Water storage chamber connection system

Abstract

A method of manufacturing a water detention chamber by providing a polymer melt, injecting a CO2 blowing agent into the polymer melt, and injecting the polymer melt and CO2 blowing agent blend into a mold cavity. The mold cavity defines an arch-shaped corrugated chamber having upstanding ribs and a flange having an upper surface and a lower surface. The flange has one or more protrusions, preferably elongated members, at the first end of the chamber. The flange also has one or more mating apertures or cavities at the opposite end from the protrusions.

Claims

1. A method of manufacturing a water detention chamber, comprising steps of: providing a polymer melt; injecting a CO2 blowing agent into the polymer melt; injecting the polymer melt and CO2 blowing agent blend into a mold cavity, the mold cavity defining: an arch-shaped corrugated chamber having corrugations distributed along a length of the chamber extending transverse to a longitudinal axis of the chamber, the chamber having a top portion and two side portions, with a base at a lower end of each side portion, the chamber length defined by a first end and a second end; said first end comprising an upstanding starting corrugation and said second end comprising an upstanding end corrugation, wherein the upstanding starting corrugation is designed to mate with and nest within an end corrugation on an identical second water detention chamber such that the water detention chamber and the second water detention chamber are non-rotatable relative to each other when connected in an end-to-end fashion; and a flange provided at the base of each lower end of each side portion, said flanges extending substantially perpendicular to the lower end of each side portion and having an upper surface and a lower surface; wherein the flanges are provided with one or more protrusions extending away from the flange at the first end; wherein the flanges are provided with one or more mating apertures or cavities having an opening at the second end; and the protrusions fit into and engage with mating apertures or cavities on an identical second chamber such that the two side portions of the chamber are prevented from moving laterally away from two side portions of the second chamber.

2. The method of claim 1, wherein the one or more protrusions extend downwardly away from the lower surface of said flange at the first end.

3. The method of claim 1, wherein said one or more protrusions comprise one or more elongated members and said one or more apertures or cavities comprise one or more elongated slots.

4. The method of claim 3, wherein the one or more elongated members and the one or more elongated slots extend in parallel with the longitudinal axis of said chamber.

5. The method of claim 1, wherein one of the protrusions is angled relative to a longitudinal length of its respective flange.

6. The method of claim 5, wherein one of said apertures or cavities is angled relative to a longitudinal length of its respective flange and is adapted to receive an angled protrusion.

7. The method of claim 1, wherein the one or more protrusions are provided with an undercut.

8. A method of manufacturing a water detention chamber, comprising steps of: providing a polymer melt; injecting a CO2 blowing agent into the polymer melt; injecting the polymer melt and CO2 blowing agent blend into a mold cavity, the mold cavity defining: an arch-shaped corrugated chamber having corrugations distributed along a length of the chamber extending transverse to a longitudinal axis of the chamber, the chamber having a top portion and two side portions, with a base at a lower end of each side portion, the chamber length defined by a first end and a second end; said first end comprising an upstanding starting corrugation and said second end comprising an upstanding end corrugation, wherein the upstanding starting corrugation is designed to mate with and nest within an end corrugation on an identical second water detention chamber such that the water detention chamber and the second water detention chamber are non-rotatable relative to each other when connected in an end-to-end fashion; and a flange provided at the base of each lower end of each side portion, said flanges extending substantially perpendicular to the lower end of each side portion and having an upper surface and a lower surface; wherein the flanges are provided with one or more elongated members extending downwardly away from the flange at the first end; and wherein the flanges are provided with one or more mating elongated slots having an opening at the second end, and the one or more elongated members on said chamber fit into and engage with one or more mating elongated slots on an identical second chamber such that one of the side portions of the chamber is prevented from moving laterally away from a side portion of the second chamber.

9. The method of claim 8, wherein the one or more elongated members and the one or more elongated slots extend in parallel with the longitudinal axis of said chamber.

10. The method of claim 8, wherein one of the elongated members is angled relative to a longitudinal length of its respective flange.

11. The method of claim 10, wherein one of said elongated members slots is angled relative to a longitudinal length of its respective flange and is adapted to receive an angled elongated member.

12. The method of claim 8, wherein the one or more elongated members are provided with an undercut.

13. A method of manufacturing a water detention chamber, comprising steps of: providing a polymer melt; injecting a CO2 blowing agent into the polymer melt; injecting the polymer melt and CO2 blowing agent blend into a mold cavity, the mold cavity defining: an arch-shaped corrugated chamber having corrugations distributed along a length of the chamber extending transverse to a longitudinal axis of the chamber, the chamber having a top portion and two side portions, with a base at a lower end of each side portion, the chamber length defined by a first end and a second end; said first end comprising an upstanding starting corrugation and said second end comprising an upstanding end corrugation, wherein the upstanding starting corrugation is designed to mate with and nest within an end corrugation on an identical second water detention chamber such that the water detention chamber and the second water detention chamber are non-rotatable relative to each other when connected in an end-to-end fashion; and a flange provided at the base of each lower end of each side portion, said flanges extending substantially perpendicular to the lower end of each side portion and having an upper surface and a lower surface; wherein at least one of the flanges is provided with a protrusion extending away from the flange at the first end; wherein at least one of the flanges is provided with a mating aperture or cavity having an opening at the second end; and wherein the protrusion fits into and engages with a mating aperture or cavity on an identical second chamber such that one of the side portions of the chamber is prevented from moving laterally away from a side portion of the second chamber.

14. The method of claim 13, wherein the protrusion extends downwardly away from the lower surface of said flange at the first end.

15. The method of claim 13, wherein the protrusion comprises an elongated member and the aperture or cavity comprises an elongated slot.

16. The method of claim 15, wherein the elongated member and the elongated slot extend in parallel with the longitudinal axis of said chamber.

17. The method of claim 13, wherein the protrusion is angled relative to a longitudinal length of its respective flange.

18. The method of claim 17, wherein the aperture or cavity is angled relative to a longitudinal length of its respective flange and is adapted to receive the angled protrusion.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of a storm water chamber in according to the invention.

(2) FIG. 1A is an enlarged perspective view of the first end of the chamber according to FIG. 1.

(3) FIG. 1B is an enlarged perspective view of the second end of the chamber according to FIG. 1.

(4) FIG. 2 is an elevation view of the second end of the chamber according to FIG. 1.

(5) FIG. 3 is an elevation view of the first end of the water chamber according to FIG. 1.

(6) FIG. 3A is an enlarged view according to FIG. 3.

(7) FIG. 3B is an alternative construction for the protrusion and aperture or cavity according to FIG. 3.

(8) FIG. 3C is an alternative construction for the protrusion and aperture or cavity according to FIG. 3.

(9) FIG. 4 is a left side elevational view of the storm water chamber according to FIG. 1.

(10) FIG. 4A is an enlarged perspective view of the first end of the chamber according to FIG. 4.

(11) FIG. 4B is an enlarged perspective view of the second end of the chamber according to FIG. 4.

(12) FIG. 5 is a right side elevational view of the storm water chamber according to FIG. 1.

(13) FIG. 6 is a top plan view of the storm water chamber according to FIG. 1.

(14) FIG. 7 is a bottom plan view of the storm water chamber according to FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

(15) Referring now to the drawings, wherein like reference numerals designate corresponding structure throughout the views.

(16) FIG. 1 is an illustration of a chamber 100 generally comprising an arch-shaped body portion 102 that includes a plurality of upstanding corrugations 104. The body portion 12 is provided with an open bottom such that side walls 106 are configured to rest on the surface of the bed of materials. Chamber 100 may be provided with a starting corrugation 108, which is designed to mate with an end corrugation 110 when chambers are connected in an end-to-end fashion.

(17) A longitudinal length (L) 150 (FIGS. 4 & 6) of the chamber 100 is defined by a first end 112 and a second end 114. The upstanding corrugations 104 follow the arched shape of the chamber and terminate at a lower end 116 of side walls 106 (FIG. 1). A flange 118 extends at the lower end 116 of side walls 106 from the second end 114 and extends toward the first end 112. The flange 118 is provided extending generally perpendicular from the lower end 116 of side walls 106 (FIGS. 2-3A).

(18) Also shown in FIG. 1 is a cut-out line 152 provided on a lateral side of the chamber 100 (also shown in FIGS. 4 & 5). It is contemplated that the section defined by the cut-out line 152 can be removed and a connection piece can be laterally inserted into the side of chamber 100, which can be used to laterally connect rows of chambers 100 to create a storm water detention system as is known in the art.

(19) FIGS. 1A and 4A are enlarged views of one side of the first end 112 of the chamber 100. In particular, the end portion of flange 118 is illustrated. Flange 118 is provided with an undercut 120 positioned on a bottom surface 122 of flange 118. A protrusion 124 is positioned on and underside 126 of undercut 120. As can be seen in the Figures, an upper surface 128 is provided offset from an upper surface 130 of flange 118. When installed in an end-to-end fashion, the undercut 120 provides an offset to the flange so that the underside 126 of undercut 120 will sit over top of upper surface 130 of flange 118 of an adjacent chamber allowing the bottom surface 122 of flange 118 to sit flush on a surface.

(20) FIGS. 1B and 4B are enlarged views of one side of the second end 114 of the chamber 100 corresponding to an opposite end of flange 118 from FIGS. 1A and 4A respectively. As can be seen, an aperture (an opening extending through the flange) or a cavity (and opening in the flange which is closed at its bottom) 132 is provided extending through flange 118. The aperture or cavity 132 is provided as an elongated slot but could comprise virtually any configuration as desired. The aperture or cavity 132 is designed to receive protrusion 124 of an adjoining chamber 100. A raised portion 134 is provided along an outer edge of flange 118. However, it can be seen in FIG. 1B that the raised portion 134 terminates a distance short of second end 114. This allows an adjoining chamber to fit over the top of the upper surface 130 of flange 118. When referencing FIGS. 1A, 1B, 4A and 4B it can be seen that the undercut 120 would fit over top of the second end 114 of flange 118 such that the protrusion 124 would be received into aperture or cavity 132. In the examples shown in FIGS. 3A and 4A, the protrusion 124 comprises an elongated linear member that would secure into aperture (slot) or cavity 132.

(21) In practice, the protrusion 124 could friction fit with the aperture (slot) or cavity 132. Alternatively, protrusion 124 could be provided with an undercut 125 as seen in FIG. 3C, that once pressed through aperture (slot) or cavity 132, could engage with an underside 133 of the aperture (slot) or cavity 132 to lock the protrusion 124 into aperture (slot) or cavity 132. Still further, the protrusion 124 could be provided as an angled member and the aperture (slot) or cavity 132 could be angled to receive the protrusion 124 (FIG. 3B). In this configuration, the angled protrusion 124 and matching aperture (slot) or cavity 132 could be provided on one side of the chamber, and the second side of the chamber could have a more vertically oriented protrusion 124 and aperture (slot) or cavity 132, and the first side of the chamber could be connected first and then the second side could be connected second.

(22) In the preferred embodiment, one or more protrusions extend downwardly from the lower surface of the flange at the first end of a chamber, and one or more apertures or cavities having upwardly facing openings on the upper surface of the flange at the second end of the chamber. However, it is possible to construct chambers and systems in accordance with the invention with reversed positioning thereof, e.g., one or more protrusions extend upwardly from the upper surface of the flange at the first end of a chamber, and one or more apertures or cavities having downwardly facing openings on the lower surface of the flange at the second end of the chamber.

(23) In practice, to connect two chambers 100 in an end-to-end configuration, a user would need to place the starting corrugation 108 of a first chamber over the end corrugation 110 of a second chamber. To secure the first chamber to the second chamber, the user could simply step on (apply pressure to) the upper surface 128 of flange 118, which would function to press the protrusion downward and through cavity (slot) 132. The undercut 120 of the first chamber would allow the two chambers to sit substantially flush on the surface.

(24) FIG. 2 is an end view of second end 114 of chamber 100 while FIG. 3 is an end view of first end 112 of chamber 100. FIG. 3A shows an enlarged view of first end 112 including a stacking lug 140 that extends from the lower end 116 of side walls 106 to the upper surface 130 of flange 118. The stacking lug 140 is provided integrally formed with chamber 100.

(25) An upper edge of the stacking lug 140 is divided into a first surface 142 and a second surface 144, which can also be seen in FIG. 1A. The first surface 142 extends from an outer surface of corrugation 104 and extends outward from the corrugation 104. The first surface 142 is provided substantially parallel with the flange 118 and is positioned a distance (d1) 146 from the flange 118. The second surface 144 is also provided substantially parallel with the flange 118 and is positioned a distance (d2) 148 from the flange 118. It can be seen in FIG. 3A that distance (d2) 148 is larger than distance (d1) 146.

(26) In function, the stacking lug 140 is provided as a plurality of stacking lugs, in this example, five along each side of a length of the chamber 100.

(27) As previously described, during storage and transit it is common that chambers 100 are stacked one on top of the other to conserve space and allow for more efficient storage and shipping. However, the chambers 100 can become tightly stuck to each other as the corrugations 104 become nested to each other over time. The stacking lugs 140 prevent the chambers 100 from becoming stuck because the underside 122 of flange 118 of the upper chamber will rest on the top of the stacking lug 140 of the lower chamber 100. This configuration allows the chambers 100 to be stacked one on top of the other, but still allows for the chambers 100 to easily be unstacked from each other when needed.

(28) This configuration is further illustrated in FIG. 7, which shows a bottom view of chamber 100. As can be seen with reference to the drawing, indentions 150 are located in the bottom surface 122 of flange 118. These indentions 150 correspond to the second surfaces 144 such that, when a first chamber 100 is stacked over top of a second chamber 100 the second surfaces 144 the second chamber engage with the indentions 150 of the first chamber. This functions to prevent any lateral shifting (sideways or longitudinal) of the chambers 100 relative to each other during transit as the weight of many chambers stacked one on top of the other can be considerable. The indentations 150 function to fix the stacked chambers to each other such that undue shifting of the load during transit does not occur.

(29) Chamber 100 is most preferably a cellular plastic material formed through a blow molding process. A method of manufacturing a chamber 100, comprises the steps of: providing a polymer melt which can be a single polymer or a copolymer blend, then injecting the polymer melt and CO2 blowing agent blend into a mold cavity. The mold cavity defines the plastic arch-shaped corrugated chamber 100 having a plurality of corrugations 104 distributed along a length of the chamber 100, and forming a flange 118 as previously described.

(30) In one system configuration, chamber 100 has an axial length of 1.25 meters, a width of 1.981 meters, and a height of 1.219 meters, and provides a storage volume for collected water of 1.84 m.sup.3/unit.

(31) Other objects of the present invention are achieved by providing the mold cavity defining an arch-shaped corrugated chamber having a top portion and two side portions, with a base at a lower end of each side portion, the chamber length defined by a first end and a second end, the mold cavity further defining a flange provided at the base of each lower end of each side portion, said flange extending substantially perpendicular to the lower end of each side portion and having an upper surface and a lower surface with the lower surface of said flange at the first end including a protrusion and the upper surface of said flange at the second end including a cavity formed therein.

(32) Although the invention has been described with reference to a particular arrangement of parts, features and the like, these are not intended to exhaust all possible arrangements or features, and indeed many modifications and variations will be ascertainable to those of skill in the art.