UNDERGROUND UTILITY ENCLOSURE SYSTEM AND METHOD

Abstract

An underground utility enclosure system and method for installation over a junction point for underground utility conduit, cables, wires, and pipes, providing lighter less-expensive shatterproof enclosures, which can be more quickly manufactured and transported, more easily stored and handled on-site, and more easily installed with less heavy equipment and fewer personnel. A corrugated enclosure body made of a shatterproof polymer material has annular correlation, and allows for slight deformation to accommodate underground obstacles and allows on-site cutting and modification with available hand tools to adapt to different installation needs, allowing the purchase and storage of a smaller number of different sizes and configurations of enclosures to address a greater number of installation circumstances. At least three anchor loops provide for efficient handing and installation. A fitted lid available in various materials provides appropriate strength at an appropriate cost for different installation needs. The underground utility enclosure can optionally be provided as a kit.

Claims

1. An underground utility enclosure comprising: (i) a corrugated enclosure body having annular corrugation, inside and outside surfaces, and a vertical top to bottom axial orientation in use; (ii) at least three anchor loops arrayed around and protruding from the outside surface of said corrugated enclosure body; and (iii) a fitted lid adapted to cover the top of said corrugated enclosure body.

2. The underground utility enclosure of claim 1, where said corrugated enclosure body further comprises a polymer material.

3. The underground utility enclosure of claim 1, where said corrugated enclosure body further comprises a thermoplastic polymer material.

4. The underground utility enclosure of claim 1, where said corrugated enclosure body further comprises an HDPE material.

5. The underground utility enclosure of claim 1, where said anchor loops are further arrayed around said corrugated enclosure body equidistant and in a 120-degree angular relationship.

6. The underground utility enclosure of claim 1, where said corrugated enclosure body is further reinforced at the top portion to provide additional support for said fitted lid.

7. The underground utility enclosure of claim 1, where said fitted lid further comprises a metal material.

8. The underground utility enclosure of claim 1, further comprising a protective collar.

9. The underground utility enclosure of claim 1, further comprising a casting-form base and a casting-form tube adapted to the forming of a cast bumper.

10. An underground utility enclosure method comprising: (i) providing an excavated hole at a junction point; (ii) providing an underground utility enclosure comprising: (a) a corrugated enclosure body having annular corrugation, inside and outside surfaces, and a vertical top to bottom axial orientation in use; (b) at least three anchor loops arrayed around and protruding from the outside surface of said corrugated enclosure body; and (c) a fitted lid adapted to cover the top of said corrugated enclosure body; (iii) lowering said underground utility enclosure into said excavated hole using said anchor loops; and (iv) backfilling said excavated hole.

11. The underground utility enclosure method of claim 10, further comprising providing a protective collar and installing said protective collar.

12. The underground utility enclosure method of claim 10, further comprising providing a casting-form base and casting-form tube, placing said casting-form base and casting-form tube upon said underground utility enclosure, and pouring concrete into said casting-form tube.

13. The underground utility enclosure method of claim 10, further comprising deforming said corrugated enclosure body to adapt to obstructions.

14. The underground utility enclosure method of claim 10, further comprising deforming said corrugated enclosure body to adapt the top of said corrugated enclosure body to correct misalignment of the bottom of said corrugated enclosure body.

15. The underground utility enclosure method of claim 10, further comprising deforming said corrugated enclosure body to adapt the top of said corrugated enclosure body to a sloping grade.

16. The underground utility enclosure method of claim 10, further comprising cutting said corrugated enclosure body to adapt to obstructions.

17. The underground utility enclosure method of claim 10, further comprising cutting said corrugated enclosure body to provide additional access to the interior of said corrugated enclosure body.

18. An underground utility enclosure kit comprising a corrugated enclosure body, at least three anchor loops, and a fitted lid.

19. The underground utility enclosure kit of claim 18, further comprising a protective collar.

20. The underground utility enclosure kit of claim 18, further comprising a casting-form base and a casting-form tube.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Reference will now be made to the drawings, wherein like parts are designated by like numerals, and wherein:

[0018] FIG. 1 is a perspective view of the underground utility enclosure of the invention in different sizes;

[0019] FIG. 2 is a top view of the underground utility enclosure of the invention;

[0020] FIG. 3 is a schematic view of the underground utility enclosure of the invention in use during installation;

[0021] FIG. 4 is a section side view of the underground utility enclosure of the invention in use after installation;

[0022] FIG. 5 is a side view of units of the underground utility enclosure of the invention showing deformations to accommodate irregularities in installation;

[0023] FIG. 6 is a perspective view of a unit of the underground utility enclosure of the invention showing deformation to accommodate an obstruction;

[0024] FIG. 7 is a perspective view of units of the underground utility enclosure of the invention showing removal of portions of the corrugated enclosure body to accommodate obstructions and provide access at higher levels than the bottom;

[0025] FIG. 8 is a perspective sequential view of an embodiment of the underground utility enclosure of the invention with a protective collar installed;

[0026] FIG. 9 is a perspective sequential view of an embodiment of the underground utility enclosure of the invention with a poured concrete bumper installed; and

[0027] FIG. 10 is a perspective view of three embodiments of the underground utility enclosure of the invention provided in kit form.

DETAILED DESCRIPTION OF THE INVENTION

[0028] Referring to FIG. 1 and FIG. 2, embodiments of the underground utility enclosure 1 of the invention are shown. The underground utility enclosure 1 can be provided in different diameter sizes and different vertical heights appropriate for different installation requirements and conditions. Because the corrugated enclosure bodies 2 of the enclosures are made from an inexpensive thermoplastic material, as treated in detail below, which can be easily cut or modified on-site during installation, a unit of the enclosure having more vertical height than needed can be easily cut down, or an opening can be cut into the side, to allow for the use of a unit already at the job site instead of having to order and wait for delivery of a differently configured unit. Because the fitted lids 4 can be made of different materials and with different bracing appropriate for different anticipated loads, as treated in detail below, and because all fitted lids 4 of a given size will fit on the same corrugated enclosure body 2 of that size, the number of different corrugated enclosure bodies 2 to be manufactured, transported, stored, and kept on-site is reduced.

[0029] The underground utility enclosure 1 provides a corrugated enclosure body 2, at least three anchor loops 3, and a fitted lid 4.

[0030] The corrugated enclosure body 2 is made from a thermoplastic polymer material having the required strength and elasticity to be molded into a corrugated tube and retain its shape while allowing for the slight deformations of the corrugated enclosure body 2 which are treated below. The thermoplastic polymer material should not have any tendency to break or shatter when dropped or struck because such dropping and striking will be a common occurrence during storage, handling, transport, installation, and use of the underground utility enclosure 1. A preferred embodiment of the corrugated enclosure body 2 is made from high-density polyethylene (HDPE) which has the needed properties, is resistant to solvents, and is available as recycled material. Other polyethylenes such as medium-density polyethylene (MDPE) are suitable, but are less common and less commonly available as recycled material. Acrylonitrile butadiene styrene (ABS) is suitable if it is treated to resist damage from ultraviolet light, but ABS is less-commonly recycled and is susceptible to damage from some solvents. Polypropylene (PP) is suitable but is vulnerable to ultraviolet radiation and is less-commonly recycled. A nylon synthetic polyamide polymer can also be suitable. The corrugated enclosure body 2 is molded as a tube having annular corrugation, which is equally spaced parallel corrugations whose main plane is perpendicular to the body axis. The corrugated enclosure body 2 has an inside surface and an outside surface. In use, installed in the ground, the corrugated enclosure body 2 has a vertical, top to bottom axial orientation. The annular corrugation provides both overall strength and some limited and controlled flexibility. The inherent slight elasticity of the thermoplastic polymer material and the flexibility provided by the annular corrugation allow for deformation of the corrugated enclosure body 2 to accommodate an obstacle or to bend the enclosure to accommodate a difference between the angle of the underground bottom portion and the desired angle of the top portion, as treated in detail below.

[0031] The underground utility enclosure 1 provides at least three anchor loops 3 arrayed around and protruding from the outside surface of the corrugated enclosure body 2. In a preferred embodiment three anchor loops 3 are arrayed around the corrugated enclosure body 2 equidistant and in a 120-degree angular relationship. Each anchor loop 3 forms a loop or an eye providing an attachment point for a rope, wire, cord, chain, or strap which can together form a harness for lowering the corrugated enclosure body 2 into a hole in the ground while allowing for exact placement and maintaining or adjusting the alignment of the main axis of the corrugated enclosure body 2, as treated in detail below. The anchor loops 3 can be provided as eye bolts or similar anchors, or as protruding loops molded, heat-welded, or otherwise affixed onto the corrugated enclosure body 2. The anchor loops 3 can also be formed from rope or strap material, either with each anchor loop attached separately to the corrugated enclosure body 2, or with the anchor loops attached to another rope or strap encircling the corrugated enclosure body 2.

[0032] The underground utility enclosure 1 provides a fitted lid 4 to cover the top of the corrugated enclosure body 2. A suitable rabbet, recess, ledge, lip, or seat is formed into the top of the corrugated enclosure body 2 to accommodate the fitted lid 4. The top of the corrugated enclosure body 2 can be reinforced with additional material where reinforcement is needed because of the size of the top opening, the weight of the lid, and the anticipated forces on the lid during use. A variety of fitted lids 4 can be provided for different anticipated loads and circumstances, which allows supplying heavy-duty and traffic-rated fitted lids 4 where needed, without increasing the costs of lighter-duty fitted lids 4. A heavy-duty, traffic-rated, or very large fitted lid 4 can be made from a strong metal or composite material or combination of materials, can be made thicker, and can have added bracing materials or bracing structures. Lighter-duty and smaller fitted lids 4 can be made from less strong materials and can be made less thick and with less bracing. Such a lighter-duty lid might be made from substantially the same thermoplastic material as the corrugated enclosure body 2. Fitted lids 4 can be provided in embodiments with or without openings or handles, and in embodiments ranging from completely sealed against water intrusion through water resistance to allowing the flow of water. In applications where the connections and junctions of the underground conduits, cables, wires, or pipes are sufficiently insulated and waterproofed, it might not be necessary to use completely sealed fitted lids 4. In applications where the fitted lid 4 and the top of the corrugated enclosure body 2 would be subject to damage from, for example, landscape maintenance equipment such as mowers, trimmers, or plows, a protective collar or bumper can be placed around or cast in place around the top of the corrugated enclosure body 2 and fitted lid 4, as treated in detail below.

[0033] Referring to FIG. 3 and FIG. 4, in normal use, at a construction job site, runs of conduit, pipe, direct-burial cable, and related utilities infrastructure will have been buried underground and will terminate at junction points where, for example, the drop for a particular structure, location, or branch might be taken off, or where long runs need to be spliced together, possibly with some kind of pump, repeater, or amplifier. At the junction points the underground conduit, pipes, or cables will emerge into a hole, often, but not always with a long ninety-degree upward bend. In other uses a new junction point might be made into existing underground utilities in order to create a new drop or branch, to splice or repair damage, or to add a needed booster. With the underground utility enclosure 1 of this invention, the burial of the underground conduit, pipes, and cables, with the raw terminations at junction points, can be done prior to and independent of the installation of the utility enclosure, which can later be placed over the terminations. Terminations approaching at odd angles or at higher levels can be accommodated by slightly deforming or by cutting into the corrugated enclosure body 2, as treated in detail below. The joining, splicing, and connecting of the utilities at the junction point can be done either before or after installation of the underground utility enclosure 1, and is usually done afterward.

[0034] The corrugated enclosure body 2 will be placed into the hole and over the terminations at the junction point. The anchor loops 3 provide for the attachment of ropes, wires, cords, chains, or straps as a harness for lifting and lowering the underground utility enclosure 1 into the hole, for adjusting the position and angle during installation, and for stabilizing the position and angle during backfilling of the hole. Because of the at least three anchor loops 3 arrayed around the corrugated enclosure body 2 equidistant and in a 120-degree angular relationship, a properly configured harness should hold the corrugated enclosure body 2 in a substantially vertical position, and manipulation of the separate legs of the harness can adjust or correct the angle. The hole is backfilled to complete the installation of the underground utility enclosure 1.

[0035] For smaller embodiments of the underground utility enclosure 1, because of the relatively light weight and resistance to damage during handling, the underground utility enclosure 1 can be installed by hand by one or two persons, either directly manipulating the anchor loops 3 or using a small harness. Also because of the relatively light weight and resistance to handling damage, large embodiments of the underground utility enclosure 1 can be installed using less-powerful lifting equipment than would be required for heavier easily damaged enclosures.

[0036] After installation and backfilling of the hole, if the positioning of the underground utility enclosure 1 needs to be adjusted, as might be needed if, for example, the landscaping plan for the site is significantly altered, the hole can be partially re-excavated at least to expose the anchor loops 3, a harness can be re-attached, and the underground utility enclosure 1 can be re-positioned, or can be removed and replaced.

[0037] Referring to FIG. 5, because of the inherent slight elasticity of the thermoplastic polymer material and the flexibility provided by the annular corrugation, the corrugated enclosure body 2 can be deformed to accommodate an obstacle or to bend the enclosure to accommodate a difference between the angle of the underground bottom portion and the desired angle of the top portion, as illustrated where the top portion and the bottom portion of the installed corrugated enclosure body 2 can be in straight alignment, where the bottom portion can be offset to avoid an obstacle or to enclose a wrongly placed termination, where the bottom portion can be set at an angle and the top portion can be returned to vertical, or where the top portion can be placed at an angle to conform to a sloping grade.

[0038] Referring to FIG. 6, the corrugated enclosure body 2 can be deformed by compression in order to accommodate an obstacle or a utility termination which is too high.

[0039] Referring to FIG. 7, portions of the corrugated enclosure body 2 can be cut away or cut into, on-site using standard hand tools, in order to avoid an obstacle or to allow entry of a utility termination or the pass-through of a utility run which is higher than the bottom of the corrugated enclosure body 2.

[0040] Referring to FIG. 8, in an optional embodiment of the underground utility enclosure 1, a protective collar 11 can be provided and placed around the top portion of the corrugated enclosure body 2, protecting the top portion of the enclosure body and the fitted lid 4 from damage, shifting, or other disturbance which might be caused by traffic or by landscape maintenance equipment such as mowers, trimmers, or plows. The protective collar 11 can stabilize the top of the corrugated enclosure body 2 and the fitted lid 4 from unwanted lateral deformation and compression, and can also stabilize and fix in place intentional deformations created during installation, such as a change of angle to conform to a sloping grade. The top surface of the protective collar 11 could also be re-shaped to provide a transition to conform to special conditions or to, for example, slope upward to a raised top portion and fitted lid 4 to prevent water pooling or slope downward to avoid damage. The inner surface of the protective collar 11 matches and conforms to the outer surface of the top portion of the corrugated enclosure body 2, providing a close fit. The protective collar 11 can be made from a variety of materials, including the same materials chosen for the corrugated enclosure body 2 or the fitted lid 4. The protective collar 11 can be provided in colors and appearance to match the installation site or to contrast with the site as a visual warning. To install the protective collar 11, after installation of the corrugated enclosure body 2, the hole is only partially backfilled, or if it has been completely backfilled, a trench to accommodate the protective collar 11 is re-excavated. The protective collar 11 is then placed upon the corrugated enclosure body 2, with the inner surface of the protective collar 11 fitted closely with the outer surface of the top portion of the corrugated enclosure body 2.

[0041] Referring to FIG. 9, in an optional embodiment of the underground utility enclosure 1, a cast bumper 14 made of concrete or of resin or similar material can be formed by casting, around the top portion of the corrugated enclosure body 2. The bumper protects the top portion of the enclosure body and the fitted lid 4, as with the protective collar 11 treated above. The cast bumper 14 is cast on site after installation, which allows for modifications appropriate for a specific site or specific use, such as size, profile, reinforcement, and tying into adjacent surfaces or structures. The concrete can be a standard cementitious concrete or a non-cementitious concrete such as asphalt concrete and polymer concrete. A resin or a silicone rubber capable of being cast could also be used. This optional embodiment provides a casting-form base 12 and a casting-form tube 13 to be used for casting the bumper in place after installation of the corrugated enclosure body 2. The casting-form base 12 and casting-form tube 13 can be made from stiff cardboard, from a wood or composite laminate, from a plastic, or from a metal. After installation of the corrugated enclosure body 2 the hole is only partially backfilled, or if it has been completely backfilled, a trench to accommodate the casting of the bumper is re-excavated. The casting-form base 12 is placed around the corrugated enclosure body 2 and is lowered to an appropriate depth below grade. As illustrated the casting-form base 12 can rest upon and be supported by the anchor loops 3. If a more shallow placement is desired, spacers can be used between the anchor loops 3 and the casting-form base 12, or the anchor loops 3 can be disregarded and the casting-form base can be temporarily set in place by another method. If it is desired to cast the bumper down to a level deeper than the anchor loops 3, the casting-form base 12 can be forced downward past the anchor loops, or the casting-form base 12 can be omitted, allowing the concrete to flow to the bottom of the hole. The casting-form tube 13 is then placed around the corrugated enclosure body 2 and is lowered to the casting-form base 12 or to another stopping point. The concrete or other casting material is then poured into the space between the casting-form tube 13 and the corrugated enclosure body 2. After the casting material hardens the casting-form 13 can be removed or optionally can be left in place. The cured casting material forms the cast bumper 14 which protects and stabilizes the underground utility enclosure 1.

[0042] Referring to FIG. 10, the constituent parts of the underground utility enclosure 1 can be provided as a kit 20, 30, 40 for an installation of the underground utility enclosure 1. A basic kit 20 embodiment provides the corrugated enclosure body 2 with anchor loops 3 and the fitted lid 4. A collar kit 30 embodiment provides the corrugated enclosure body 2, anchor loops 3, and fitted lid 4, and additionally provides the protective collar 11. A casting kit 40 embodiment provides the corrugated enclosure body 2, anchor loops 3, and fitted lid 4, and additionally provides the casting-form base 12 and casting-form tube 13.

[0043] Many other changes and modifications can be made in the system and method of the present invention without departing from the spirit thereof. I therefore pray that my rights to the present invention be limited only by the scope of the appended claims.