Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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AGGREGATE REPLACEMENT
This invention relates to French drains and in particular to a device which
can be used to replace the aggregate used in French drains or other water
distribution systems.
Background Art
French drains are widely used in residential and commercial building
applications to collect groundwater and distribute it away from the proximity
of
basements, foundations, footings, and similar surface and subterranean
building
structures where water may penetrate and/or damage these structures. An
additional use of this technology is to deliver water into the sub-surface of
the
ground. For example, a French drain may be used to distribute fluid into the
drain
field of a residential septic system.
Various structures have been developed over the last two hundred years to
accomplish this diversion of fluids. Generally, they consist of a pipe
containing
multiple small perforations throughout its sidewall through which water or
fluid
enters the pipe. The fluid then travels down the pipe to a desired location.
To
keep the perforations in the pipe from clogging, and to prevent dirt or other
material from the surrounding substrate from entering the pipe, the pipe is
laid
within a bed of solid granular material that creates a porous aggregate
unrestrictive to the flow of fluid, such as gravel, or a similar synthetic
aggregate.
Finally, a woven, coarse, landscape textile or filter fabric is used to
surround and
cover the aggregate to prevent the aggregate from becoming clogged with dirt
or
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other surrounding substrate. The pipe, surrounding aggregate, and textile are
typically installed within a trench which is then filled to grade level with
dirt or
other substrate. Rainwater or other surface water in the area seeps from the
surrounding substrate through the textile where it may trickle freely through
the
aggregate into the pipe for removal from the area.
One significant problem with this system is the labor and expense
necessary to surround the pipe with the aggregate. Also, if the aggregate is
too
heavy or is not placed carefully on top of the pipe, the pipe may break or
collapse
while the aggregate is being placed. This can cause time consuming and
expensive problems.
Various inventions have been made in order to try and prevent these
problems. For example, U.S. Patent Number 5,810,509 issued to Nahlik, Jr.
discloses a cell system for buried drainage pipes. These cells, however,
cannot be
used to form continuous French drains. Instead, there are individual cells
that are
spaced throughout the drainage area. These cells also do not protect the areas
of
pipe between the cells and therefore there may be a problem with these areas
of
pipe being damaged when the trench they are laid in is filled.
U.S. Patents 7,191,802 issued to Koerner (hereinafter "Koerner") and
5,051,028 issued to Houck et al. (hereinafter "Houck"), also attempt to
improve
French drains by replacing the standard aggregate. They, however, do not allow
the aggregate replacement and pipe to be easily assembled on site.
Instead Houck discloses units that are manufactured as one piece with
sections of perforated pipe inside. Multiple units are hooked together.
Therefore
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if a section of pipe becomes damaged, the entire unit must be replaced rather
than
just the pipe.
Koerner discloses a system where netting filled with aggregate is wrapped
along a perforated pipe. This system takes too long to conveniently assemble
on
site and therefore will likely need to be preassembled. Therefore if the pipe
gets
damaged the entire assembly will need to be replaced rather than simply
replacing
the pipe.
Also, while these patents claim to protect the pipe, in reality they would
provide very little protection to the pipe when the trench is being filled in
with
substrate.
Accordingly, what is needed is an aggregate replacement device that is
light weight, easy to use, quick Lo install and which allows the pipe to be
accessed
and inserted after the aggregate replacement has been placed in the trench.
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SUMMARY OF THE INVENTION
The aggregate replacement device, as disclosed hereafter in this
application, is strong, lightweight and easy to assemble.
In particular embodiments, an aggregate replacement device includes a
structure with a proximal end, a distal end, and at least one face wherein the
at
least one face includes a plurality of first openings. A second opening in the
structure extends from the proximal end to the distal end continuing
uninterrupted
through at least one of the at least one faces. The second opening is
configured to
receive at least one pipe inserted in a radial direction of the at least one
pipe.
Additional embodiments of an aggregate replacement device may include
a structure having a proximal end, a distal end, and at least one face that is
water
permeable. The aggregate replacement device may also include an opening in the
at least one outer face that extends from the proximal end to the distal end
of the
structure continuously. The opening may be configured to receive at least one
pipe inserted in a radial direction of the at least one pipe. The opening may
further include at least one pipe retainer.
Other embodiments of an aggregate replacement device may include a
structure having a proximal end, a distal end, and at least two faces. The at
least
two faces further contain a plurality of first openings. A stake may be
coupled to
the structure to secure the structure in a desired position. A concrete
barrier may
be placed abutting at least one of the at least two faces. An second opening
in the
structure may extend from the proximal end of the structure to the distal end
of
the structure continuing uninterrupted through at least one of the at least
two
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faces. The second opening, however, continues through a different at least one
of
the at least two faces than the concrete barrier abuts. The second opening may
be
configured to receive at least one pipe inserted in a radial direction of the
at least
one pipe.
Further embodiments of an aggregate replacement device may include a
structure having a proximal end, a distal end, and at least one face. The at
least
one face has a plurality of first openings. A second opening may be located in
the
proximal end. A third opening may also be located in the structure. A first
end of
a pipe is in communication with the second opening and the pipe extends
through
the structure. A second end of the pipe is in communication with the third
opening.
Embodiments of an aggregate replacement device may also include a
structure having a proximal end. a distal end, and at least one face. The at
least
one face may have a plurality of first openings. The proximal end may also
comprise at least one cutout, wherein the at least one cutout intersects an
edge of
the proximal end.
Yet more embodiments of an aggregate replacement device may include at
least one face, wherein the at least one face has a plurality of openings. At
least
one coupler may be coupled to the at least one face. At least one distal end
and at
least one proximal end may be hingedly coupled to at least one the at least
one
face.
The foregoing and other features and advantages of the aggregate
replacement device will be apparent to those of ordinary skill in the art from
the
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following more particular description of the invention and the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will hereinafter be described in conjunction with the
appended drawings where like designations denote like elements, and:
FIG. 1 is an isometric view of an aggregate replacement configured according
to
a first embodiment;
FIG. 2 is an isometric view of an aggregate replacement configured according
to a
second embodiment;
FIG. 3 is a first side view of an aggregate replacement configured according
to the
embodiments of FIG. 1;
FIG. 4 is a second side view of an aggregate replacement configured according
to
the embodiments of FIG. 1;
FIG. 5 is an end view of an aggiegate replacement configured according to the
embodiments of FIG. 1;
FIG. 6 is an isometric view of an aggregate replacement covered by a liner
configured according to a third embodiment;
FIG. 7 is an isometric view of an aggregate replacement configured according
to a
fourth embodiment;
FIG. 8 is an isometric view of an aggregate replacement configured according
to a
fifth embodiment;
FIG. 9 is an isometric view of an aggregate replacement configured according
to a
sixth embodiment;
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FIG. 10 is an isometric view of an aggregate replacement configured according
to
a seventh embodiment;
FIG. 11 is a close up view of an area denoted by A in FIG. 2;
FIG. 12 is an isometric view of an aggregate replacement concrete form
configured according to an embodiment;
FIG. 13 is an isometric view of an aggregate replacement configured according
to
a seventh embodiment;
FIG. 14 is an isometric view of an aggregate replacement configured according
to
an eighth embodiment;
FIG. 15 is an isometric view of an aggregate replacement configured according
to
a ninth embodiment;
FIG. 16 is an isometric view of an aggregate replacement configured according
to
a tenth embodiment;
FIG. 17 is an isometric view of an aggregate replacement configured according
to
an eleventh embodiment;
FIG. 18 is a top view of an aggregate replacement configured according to a
twelfth embodiment;
FIG. 19 is an isometric view of an aggregate replacement concrete form
configured according to a second embodiment; and
FIG. 20 is an isometric view of an aggregate replacement concrete form
configured according to a third embodiment.
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DETAILED DESCRIPTION OF THE DRAWINGS
As discussed above, embodiments of the present invention relate to an
aggregate replacement device for use in French drains and the like. In
particular,
disclosed is an aggregate replacement device including a structure with fluid
permeable surfaces, and an opening configured to receive a pipe inserted
parallel
to a diameter of the pipe.
When French drains or other drainage or fluid distribution systems are set
up, a trench is dug in the ground in the area where the water is to be drained
from.
The trench is then lined with a landscape, filter fabric or other water
permeable
material which prevents the soil or substrate from the surrounding area from
entering the trench. Aggregate may then be placed in the bottom of the trench.
This aggregate is typically washed gravel or a synthetic aggregate that allows
water to flow freely through. A perforated pipe is then placed on top of the
aggregate. The perforated pipe could also be placed directly on the filter
fabric in
the bottom of the trench. The perforated pipe is then covered with additional
aggregate. The top of the additional aggregate may have more filter fabric
placed
on it. Then top soil and plants may be placed on the filter fabric hiding the
French
drain underground.
FIGs 1-6 illustrate an aggregate replacement 10 configured according to
embodiments of the present invention. The aggregate replacement 10 takes the
place of the washed gravel or synthetic aggregate in a French drain or other
water
distribution system.
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The aggregate replacement 10 includes a structure 26 which is formed as
an open scaffolding. The structure 26 includes a proximal end 12, a distal end
32
and at least one face 18. The proximal end 12 is coupled to the at least one
face
18. In the figures, the proximal end 12 is coupled at a 90 degree angle to
four
faces 18. The four faces 18 illustrated are rectangular or square. It is
anticipated,
however, that only one face 18 could be used. This face 18 would be curved in
order to form a cylindrical aggregate replacement. It is also anticipated that
three
faces 18 could be utilized in order to form a structure with a triangular
cross
section. A plurality of faces 18 greater than four could also be used to form
the
structure 26. The number of faces 18 and the desired shape of the structure 26
will determine the angle at which the faces are coupled to the proximal end
12.
The four faces 18, shown in the figures, are also coupled to each other at 90
degree angles. The angle at which the faces 18 are coupled to each other will
vary
depending on the number and shape of faces 18 utilized. The distal end 32 is
coupled to the remaining open edges of the four faces 18. The arrangement
described and depicted in the figures results in a cube or rectangular prism
shaped
structure 26. However, the structure 26 may be any type of shape desired. The
at
least one face 18, proximal end 12, and distal end 32 may also be formed in
any
shape desired.
In additional embodiments, the structure 26 may be curved in order to
form circular, serpentine or other irregularly shaped drains.
The structure 26 forms a mostly hollow interior 20. The mostly hollow
interior 20 may contain supports or other devices necessary to strengthen the
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structure 26. However, these devices should not impede the flow of water in
the
interior 20 of the structure 26. The mostly hollow interior 20 of the
structure 26
allows water to drain through the structure 26 just like water would drain
through
the washed gravel or synthetic aggregate of traditional drains.
The proximal end 12, distal end 32 and at least one face 18 are water
permeable. This is accomplished by forming at least one first opening 28 in
the
proximal end 12, distal end 32 and at least one face 18. In FIG 1, the
proximal
end 12, distal end 32 and four faces 18 are all formed with multiple square
openings 28 separated by thin structural members which help structure 26
maintain its shape while allowing fluid, typically water, to pass easily
through the
proximal end 12, distal end 32 and faces 18. FIG 2 has multiple round openings
28 in the proximal end 12, distal end 32 and at least one face 18. The at
least one
first opening 28 may be any size or shape desired so long as the openings 28
are a
size and shape that allow water to easily permeate the surfaces of the
structure 26
and enter the mostly hollow interior 20.
It alternate embodiments, the proximal end 12, the distal end 32 of the
structure 26 and at least one but not all of the faces 18 may not contain any
openings 28.
The aggregate replacement 10 may be formed as one single piece that runs
the entire length of the drain or it may be formed in smaller pieces that are
connected together. FIG. 2 illustrates an embodiment of an aggregate
replacement 10 which is composed of multiple units 36 which are coupled
together with connectors 34. These connectors 34 may be any type of connector
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that holds two aggregate replacement units 36 together. FIG. 11 is a close up
of
section A from FIG. 2. FIG. 11 shows a connector 34. In this illustration, the
connector is a pin 48 which slides into a receiver 50. The pin 48 is simply a
cylindrical extension from the structure 26 of the aggregate replacement 10.
The
receiver 50 is an open cylindrical extension of the structure 26 of the
aggregate
replacement 10. The pin and the receiver are close enough in size that by
inserting the pin 48 into the receiver 50, the units 36 are kept reasonably
securely
connected.
In alternate embodiments, the connector 34 may be flexible in order to
allow the units 36 to be connected in a circular, serpentine, or non-linear
arrangement.
In other embodiments, multiple units 36 may simply be placed adjacent
each other without the use of connectors. The pipe 14 would then be inserted
into
the units 36. The units 36 would be held adjacent to each other by the pipe
14.
FIGs 1-6 also show a second opening in a face 18 of the structure 26. The
second opening may comprise an insertion opening 22, a pipe retainer and a
pipe
receiver 30. The insertion opening 22 is created in one of the at least one
faces 18
of the structure 26. The insertion opening 22 allows a pipe 14 with
perforations
16 to be inserted in a radial direction into the aggregate replacement 10. The
insertion opening 22 should be large enough to allow a pipe 14 of a desired
size to
be inserted into the structure 26 of the aggregate replacement 10. The
insertion
opening 22 runs the entire length of one of the at least one faces 18 as shown
FIG.
4 which is a side view of the aggregate replacement 10.
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FIG. 5 is a view of the proximal 12 or distal end 32 of the structure 26.
The insertion opening 22 also extends through the proximal end 12 and the
distal
end 32 of the structure 26. In the proximal end 12 and the distal end 32 of
the
structure, the insertion opening 22 forms a pipe receiver 30.
The pipe receiver 30 is an opening formed in the proximal end 12 and the
distal end 32 of the structure 26. The pipe receiver 30 is slightly larger
than the
diameter of the pipe 14 and holds the pipe 14 when the drain is in place. The
pipe
receiver 30 has a mouth which connects to the insertion opening 22.
At the mouth 31 of the pipe receiver 30, may be a pipe retainer. The pipe
retainer may comprise at least one protrusion 24. The at least one protrusion
24
narrows the insertion opening 22 to less than the diameter of the pipe 14. The
at
least one protrusion 24 may be flexible, or the pipe 14 may be slightly
flexible in
order to allow the pipe 14 to be forced past the at least one protrusion 24and
through the mouth 31 of the pipe receiver 30. The at least one protrusion 24
will
then hold the pipe 14 within the pipe receiver 30.
The pipe retainer may also be simply a narrowing of the insertion opening
22 or in an alternate embodiment of the invention as shown in FIG. 8, the pipe
retainer may be tabs 25 manufactured at the mouth of a U shaped pipe receiver
30.
The tabs 25 along with the U shaped pipe receiver 30 act to hold the pipe 14
in
place within the aggregate replacement 10.
FIG. 7 illustrates an additional embodiment of the aggregate replacement
10, where the pipe retainer uses a pipe clip 52 placed on the pipe 14, prior
to the
pipe 14 being placed in the insertion opening 22. The pipe clip 52 is then
snapped
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into a pipe clip retainer 54 which is formed into the edge of the pipe
receiver 30.
The pipe 14 is then held firmly in place in the pipe receiver 30.
FIG. 9 illustrates yet another embodiment of the pipe retainer. In this
embodiment, the pipe 14 is held in the pipe receiver 30 by a strap 38 which is
coupled to the structure 26 of the aggregate replacement 10.
In FIG. 10, the pipe 14 is retained in place in the pipe receiver 30 by
gravity. The insertion opening 22 is located slightly above the center of the
pipe
receiver 30. The pipe 14 passes through the insertion opening 22 and drops
into
the pipe receiver 30. The pipe 14 then stays in place because it is lower than
the
insertion opening 22.
FIG. 10 also shows a pipe retainer using a stake 44 which is placed in a
stake retainer 46. The stake 44 is simply a metal or wooden stake or rigid rod
that
is placed inside of an opening called a stake retainer 46. The stake 44 is
then
usually driven into the ground under the aggregate replacement 10. The stake
44
serves two purposes. First, the stake 44 holds the aggregate replacement 10 in
place. Second, the stake 44 prevents the pipe 14 from leaving the pipe
receiver
30.
The stake retainer 46 may be a hole in the structure which is designed to
have the stake 44 placed in it, as shown in FIG. 10. The stake retainer 46 may
also be a strap which straps the stake 44 to the outside of the structure 26.
The
stake retainer 46 may further be a bolt or screw which bolts or screws the
stake 44
to the structure 26. The stake retainer 46 may be any device which couples the
stake 44 to the structure 26. Coupling the stake 44 to the structure 26 may
include
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receiving the stake 44 in an opening, physically attaching the stake 44 to the
structure 26 or the like.
Once the pipe 14 is inserted into the aggregate replacement 10, the
aggregate replacement 10 is either placed in a trench lined with filter fabric
or the
aggregate replacement 10 is wrapped in filter fabric. FIG. 6 illustrates the
aggregate replacement 10 wrapped in filter or landscape fabric 35. The filter
or
landscape fabric 35 is the same type of fabric used in traditional
arrangements of a
French drain. The fabric 35 is a water permeable material that prevents soil,
rocks, substrates or other things that might clog the perforations 16 in the
pipe 14
from entering the aggregate replacement 10.
In using the aggregate replacement 10 embodiments described above, a
trench is dug where the drain or distribution system is to be placed. The
trench is
lined with a water permeable fabric 35 such as landscape fabric, filter
fabric,
water permeable material or the like. The aggregate replacement 10 is then
assembled. If there is more than one unit 36, then the units 36 may be
connected
together through use of the connectors 34. The pipe 14 is then inserted
through the
insertion opening 22. The pipe 14 is forced past the protrusions 24 or tabs 25
if
protrusions 24 or tabs 25 are being used. The pipe 14 passes through the mouth
of
the pipe receiver 31 and into the pipe receiver 30. If protrusions 24 or tabs
25 are
not being used, then the pipe retainer is now engaged. The aggregate
replacement
along with the pipe 14 already inserted is then laid on top of the fabric 35
in
the trench. Typically, the aggregate replacement 10 will be placed in the
trench
with the insertion opening 22 positioned towards the bottom of the trench as
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shown in FIG. 6. This position places the pipe 14 towards the bottom of the
trench where more water can flow through the perforations 16 into the pipe 14.
The fabric 35 is then wrapped around the aggregate replacement 10 and the
trench
is filled in.
In alternate embodiments the aggregate replacement 10 may be wrapped in
the fabric 35 prior to being placed in the trench.
The pipe 14 could also be inserted into the aggregate replacement 10 after
the aggregate replacement 10 is in place in the trench.
When in use, water flows through the fabric 35 and through the openings
28 in the faces 18 of the aggregate replacement 10 structure 26. The water
then
flows through the perforations 16 into the pipe 14. The pipe 14 will typically
be
angled so that the water flows down the pipe 14 and to a desired location.
This process works in reverse for other water distribution systems such as
those used in residential septic systems.
An additional embodiment of the aggregate replacement is illustrated in
FIG. 12. In this embodiment, the aggregate replacement 40 is formed as
described above. A stake retainer 46 may also be formed in the structure 26 on
the side of the pipe receiver 30 away from the insertion opening 22. The stake
44
in this case will be used only to hold the aggregate replacement 40 in place.
In
alternate embodiments, a stake retainer 46 may be anything that couples the
stake
44 to the structure 26. The aggregate replacement 40 is put in position with
the
face 18 of the structure 26 opposite the insertion opening 22 acting as a
concrete
form. The face 18 of the structure 26 opposite the insertion opening 22 is
covered
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with a concrete barrier 35 such as filter fabric, landscape fabric, screen,
water
permeable material, solid plastic or the like. The concrete barrier 35 may or
may
not be water permeable. The concrete barrier 35 may be any material that
retains
the concrete in place while it is curing.
Concrete 42 may then be poured, with the concrete 42 coming up against
the water permeable barrier 35. Once the concrete 42 has dried, the pipe 14
may
be placed in the aggregate replacement 40 if it has not already been placed.
This arrangement allows moisture to be drained away from the concrete
42. The moisture travels through the material 35, passes through the aggregate
replacement 40 and enters the pipe 14 through the perforations 16. The
moisture
then travels down the pipe 14 and away from the concrete 42.
FIG. 13 illustrates another embodiment of an aggregate replacement 10.
In this figure, the aggregate replacement 10 is formed from multiple units 36.
Each unit 36 is formed from four faces 18. Each face 18 is illustrated as a
flat
rectangular member as described previously. Each face 18, however, may also be
curved or angled. The face 18 may also be formed as a rectangle, square, oval,
circle or the like. Each face 18 may be formed in any shape or size desired.
Each face 18 also has at least one opening 28 formed in it. Typically,
multiple openings 28 will be formed in the face 18. Each opening 28 passes
completely through the face 18 in order to allow fluid, such as water, to
travel
through the face 18 to the interior of the aggregate replacement 10. In
alternate
embodiments, the fluid may travel through the face 18 to the exterior of the
aggregate replacement 10.
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The openings 28 are illustrated as circles, however, they may be circles,
squares, triangles, rectangles, hexagons, pentagons, polygons and the like.
The
openings 28 may be formed in any shape desired that allows fluid to easily
pass
through the face 18 while leaving the face 18 strong enough to withstand the
weight and stresses of use.
In FIG. 13, the aggregate replacement 10 units 36 are formed using four
faces 18 coupled together at right angles. In alternate embodiments, however,
multiple faces 18 may be used. The angle that each face 18 is coupled to the
next
face 18 depends on the number of faces 18 being used.
Each face 18 is additionally coupled to a proximal end 12 and a distal end
32 in order to form a structure 26. The faces 18 and the proximal end 12 and
distal end 32 may be identical or similar and may be interchangeable in
certain
embodiments.
The proximal end 12 and the distal end 32 are illustrated as square or
rectangular members. The shape of the proximal end 12 and the distal end 32,
however, will depend on the number of faces 18 used in order to form the
structure 26. The proximal end 12 and the distal end 32 may be any size or
shape
desired. The proximal end 12 and the distal end 32 should, however, provide a
cover or substantially close the open ends of the structure 26 formed by the
faces
=
18.
The proximal end 12 and the distal end 32 of each unit 36 may be similar
to the at least one face 18 discussed above. The proximal end 12 and distal
end 32
may each have at least one opening 28 in its surface in order to allow fluid
to
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easily pass to through the surface of the aggregate replacement 10. The fluid
may
pass to the inside of the aggregate replacement 10 or to the outside,
depending on
the desired use of the aggregate replacement 10.
Certain configurations of aggregate replacement 10 units 36 may simply
replace large portions of aggregate. These units 36 may be referred to as pipe-
less
units 52. Pipe-less units 52, as illustrated, have multiple openings 28 on all
surfaces. They do not, however, have an opening that would retain or replace a
pipe such as a pipe used in a typical drainage field.
Pipe-less units 52 may be any size or shape desired.
Pipe-less units 52 may be coupled to units 36 containing pipe, in order to
replace larger areas of aggregate. Multiple pipe-less units 52 may be coupled
to
units 36 with pipe in order to create large drain fields.
If desired, pipe-less units 52 may also be used in areas where it is desired
to drain fluid, but not divert it. Diverting fluid from a given area typically
requires some sort of pipe or conduit to direct the fluid. However, if the
user
simply wants to help a field or yard drain better, pipe-less units 52 may be
placed
under the surface of the soil in order to give the fluid an area to drain to.
Multiple pipe-less units 52 may also be coupled together.
In alternate embodiments, pipe-less units 52 may be formed from multiple
panels, faces or ends which may be coupled together to form the desired shape
and size. The multiple panels, faces or ends could also be cut to the desired
size
in order to allow a user to create custom size pipe-less units 52 for their
various
applications. Similar configurations could be used for units 36 containing
pipe.
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As illustrated in FIG. 13, other units 36 may contain a pipe 14. These
units 36 are similar to those discussed above with respect to previous
figures,
except that in the units 36 illustrated in this figure, the pipes 14 are
formed as an
integral part of the aggregate replacement 10 units 36. The pipes 14 may also
be
coupled to the aggregate replacement 10 units 36 or may simply be placed in
the
aggregate replacement 10 units 36, rather than formed as an integral part of
the
aggregate replacement 10 units 36.
The pipes 14 used in the aggregate replacement 10 will typically be a
plastic pipe with perforations 16 formed in it. These perforations 16 allow
fluid
from the outside of the pipe 14 to seep into the pipe 14. The perforations 16
may
be circular holes, linear cuts or the like formed in the pipe 14. The pipe 14
then
diverts the fluid such as water to a more desirable location.
In alternate uses, such as septic drainage fields, the perforations 16 in the
pipe 14 may allow the fluid inside the pipe 14 to seep out.
The pipe 14 may or may not be corrugated. The pipe 14 may be any size,
shape or length desired. The pipe 14 may have a circular, square, rectangular
or
triangular cross-section or the like. The pipe 14 may be rigid or flexible
plastic.
The pipe 14 may also be formed from any material desired, such as plastic,
fiberglass, iron, copper, steel, aluminum or the like.
The pipes 14 are in communication or coupled to a pipe opening 51
formed in the proximal end 12 and the distal end 32 of each unit 36. The pipe
opening 51 is an opening in the proximal end 12 and the distal end 32 of the
units
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36 that is approximately the same size as the pipe 14 and which secures the
pipe
14 in place,
Additional embodiments of aggregate replacement 10 units 36 may
include units that act as 90 degree turns, T's, 45 degree turns, and
discharges. A
90 degree turn unit 50 is illustrated in the figure. The 90 degree turn unit
50 has a
pipe opening 51 in the proximal end 12 of the unit. It also has a pipe opening
51
in one of the faces 18 of the unit 50. This causes the pipe 14 in the 90
degree turn
unit 50 to turn 90 degrees within the aggregate replacement 10. This type of
unit
50 may be useful in draining water from around concrete foundations and the
like.
A T unit 36 in the aggregate replacement 10 would include a pipe opening
51 in the proximal end 12 of the unit 36. Additional pipe openings 51 would be
located in two parallel faces 18 located opposite each other in the unit 36.
The
pipe 14 would start at the proximal end 12 of the aggregate replacement unit
36.
The pipe 14 would then split into two pipes 14 with one pipe 14 coupled to
each
of the pipe openings 51 formed in the faces 18 of the unit 36. In use, fluid
would
either flow into the unit 36 as one stream and leave the unit 36 as two, or
else two
streams of fluid would be combined into one stream as it leaves the unit 36.
Other pipe 14 configurations or fittings could be formed in the aggregate
replacement 10 units 36 similarly to those described above.
Multiple aggregate replacement 10 units 36 may be coupled together using
connectors 34. Connectors 34 may be any type of coupling device or method that
allows multiple units 36 to be hooked together. This may include units 36
being
coupled with male and female connectors or units being coupled with connectors
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34 such as those described in conjunction with FIG. 11. Connectors 34 may be
permanent or removable. Removable connectors 34 may be desirable in order to
allow damaged aggregate replacement 10 units 36 to be removed and replaced.
Units 36 may be coupled together end to end, such as where the proximal
end 12 of one unit 36 is coupled to the distal end 32 of another unit 36, or
the
units 36 may be coupled or connected side to side or stacked.
In embodiments where a pipe 14 is formed as an integral part of the
aggregate replacement 10, it may be desirable to couple the separate pipe 14
sections together as well as the units 36.
FIG. 14 illustrates an alternate embodiment of FIG. 9. In FIG. 14 the strap
38 covers the entire mouth of the pipe retainer 31. The strap 38 may also
cover
the entire face 18 of the aggregate replacement 10 in which the mouth of the
pipe
retainer 31 is located. The strap 38 may be any size, shape, thickness or
formed
from any material desired. The strap 38 may be corrugated or flat. The strap
38
may also be bent, curved, angled or the like. The strap 38 may be formed from
rigid or flexible material.
FIG. 15 illustrates an additional embodiment of an aggregate replacement
10. In this embodiment, the aggregate replacement 10 is formed in two sections
56. Each section 56 has three faces 18 and a proximal end 12 and a distal 32
end.
The proximal end 12 and distal end 32 of the aggregate replacement 10 include
or
comprise a cutout 58. The cutout 58, as shown in the figures, is a half circle
opening along the edge of the proximal end 12 and distal end 32 configured to
receive a pipe. The cutout 58 may also be any shape desired. The cutout 58 may
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be horseshoe shaped, square, rectangular, triangular or the like, provided the
cutout 58 can accommodate or receive a pipe.
The two sections 56 of the aggregate replacement 10 are coupled together
on one side by at least one hinge 54 or other rotatable coupler. Hinge 54 may
be
anything that rotatable couples the two sections 56 together on one side.
Examples of hinges 54 may include hinges, flexible members, tethers, and the
like. The other side of the two sections 56 are not connected. Two hinges 54
are
illustrated in the figure, however, depending on the size of the aggregate
replacement 10, more or fewer hinges 54 may be required.
In order to use the embodiment illustrated in FIG. 15, the two sections 56
are rotated into an open position. A pipe is then placed in the cutout 58 of
the
lower section 56 of the aggregate replacement 10. Once the pipe is in place,
the
top section 56 of the aggregate replacement 10 is rotatably lowered into a
closed
position.
In alternate variations on this embodiment, a latch may be used to keep the
two sections 56 of aggregate replacement 10 in a closed position.
Additional embodiments may have multiple sections 56 rather than just
two. Latches and hinges 58 could be used to secure the multiple sections 56
together.
FIG. 16 illustrates an embodiment of an aggregate replacement 10 where
the two sections 56 are completely separate. Once the pipe 14 is placed in
position in the cutout 58 in the lower section 56 of the aggregate replacement
10,
the upper section 56 of the aggregate replacement 10 is put in place.
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The upper section 56 of the aggregate replacement 10 may have pins 64
which are inserted into receivers 66 on the lower section 56 of the aggregate
replacement 10 in order to secure or couple the two sections 56 together. The
pins
64 slide into receivers 66. The pins 64 are simply cylindrical extensions from
the
structure 26 of the aggregate replacement 10. The receivers 66 are open
cylindrical indentations into the structure 26 of the aggregate replacement
10.
The pins 64 and the receivers 66 are close enough in size that by inserting
the pin
64 into the receiver 66, the sections 56 are kept reasonably securely
connected.
Other coupling or connecting configurations may also be used to secure
the two sections 56 together. Other connectors may include glue, epoxy,
screws,
bolts, tabs, latches or the like.
FIG. 17 illustrates an embodiment of an aggregate replacement 10 which
has two sections 56 with half pipes 60 formed integrally in each of the
sections
56. The half pipe 60 may alternatively be coupled to each of the sections 56.
Each half pipe 60 also has perforations 62 in order to allow fluid to move in
and
out of the pipe 60. The two sections 56 of the aggregate replacement 10 are
snapped together using pins 64 and receivers 66 as described in the previous
figure. The pins 64 slide into receivers 66. The pins 64 are cylindrical
extensions
from the structure 26 of the aggregate replacement 10. The receivers 66 are
cylindrical openings in the structure 26 of the aggregate replacement 10. The
pins
64 and the receivers 66 are close enough in size that by inserting the pin 64
into
the receiver 66, the two sections 56 of the aggregate replacement 10 are kept
reasonably securely connected.
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The two sections 56 may also be coupled together using bolts, screws,
glue, epoxy, latches and the like.
When the two sections 56 are coupled together, the two half pipes 60 meet
and form a channel or pipe through which water or other fluid may flow.
In alternate configurations of this embodiment, the two half pipes 60 may
have connectors, couplers or latches which secure the two half pipes 60
together.
FIG. 18 illustrates a collapsible embodiment of an aggregate replacement
10. In this configuration, each face 18 of the aggregate replacement 10 is
hingedly coupled to at least one other face 18 of the aggregate replacement
10.
The two faces 18 on the ends have connectors 82 coupled to their outside
edges. These connectors 82 act to hook the two outside faces 18 together in
order
to form a rectangular prism from all of the faces 18.
In alternate embodiments, one face 18 may be bent and coupled together
in order to form a cylindrical aggregate replacement 10. Three faces 18 may be
coupled together to form a triangular prism. Different numbers of faces 18 may
be used in order to form different shapes of aggregate replacement 10.
Two of the faces 18 are also hingedly coupled to a partial proximal end or
distal end 84. The partial ends 84 may be formed as a square with a half
circle
cutout 86 formed in the edge. The partial ends 84 may also be formed in any
other shape desired. The shape of the partial ends 84 will likely depend on
the
shape created by the faces 18 when they are coupled together.
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The partial ends 84 may have at least one connector 82 coupled to at least
one of their edges. The at least one connector 82 may serve to secure the
partial
ends 84 in place when the aggregate replacement 10 is fully assembled.
In order to assemble the collapsible aggregate replacement 10 illustrated,
the faces 18 may be coupled together in a rectangular prism using the
connectors
82 attached to the two end faces 18. A pipe may then be inserted into the
aggregate replacement 10. The partial ends 84 are then rotated and secured
into
place using the connectors 82 coupled to them.
The partial ends 84 secure the pipe in place in the aggregate replacement
10.
The collapsible aggregate replacement 10 may also be assembled by
placing the pipe across at least one face 18 of the aggregate replacement 10.
The
aggregate replacement 10 is then assembled around the pipe.
FIG. 19 illustrates a configuration of an aggregate replacement 70 for use
with a concrete form. In this configuration, a permanent concrete form 72 such
as
a form that acts as a drain is put in place. The aggregate replacement 70 is
then
placed adjacent the concrete form 72. The aggregate replacement 70 acts to
replace the aggregate, such as loose gravel, which is placed around permanent
concrete forms 72 in order to help the concrete form 72 to drain any water
near
the concrete 42.
The aggregate replacement 70 in this configuration also has a cutout 58
which intersects the edge of the proximal end 12 and the distal end 32 and
which
would allow a pipe to be placed next to the permanent concrete form 72 in
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CA 02892067 2015-05-20
to aid with the drainage of water. The cutout 58 or open area may run the
entire
length of the aggregate replacement 70 along the area where the pipe would be
placed, so that the pipe abuts the concrete form 72 directly.
In alternate embodiments, water permeable material may be placed
between the aggregate replacement 70 and the concrete form 72. In these
configurations, the pipe would abut the water permeable material which would
abut the concrete form 72.
In other embodiments, a small section of aggregate replacement 70 may
separate the pipe from the concrete form 72 or water permeable material.
Additional embodiments, may not include cutouts 58 for pipe.
FIG. 20 is an additional embodiment of an aggregate replacement 70 for
use as a concrete form. In this embodiment, the aggregate replacement 70 is
the
concrete form. The aggregate replacement 70 is placed into position along the
location where the concrete 42 is to be poured. A water permeable material 74
is
placed over the surface of the aggregate replacement 70 and then the concrete
42
is poured. The water permeable material 74 prevents the concrete from entering
the aggregate replacement 70 while allowing any moisture near the concrete to
travel out into the aggregate replacement 70.
The aggregate replacement 70 illustrated in this figure is also configured
with a cutout 58 for receiving a pipe. The pipe may be placed before or after
the
concrete 42 is poured. Typically, however, the pipe will be placed prior to
the
concrete 42 being poured because it would be too difficult to place the pipe
after.
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The cutout 58 is formed in the edge of the proximal end 12 and the distal
end 32 of the aggregate replacement 70. The cutout 58 also runs along the
entire
length of the aggregate replacement 70 so that the pipe abuts the water
permeable
material directly. The pipe acts to collect moisture around the concrete. The
pipe
then channels the moisture away from the concrete.
In alternate embodiments, a. small section of aggregate replacement 70
may separate the pipe from the water permeable material.
Additional embodiments may not include cutouts 58 for a pipe.
In configurations where the aggregate replacement 70 is used as a concrete
form or with a concrete form, it may be necessary to secure the aggregate
replacement 70 in position by driving a wooden or metal stake through the
aggregate replacement 70 and into the ground.
Accordingly, for the exemplary purposes of this disclosure, the
components defining any embodiment of the invention may be formed as one
piece if it is possible for the components to still serve their function. The
components may also be composed of any of many different types of materials or
combinations thereof that can readily be formed into shaped objects provided
that
the components selected are consistent with the intended mechanical operation
of
the invention. For example, the components may be formed of rubbers (synthetic
and/or natural), glasses, composites such as fiberglass, carbon-fiber and/or
other
like materials, polymers such as plastic, polycarbonate, PVC plastic, ABS
plastic,
polystyrene, polypropylene, acrylic, nylon, phenolic, any combination thereof,
and/or other like materials, metals, such as zinc, magnesium, titanium,
copper,
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iron, steel, stainless steel, any combination thereof, and/or other like
materials,
alloys, such as aluminum, and/or other like materials, any other suitable
material,
and/or any combination thereof.
The embodiments and examples set forth herein were presented in order to
best explain the present invention and its practical applications and to
thereby
enable those of ordinary skill in the art to make and use the invention.
However,
those of ordinary skill in the art will recognize that the foregoing
description and
examples have been presented for the purposes of illustration and example
only.
The description as set forth is not intended to be exhaustive or to limit the
invention to the precise form disclosed. Many modifications and variations are
=
possible in light of the teachings above without departing from the spirit and
scope of the forthcoming claims. Accordingly, any components of the present
invention indicated in the drawings or herein are given as an example of
possible
components and not as a limitation.
28
