CONICAL WALL RISER WITH INTERLEAVED TAB CONNECTORS

Abstract

A plastic article useful as a riser assembly for a septic tank or as part of another structure is comprised of a multiplicity of identical shape conical wall plastic risers. The risers are attached to each other at joints by tabs which engage rim segments; each end of the riser has alternating tabs and rim segments. A riser assembly wall undulates in the lengthwise direction. The risers nest within each other for shipment or storage.

Claims

1-14. (canceled)

15. A riser for use in a riser assembly, wherein the riser comprises: an angled wall connecting a first end and a second end spaced apart along a central lengthwise axis; wherein the first end is circular and comprises: a first diameter; a first plurality of tabs spaced apart around a circumference of the first end, wherein each of the first plurality of tabs comprises angled circumferential direction-facing opposing ends and a radially extending lip; and a first plurality of rim segments spaced apart around the circumference of the first end, wherein each of the first plurality of rim segments is positioned in a space between each of the first plurality of tabs; wherein the second end is circular and comprises: a second diameter; a second plurality of tabs spaced apart around a circumference of the second end, wherein each of the second plurality of tabs comprises angled circumferential direction-facing opposing ends and a radially extending lip; and a second plurality of rim segments spaced apart around the circumference of the second end, wherein each of the second plurality of rim segments is positioned in a space between each of the second plurality of tabs.

16. The riser of claim 15, wherein the first end of the riser is configured to mate to a first end of an identical second riser to form a joint between the first end of the riser and the first end of the identical second riser.

17. The riser of claim 15, wherein the second end of the riser is configured to mate to a second end of an identical second riser to form a joint between the second end of the riser and the second end of the identical second riser.

18. The riser of claim 16, wherein each of the first plurality of tabs of the first end are configured to engage with each of a plurality of rim segments of the identical second riser and each of the first plurality of rim segments of the first end are configured to engage with each of a plurality of tabs of the identical second riser.

19. The riser of claim 17, wherein each of the second plurality of tabs of the second end are configured to engage with each of a plurality of rim segments of the identical second riser and each of the second plurality of rim segments of the second end are configured to engage with each of a plurality of tabs of the identical second riser.

20. The riser of claim 15, wherein the second diameter is greater than the first diameter.

21. The riser of claim 15, further comprising an adapter configured to attach the riser to an opening of a tank.

22. The riser of claim 21, wherein the adapter comprises: a first end comprising a flange extending outwardly from a central axis; a second end comprising a cylindrical section; and an intermediate section connecting the second end with the first end.

23. The riser of claim 22, wherein a diameter of the first end is greater than a diameter of the second end.

24. The riser of claim 22, wherein the first end further comprises a ledge extending inwardly towards the central axis.

25. The riser of claim 24, wherein a diameter of the ledge corresponds to a diameter of the plurality of second rim segments.

26. The riser of claim 21, wherein the adapter is configured to be screwed to a flange of the opening of the septic tank.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 is a perspective view of a riser assembly comprised of identical risers.

[0015] FIG. 2 is a perspective view of a riser which is part of the assembly of FIG. 1.

[0016] FIG. 3 is a partial vertical cross section through the riser assembly of FIG. 1, with an additional riser added at the top of the assembly.

[0017] FIG. 4 is perspective view of a portion of the large end of the riser in FIG. 3.

[0018] FIG. 5 is another perspective view of a portion of the large end of the riser in FIG. 3.

[0019] FIG. 6 is a vertical cross section through the large-end joint region of the riser assembly of FIG. 1.

[0020] FIG. 6A is a view like FIG. 6 showing a joint which lacks a seal and a channel between the wall and latching tab.

[0021] FIG. 7 is a vertical cross section through the small-end joint region of the riser assembly of FIG. 1.

[0022] FIG. 8 is a side view of the end of a riser showing a latching tab and (in phantom) portions of tooling which enables the riser to be injection molded.

[0023] FIG. 9 is a vertical plane cross section through the structure of FIG. 8, near the end of the tab.

[0024] FIG. 10 is a vertical plane cross section through the structure of FIG. 8, near the middle of the tab.

[0025] FIG. 11 is a view like FIG. 9, showing an alternative embodiment of tab where the tab is not spaced apart from the wall at the end of the riser.

[0026] FIG. 12 is a perspective view of a riser with a safety grating positioned within the bore of the riser.

[0027] FIG. 13 is a partial vertical cross section of the grating shown in FIG. 12.

[0028] FIG. 14 is a partial vertical cross section of the assembly of FIG. 12, showing in phantom an additional riser, along with the grating as it was being inserted into the riser assembly from the top.

[0029] FIG. 15 is a view like FIG. 13, showing an alternative embodiment grating.

[0030] FIG. 16 is a perspective view of an adapter for connecting a riser to the top of a septic tank or to the end of a piece of pipe.

[0031] FIG. 17 shows a portion of the adapter of FIG. 17 in partial vertical cross section.

[0032] FIG. 18 is a partial cross section showing how a taper wall riser is connected to the top of a septic tank by means of an adapter of FIG. 16.

[0033] FIG. 19 is a partial cross section showing how a piece of pipe is connected to the top of a septic tank by means of an adapter of FIG. 16.

[0034] FIG. 20 is a partial cross section showing how a taper wall riser is connected to the end of a piece of pipe by means of an adapter of FIG. 16.

DESCRIPTION

[0035] In the present invention molded plastic riser articles (sometimes referred to as rings) can be used individually or as assemblies. As will be seen, risers have inward or outward tapering walls, also referred to as conical walls. For simplicity of description, the risers and riser assemblies are often described herein using terminology applicable to cylindrical shapes. While the invention is described in terms of circular rings/risers, the scope of the claimed invention includes articles which have walls which are non-circular, e.g. oblong; and those shall be considered equivalents.

[0036] The following description concentrates on an exemplary product and application, namely a riser for a septic tank. A riser is an open ended structure which may be closed by a lid when positioned on a tank. In the present invention, a riser may be mated with one or more other risers to form a riser assembly. In the art, a riser assembly may be also referred to simply as a riser. In this description and elsewhere a single riser piece may be alternatively referred to as a ring.

[0037] The disclosures of commonly owned patent application Ser. No. 62/295,408, filed Feb. 15, 2016, entitled Multi-ring plastic riser with tab connectors, and patent application Ser. No. 14/444,960, filed Jul. 28, 2014, entitled Multi-ring plastic storage tanks and risers (the '960 application) are hereby incorporated by reference.

[0038] FIG. 1 is an elevation perspective view, showing three identical risers 20, 20B, 20C that are joined to each other as riser assembly 18. A single riser 20 is shown in FIG. 2. FIG. 3 is a cross section through the assembly of FIG. 1, with addition of a further riser 20A. The small end of riser 20B mates with the small end of riser 20C at joint 142. The large end of riser 20A mates with the large end of riser 20C at joint 42. The wall of the riser assembly undulates in the lengthwise direction, so the wall is close to the central axis at circumferential joints 142 and distant at circumferential joints 42.

[0039] A riser assembly of the present invention may comprise two or more mated and latched-together articles. A riser assembly may sometimes be simply called a riser herein, particularly when the assembly is installed in a working position. When installed on a septic tank, a riser assembly is typically fastened to a fitting around the opening in the top of the tank and the assembly has a lid closure at its top. An exemplary lid closure is consistent with the lid shown in FIG. 8-10 of the aforementioned '960 application.

[0040] An exemplary riser 20 may have a vertical height of about 15 cm (about 6 inch), a larger diameter end of about 69 cm (about 27 inch) and a smaller diameter end of about 58 cm (about 23 inch). Other risers may have heights in the range 2 to 18 inches (5 to 46 cm). Joints between several identical risers 20 are formed by tabs on one part that engage rim segments on the mating part by latching to them. An exemplary riser is preferably made of injection molded thermoplastic, such as polyethylene or polypropylene, with a wall thickness of about 4.5 mm (about 0.18 inches). Alternative plastic materials may be used.

[0041] Riser 20 has a lengthwise central axis L, around which is centered a wall 30 that generally has the shape of a truncated hollow cone. The wall of riser 20 has opposing ends 22, 32. End 22 has a larger diameter than does smaller end 32. The wall of an exemplary ring is preferably inclined at an about 7 degree angle to the lengthwise axis L, more generally, preferably within the range 5-20 degrees.

[0042] As best seen in FIGS. 1, 2 and 5, the larger end 22 of a riser 20 is characterized by a plurality of tabs 26 which are circumferentially spaced apart by rim segments 28. Rim segments may be referred to as simply rims hereafter. The tabs extend in the lengthwise direction from the exterior surface of the wall of the riser. Each tab has a lip 52, for latching onto the rim segment 28 of a mated like riser. The inner edges of the lips are disposed around a circle. The outer edges of the rim segments are disposed around a circle which is congruent with the circle of the lip edges. A joint 42 between risers is formed when the plurality of tabs 26 of one riser are engaged with a plurality of rims 28 of a mating riser. Likewise, joints 142 are formed between mated riser smaller ends. See the cross sections at joint locations in FIG. 3. FIG. 6 shows an added gasket 50 captured in a circumferential channel 44 that is associated with joint 42. Gaskets may also be included in joints 142.

[0043] FIG. 3 shows an optional step 53 in the wall 30 proximate the small end of riser 20C; this is discussed below in connection with a safety grating which optionally rests on the step.

[0044] Referring to FIGS. 1, 2, and 7, the smaller end 32 of a riser 20 has many similarities with larger end 22, but also some differences. Smaller end 32 is characterized by a plurality of tabs 36 which are circumferentially spaced apart by rim segments 38, which may be referred to simply as rims hereafter. Joint 142 is formed when the plurality of tabs 36 are engaged with a plurality of rims 38 of a mating riser. Each tab 36 has an outward facing lip 152. When two risers are mated, each lip 152 engages a rim 128. See the assembly cross section at joint 142 in FIG. 3 and FIG. 7. A gasket 150 is preferably captured within a circumferential channel 144 at the circumferential end of the wall of each riser, to seal joint 142. See FIG. 7.

[0045] When used, gaskets 50, 150 are preferably made of a rubber or elastomer material, for example EPDM having a Shore A hardness number of about 30. Optionally, where resistance to water passage through the joint is not important to the user, the risers can be assembled without the use of a gasket, and risers may be constructed without a channel 44. See FIG. 6A, discussed below.

[0046] Exemplary riser 20 has ten tabs 26, 36 at each end. Preferably, the tabs at one end are aligned in the lengthwise direction with the tabs at the other end of the riser. In other embodiments of the invention, there may be fewer or more tabs; and there may be a different number of tabs at one end, compared to the other end.

[0047] FIG. 4 to 7 illustrate certain features of the ends of a riser which enhance the convenient making of a good joint with a like riser. (This portion of the description interchangeably applies to the small ends and large ends of risers.) FIG. 4 and FIG. 5 are perspective views of portions of the larger end 22 of riser 20. They show that each tab 26 has an inward facing lip 53 and that rim 28 runs circumferentially between two spaced apart tabs. Also, each tab 26 has circumferential direction-facing ends 66 which are canted at angle A to a lengthwise diametrical plane PL, shown in phantom, within which plane lies lengthwise axis L. The angled ends 66 enable easier engagement of the tabs of two mated risers, as each tab of a first riser nestles into the space between the tabs of the mating second riser, so that each tab engages a rim segment. FIG. 1 shows that in a resultant assembly 18, the angled ends 66 of each tab 26 of a first riser 20 mate/abut the angled ends 76 of spaced apart tabs 36 of the second riser, so that interleaved tabs appear continuous around the circumference of the joint 42.

[0048] With particular reference to FIG. 5, lip 52 of tab 26 has an inner edge 53 which is angled with respect to the diametrical plane of the riser, so that the tab is thrust elastically outwardly when the lip of the tab first engages with rim 28 of a mating riser. For the same reason, the outer edge 55 of rim 28 is angled with respect to the diametrical plane.

[0049] FIG. 6 is a cross section through the riser assembly 18 at joint 42. FIG. 6 shows how the large ends 22 of risers 20 mate; the small ends will mate comparably. FIG. 6 shows lip 52 of tab 26 is engaged with rim 28. Seal 50 is captured in the groove 44. As pictured in cross section, tab 26 has a body 48, which is the lengthwise extending portion of the tab (i.e., the vertical portion in FIG. 6). Tab body 48 is an arc-shape structure that runs circumferentially, congruently with wall 30 and with the rim segments of the riser. One lengthwise end of tab body 48 is connected to the exterior wall of riser end 22 by radially inward-running web 46 (which is a horizontal section shown in FIG. 6). The other lengthwise end of the tab body extends beyond the end of the wall where the joint 42 is formed. As described in more detail below, in a preferred injection molded riser, the web 46 may be discontinuous in the circumferential direction.

[0050] The combination of elements 48, 46 and local portion 130 of wall 30 defines circumferentially-running channel 47 (which has a length nominally equal to the tab width). Channel 47 provides an advantageous arrangement for the following reasons: When force is applied to the risers, to separate the risers from each other at the joint 42, a bending moment (represented by the curved vectors M) is created in web 46. That moment has the effect of thrusting section 48 and lip 52 radially inwardly, toward the central axis L of the riser, better to engage rim 28. That enhances the resistance of the joint to separation, compared to the resistance which the assembly would have if channel 47 and section 46 were not present, i.e., compared to the structure shown in FIG. 6A. Secondly, by increasing the effective length of the tab body, even without the foregoing phenomenon, deflection of tabs by contact with rim segments, and thus engagement of mating parts, is made easier.

[0051] FIG. 6A shows two mated risers 222, and illustrates an alternate embodiment of the invention. One of a plurality of tabs and rim segments is shown. Joint 242 is formed between two mated risers 222 when lip 252 of tab 226 engages rim segment 228. First, the risers 222 lack any optional circumscribing channel for a seal between the mating parts. Second, there is no channel like channel 47 that spaces the tab body away from the end of the wall, as there is in the embodiment shown in FIG. 6. See also FIG. 11 and related discussion, where the tab body is also not spaced apart, but is a lengthwise continuation of a portion of the wall.

[0052] FIG. 7 is a cross section through the riser assembly 18 at joint 142, showing how the small ends 32 of risers 20 mate. The ends are shown as they are being moved toward each other to their final joined-together configuration, as indicated by the vertical arrows. Tab 126 has a construction like tab 26. Lip 152 is at the end of tab body 148, which is connected to web 146 that extends radially from the wall 30 of riser 20 at small end 32. (As mentioned, lip 152 faces outwardly from the center of the riser, which compares with inward-facing lip 52 of tab 26.) In FIG. 7, the engagement of lip 152 with rim 128 and movement of the risers toward each other causes lip 152 to be deflected radially inwardly as indicated by arrow N. This action is facilitated by the angled terminal ends of lip 152 and rim 128, previously discussed.

[0053] Once the mating features of the ends are engaged, the risers cannot conveniently be separated other than by use of tools which pull all tabs from engagement with the mating rims. It is not expected that a user will often seek to separate the risers once they are joined to each other.

[0054] Referring again to FIG. 4, each of the plurality of rim segments 28 may be interrupted by a boss 39, which is nominally in the center of the rim segment. Boss 39 is shaped so it can receive a screw, thus enabling the end of the riser to be fitted with a screw-attached lid. When boss 39 is present, a notch 45 is preferably present in the lip of the tab which is shaped to engage the rim segment, to accommodate the boss 39 and screw.

[0055] FIG. 8-10 show in more detail other aspects of a tab of a preferred injection molded riser 20. The tab is mated to the wall of the riser by a web that is comprised of two spaced apart portions, which facilitates manufacture. FIG. 8 is a side view of a portion of the end 22 of a riser showing tab 26. FIG. 9 and FIG. 10 are vertical plane portions through the tab and riser end shown in FIG. 8. Also shown in FIG. 8, in phantom, are mold parts 41, 43 in their spaced apart (or open mold) condition. The arrows PP show how the mold parts 41, 43 move toward each other when the mold is closed so plastic can be injected into the mold.

[0056] With reference to FIG. 8, 9, 10, there is a space 49 between the two circumferentially spaced-apart portions of web 46. Space 49 is created by mold part 43. When the tab has the configuration which comprises space 49 that enables mold part 43 to create the underside surface of lip 52. An alternative embodiment of tab may have a web 46 which is continuous from one circumferential edge of the tab to the other. In such case, a more complex mold may be necessary for efficient injection molding.

[0057] FIG. 11 is a view like FIG. 9, showing an alternative embodiment tab 426 at the large end of a riser. There is no channel like channel 47; tab body 448 is a continuation of a portion of the riser wall. Lip 452 overhangs the channel 444 within which a seal will be placed prior to a joint between risers being made.

[0058] The next paragraphs describe a safety grating that is particularly useful with the foregoing kinds of conical risers which have different diameter ends, compared to known safety gratings which are used with more or less constant diameter risers of the prior art.

[0059] FIG. 12 is a perspective view, looking down on the larger end 22 of riser 20. Grating 60 is set within the bore of the riser. FIG. 13 is a side elevation view of a portion of the grating 60 (also referred to as a grate). Exemplary grating 60, preferably made of plastic like that of the associated riser, comprises a hub 64 having a pentagonal opening 67. The first ends of five lattice-like arms 62 are attached to the hub at hinge points 68 and extend generally radially outwardly from the hub. The free or outer ends of the arms are in contact with circumferential step 53 on the interior wall of riser 20, near the small end 32 of the riser. See FIG. 3, FIG. 12, and FIG. 14 which is a partial vertical cross section of the grating and riser assembly shown in FIG. 12. The length of the arms 62 and size of hub 64 are such that, as shown by FIG. 14, the grate, in riser lengthwise cross section view, has a cross section which is substantially in the shape of an arch. Thus any vertical load placed on the grate (such a child, pet, or other object entering the open top of the riser assembly) may be substantially resisted by the grate and hindered from moving further downward. The ends of the legs are constrained from outward and downward movement by the riser wall circumferential and vertical structure.

[0060] Importantly, arms 62 are hinged. The hinging enables placement of a grating by passing the grating through the small end of a riser, for example, the small end of riser 20P which has a diameter DA of the opening of an imaginary cylinder, as shown in phantom in FIG. 14. The arms 62 hinge inwardly, as indicated by arrow Pin FIG. 14 for arm 62P of riser 60P, both shown in phantom, as the grating is being inserted into the riser assembly. The hinging makes the effective outside diameter of the grating smaller than the diameter DB which the grating has when in its working position. Effective outside diameter refers to the diameter of the smallest imaginary short cylinder through which a grating may be passed lengthwise.

[0061] Referring again to FIG. 1, it can be appreciated that hinging is necessary to position a grating within the lowermost riser 20 of assembly 18 when the grating is lowered from the top. An exemplary grating of the present invention compares with a prior art grating having an unchangeable effective outside diameter. The grating of the present invention may be used on risers other than those described herein.

[0062] Springs (not shown) may be employed to bias the arms in the outward, or most-extended, direction. For example, a torsion spring may be put around the pin of the hinge joint, when the hinge joint has appropriate construction. For example, compressible elastic bumpers may be used to resist the inward or collapsing motion of the arms. Likewise, the movement of one arm may be interlocked with the movement of adjacent arms, so all arms move radially outward or inward in coordination. The interlocking may be on the nature of a flexible tang which is fixed to one arm and extends in the circumferential direction, from the one arm to engage slidingly a surface of an adjacent second arm.

[0063] An alternative embodiment grating may have one or more arms which are not hinged in combination with at least one, or more than one, arm which is hinged. In a functionally-limiting embodiment of the invention, hinged arms need only be in number sufficient to decrease the effective outside diameter of the grating, so that such effective diameter is smaller than the small end opening of a riser like riser 20 (or the opening of an imaginary cylinder associated with the small end opening, with which the grating is used. Thus there is an embodiment which has only one hinged arm.

[0064] In still another alternative embodiment of grating, illustrated by FIG. 15, the hub 164 of grating 160, having a bore 167, has at least one, and preferably a multiplicity, of fixed arm portions 162, each of which has a movable arm portion 162A. The portion 162A is attached to the portion 162 at hinge point 168, which is radially outward from the point where the arm portion 162 connects to the hub.

[0065] A grating within the present invention may have a number of arms which is different from five arms of exemplary grating 60. For example, 3, 4, or 6 or more arms may be used. And although a correlation between the number of polygon sides of the center opening with the number of arms is preferred (i.e., pentagonal for five arms, hexagonal for six arms, etc.), in alternative embodiments of the invention the shape of the center opening may be uncorrelated with the number or arms. In further alternative embodiments, the opening may be round or there may be no opening. When an opening is present, it is preferably sufficient in diameter to allow passage of a hose line, but not a child's body, to facilitate pumping out of the septic tank without removal of the grate.

[0066] The following paragraphs describe adapters which are particularly useful with the foregoing kinds of risers which have tapered walls, also referred to as conical walls.

[0067] FIG. 16 shows in perspective an exemplary adapter 70 having lengthwise central axis LL, and FIG. 17 is a partial cross section. Adapter 70 which has multiple uses, including (a) enabling attachment of the small end of a riser of the present invention to the top of a tank, such as a septic tank; (b) enabling attachment of a corrugated pipe or prior art riser or other future riser to the top of a tank; and (c) enabling a riser of the present invention to be attached to the end of a corrugated pipe or to a prior art riser, or vice versa.

[0068] Adapter 70 has a first larger end comprising flange 72, and has a second end 78 comprising cylindrical section 76 which has a diameter smaller than the outside diameter of adapter flange 72. An intermediate size section 74 connects the section 76 with the flange. Within the bore of the first end flange is inward projecting ledge 80. Ledge 80 has an inside diameter and other dimension which preferably corresponds with the effective diameter of the rims 128 at the smaller end 32 of a riser 20.

[0069] When a septic tank has an opening with a top flange that has a suitable inward extending rim, the small end of a riser 20 of the present invention can be snapped onto the tank top flange, and the tabs will latch onto the rim. When the tank does not have such a suitable top flange, as illustrated by flange 77 of tank 75, the adapter flange 72 can be screwed or otherwise attached to the flange 77, as shown in the partial vertical cross section of FIG. 18. In FIG. 18, tabs 36 of riser 20 are shown after they have been engaged with ledge 80 of the adapter.

[0070] FIG. 19 shows how the adapter 70 can be used to mount a piece of pipe (or other item having a suitable diameter) on the top of a tank. The small end 78 of adapter 70 faces in the upward direction (away from the interior of the tank 75) and the flange 72 is screwed or otherwise attached to the rim 77 at the septic tank opening. A corrugated pipe 71 is shown mounted on the section 76 at the small end 78 of the adapter; alternatively, the pipe fits the intermediate section 74.

[0071] It is sometimes desired replace a portion of a prior art riser that is spaced apart from the tank, or to add to the length of a prior art riser. FIG. 20 shows how the small end 78 of adapter 70 is inserted into the top of a riser 79 that does not have an end that mates with a riser of the present invention. Adhesive and or radially-running screws may be used to fasten adapter 70 to the original in-place riser 79. Then riser 20 of the present invention is inserted into the opening of flange 72 and the tabs at the small end 32 of the riser become engaged with the ledge 80 of the adapter.

[0072] Assembled structures embodying features of the present invention may be put to other uses including, for example, manhole sleeves for access to subterranean chambers. An open ended hollow article like a riser, made in accord with the invention, may be fitted with a bottom closure (and optionally a top also), thus making the article into a bucket or tank like vessel, suitable for storing water, other liquids, or solid items. A claim to a riser shall be construed as comprehending a structure which may be used for a manhole in the earth or other material, or for a structure which forms part of a vessel. For convenience of description, the invention has at least in part been described with respect to a particular orientation, and such terms as top, bottom, side, etc., that relate to orientation shall not be construed as limiting with respect to the claims.

[0073] The invention, with explicit and implicit variations and advantages, has been described and illustrated with respect to several embodiments. Those embodiments should be considered illustrative and not restrictive. Any use of words such as preferred and variations suggest a feature or combination which is desirable but which is not necessarily mandatory. Thus embodiments lacking any such preferred feature or combination may be within the scope of the claims which follow. Persons skilled in the art may make various changes in form and detail of the invention embodiments which are described, without departing from the spirit and scope of the claimed invention.