid 100 to the top of a
utility enclosure.
FIG. 16 shows a bottom view of the lid 100. The lid 100 has an open bottom 109
with large
size reinforcement ribs 110 attached to an interior surface 116 of the top lid
portion 105. The large
size reinforcement ribs 110 extend from the front end 101 to the rear end 102
and from the right
side 103 to the left side 104. The large size reinforcement ribs 110
crisscross forming a lattice-
type structure, with medium size reinforcement ribs 111 and small size
reinforcement ribs 112
mounted in spaces formed by the lattice type structure. The large size
reinforcement ribs 110 are
larger than the medium size reinforcement ribs 111 and the small size
reinforcement ribs 112, and
the medium size reinforcement ribs 111 are larger than the small size
reinforcement ribs 112.
FIG. 17 shows a rear, bottom, perspective view of the lid 100. FIG. 17 further
illustrates
the interior surface 116 and the lattice-type structure, with medium size and
small size
reinforcement ribs in the spaces of the lattice-type structure.
FIG. 18 shows a front-end view of the lid 100. FIG. 18 shows that the bottom
114 of the
large reinforcement ribs 110 extends below the bottom 109 of the lid 100. The
large reinforcement
ribs 110 must be of sufficient size to sufficiently reinforce the lid to
resist 33,750 pounds of force.
FIG. 19 shows a rear, top, perspective, sectional view of the lid 100. The
recess 106 is of
sufficient size so that a lift tool can be inserted into the recess 106. Lift
pin 107 extends across the
recess 106 so that a lift tool can be positioned under the lift pin 107 and
can lift the lid 100 off the
top of a utility enclosure.
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FIG. 20 shows a bottom, perspective, sectional view of the lid 100. FIG. 20
further shows
the positioning of metal rods or rebar 11.15 in the large reinforcement ribs
110. The rebar 115 is
near the bottom end 114 of the large reinforcement ribs 110 but is positioned
above the bottom
end 114. During the molding process of the lid 100 the rebar tends to settle
to the bottom 114 of
non-solidified large reinforcement ribs 110. That settling of the rebar 115
would prevent the rebar
115 from being properly encased in the large reinforcement ribs 110. To
prevent this settling a
stud cradle is used in a mold to support the rebar 115 above the bottom 114 of
the large
reinforcements rib 110. When the lid 100 is removed from the mold after curing
the stud cradle
remains in the mold.
FIG. 21 shows an enlarged view of rebar 115 positioned in a large
reinforcement rib 110
of the lid 100 near the bottom 114 of the large reinforcement rib 110 and
spaced above the bottom
114. FIG. 21 further shows a void 117 of a stud cradle which is removed from
the lid 100 when
the lid 100 is removed from the mold.
The lid 100 is made with a thermoplastic, preferably with polypropylene
containing glass
fiber and preferably in the amount of 15% to 40%. Glass fiber-reinforced
polypropylene has
improved dimensional stability, resistance to warpage, rigidity, and strength.
Heat deflection
temperature at 264 psi is increased up to 300 F (150 C) for 40% glass fiber
reinforced
polypropylene. Polypropylene's coefficient of thermal expansion is cut in half
with 40% glass
reinforcement. Glass fiber-reinforced polypropylene has good impact strength,
very good mold
filling capability, excellent stiffness, good dimensional stability, and low
creep under load at
elevated temperatures (RTP Company, Winona, Minnesota). The physical structure
of the lid as
described above and its composition consisting essentially of glass fiber-
reinforced polypropylene
are constructed so that the lid withstands up to 33,750 pounds of force
without breaking or being
deformed.
FIG. 22 illustrates a testing device for measuring the load strength of the
lid as described
in AN SI/SCIE 77. "[he lid 100 is tested while sitting on the interior ledge
18 of the utility enclosure
10. A rubber load plate 120 is centered on the top 105 of the lid 100 and a 10-
inch by 10-inch by
1-inch steel load plate (Tier 15) or 10-inch by 20-inch by 1-inch steel load
plate (Tier 22) 121 is
centered on the rubber plate 120. A load frame 124 is centered over the top
portion 105 and a
hydraulic load device 123 engages the 1-inch steel load plate 121. Increasing
force, perpendicular
to the top lid portion 105, is applied to a center of the steel plate 121
until the lid 100 bends or is
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deformed. Linear measurement gauges 125 and 126 are mounted to a measurement
gauge
mounting arm 127 to measure the amount of displacement to the top 105 of lid
100.
The foregoing description illustrates and describes the disclosure.
Additionally, the
disclosure shows and describes only the preferred embodiments but, it is to be
understood that the
preferred embodiments are capable of being formed in various other
combinations, modifications,
and environments and are capable of changes or modifications within the scope
of the invention
concepts as expressed herein, commensurate with the above teachings and/or the
skill or
knowledge of the relevant art. The embodiments described herein above are
further intended to
explain the best modes known by applicant and to enable others skilled in the
art to utilize the
disclosure in such, or other, embodiments and with the various modifications
required by the
particular applications or uses thereof. Accordingly, the description is not
intended to limit the
invention to the form disclosed herein. Also, it is intended that the appended
claims be construed
to include alternative embodiments. It will be further understood that various
changes in the
details, materials, and arrangements of the parts which have been described
and illustrated above
in order to explain the nature of this invention may be made by those skilled
in the art without
departing from the principle and scope of the invention as recited in the
following claims.
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