Abstract:
An irrigation valve vault including a base frame member having a plurality of sides forming an enclosed area including a first side having a water inlet passage with a plurality of apertures along its length and opening into the enclosed area, a second side having a plurality of apertures extending from the enclosed area to connection points for water lines located on the outside of the second side, a plurality of valves located within the enclosed area and connecting between apertures on the first side and apertures on the second side, a sloped compartment located on top of the base frame, and a lid placed on the top aperture of the sloped compartment.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     The present application is a continuation in part of patent application Ser. No. 11/752, 763, filed May 23, 2007 now abandoned, incorporated by reference herein in its entirety, and which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/803,005, filed May 23, 2006, also incorporated by reference herein in its entirety. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     REFERENCE TO A MICROFICHE APPENDIX 
     Not applicable. 
     TECHNICAL FIELD 
     The present invention relates generally to irrigation system apparatus, and more particularly to irrigation system valve manifolds, and still more particularly to an irrigation system valve manifold enclosure for subsurface installation and protection of an electronically-powered irrigation system valve manifold. 
     BACKGROUND INFORMATION AND DISCUSSION OF RELATED ART 
     Irrigation system pipes are customarily buried below ground in order to protect the pipes from mechanical and weather related damage, to clear space for the free movement of foot and vehicular traffic, and eliminate unsightly apparatus from otherwise aesthetic environments. Valves and valve manifolds commonly employed to control automatic irrigation systems are also frequently buried, generally for the same reasons. The preferred method of burying an irrigation valve manifolds entails providing an enclosure or box for placement in a hole, wholly or partially burying the enclosure, constructing the manifold within the enclosure and connecting it to pipes running to the irrigation areas, and coupling the manifold to a water supply line with a union. In most residential applications, the valve box is left with a portion above ground level, to provide easier access. An electronic valve controller is installed, typically on or in a nearby structure, with leads to each valve passing through a hole into the enclosure interior. 
     Irrigation system valve manifold boxes are known in the art. The industry leader by a considerable margin is Rain Bird Corporation of Azusa/Glendora, Calif. Valve boxes manufactured by this company typically include a rigid rectangular enclosure for valve system components manufactured from foam high density polyethylene (HDPE) resin, knock-outs for running pipes and wires into the box interior, and a removable lid. Some models provide connection structure to facilitate mounting one box atop another valve box for deep installations. However, none of the Rain Bird brand boxes includes structure for pre-mounting a valve manifold and/or valve manifold pipe assembly, which must be constructed and installed independently and then fit into the box. 
     Most of the known valve boxes provide insufficient protection of the valve assembly from water intrusion, insects, migrating soils, and so on. Additionally, the valve manifold assemblies generally remain unsupported within the enclosure, and special apparatus or connectors must therefore be installed on the valve box or other structure provided in order to secure, stabilize, and protect the assembly from movement and damage. 
     A few solutions to the foregoing problems have been proposed and are known. These include, as examples, U.S. Pat. No. 3,984,023, to Hodas, which shows a plastic cuboid underground valve box including separate side and end walls that include interlocking portions adjacent their edges that secure them to each other during assembly of the box. The bottom side of the box is open to permit positioning of the box over one or more underground valves. A plastic cover is pivoted to the box so as to control access to the valve or valves within the box. The box may be divided into one or more compartments that each receive an associated valve. 
     U.S. Pat. No. 4,976,366, to Russell, shows an underground valve box having a tubular base divided into upper and lower portions by a horizontal member. Concentric steps descend downwardly and inwardly from the horizontal member into the lower portion of the base forming a series of seats, decreasing in diameter and increasing in depth, one of which will accommodate the selected valve body. The upper portion of the base has a pair of accessible diametrically opposed notches in which the inlet and outlet lines of the valve will be disposed when the valve body is inserted in its appropriate seat. The valve box also includes a tubular body which has a pair of accessible notches which can be aligned with the accessible notches of the tubular base. The tubular body is configured to securely removably gird the upper portion of the tubular base with the inlet and outlet lines of the valve disposed in the bottomwardly accessible notches. Preferably, the tubular body is contoured to also restrictively receive the body of the valve so as to minimize the possibility of rotation of the valve within the box. 
     U.S. Pat. No. 4,872,575, to Kobilan, teaches a protective housing for underground devices, including valves. It includes a base assembly with an open bottom and open top which may be closed with a snap-fit lid, but constructed for stackable arrangement of a plurality of housing structures. The sidewalls and endwalls are constructed to facilitate incisions, slots, and removable flap. 
     The foregoing patents and prior art devices reflect the current state of the art of which the present inventor is aware. Reference to, and discussion of, these patents is intended to aid in discharging Applicant&#39;s acknowledged duty of candor in disclosing information that may be relevant to the examination of claims to the present invention. However, it is respectfully submitted that none of the above-indicated patents disclose, teach, suggest, show, or otherwise render obvious, either singly or when considered in combination, the invention described and claimed herein. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention provides an irrigation system valve manifold vault for subsurface installation and maintenance. The inventive apparatus provides a secure enclosure to prevent migration of the vault within and along the ground and that protects irrigation valves and valve components from water, contamination by dirt and debris, chemical damage from soils, insect infestation, and damage from impact and weather. In a first preferred embodiment, the inventive apparatus comprises a generally rectangular support base containing an inlet pipe section and a plurality of pipe outlets, a vault truncated, four-side pyramidal vault enclosure mounted on the support base, an openable lid removably attached to the top of the vault enclosure for access to the interior in which a valve manifold is contained, and numerous electrical devices that operate in conjunction with the valve manifold of the present invention. 
     In most instances, the above-described apparatus is installed essentially below ground level, such that the top surface of the support base is essentially at grade or ground level. 
     Accordingly, it is a first and principal object of the present invention to provide a novel irrigation system valve manifold cover that encloses a valve assembly in an easily accessible vault. 
     Yet another object of the present invention is to provide an irrigation system valve manifold cover that protects irrigation system valves from water intrusion, insects, and migrating soils. 
     Still another object is to provide a valve manifold assembly base and vault combination that secures, stabilizes, and protects the valve assembly from movement and damage from impact. 
     The foregoing summary broadly sets out the more important features of the present invention so that the detailed description that follows may be better understood, and so that the present contributions to the art may be better appreciated. There are additional features of the invention that will be described in the detailed description of the preferred embodiments of the invention which will form the subject matter of the claims appended hereto. 
     Accordingly, before explaining the preferred embodiment of the disclosure in detail, it is to be understood that the disclosure is not limited in its application to the details of the construction and the arrangements set forth in the following description or illustrated in the drawings. The inventive apparatus described herein is capable of other embodiments and of being practiced and carried out in various ways. 
     Also, it is to be understood that the terminology and phraseology employed herein are for descriptive purposes only, and not limitation. Where specific dimensional and material specifications have been included or omitted from the specification or the claims, or both, it is to be understood that the same are not to be incorporated into the appended claims. 
     As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based may readily be used as a basis for designing other structures, methods, and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims are regarded as including such equivalent constructions as far as they do not depart from the spirit and scope of the present invention. Rather, the fundamental aspects of the invention, along with the various features and structures that characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the present invention, its advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated the preferred embodiment. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein: 
         FIG. 1  is an upper left perspective view showing the irrigation system manifold vault of the present invention; 
         FIG. 2  is an exploded upper left perspective view showing the structural elements of the irrigation system valve manifold vault of  FIG. 1 ; 
         FIG. 3  is an upper left perspective view showing a valve manifold installed and mounted on the base portion of the valve manifold vault, shown without the vault top enclosure; 
         FIG. 4  is a cross-sectional front side view in elevation showing a valve manifold and valves mounted on the base portion and covered with the vault top enclosure; 
         FIG. 5A  is a cross-sectional left end view in elevation shown along section line  5 A of  FIG. 1  showing the vault top enclosure lid closed and bolted shut; and 
         FIG. 5B  is a cross-sectional end view in elevation showing the vault top enclosure with the lid open and the valve assembly removed. 
         FIG. 6  is an exploded view of an alternative embodiment of the present invention. 
         FIGS. 7A and 7B  are perspective elevation views of an alternative embodiment of the present invention. 
         FIG. 8  is a view of the underside of the central compartment of the alternative embodiment of the present invention. 
         FIG. 9  is a perspective view of the lid that covers the alternative embodiment of the present invention. 
         FIG. 10  is an elevation view of the central compartment and lid of the present invention, showing functional elements incorporated into alternative embodiments of the present invention. 
         FIG. 11  is an elevation view showing an electrical connection between the central compartment and lid of the present invention. 
         FIG. 12  is a perspective view of the base frame of an alternative embodiment of the present invention having a plurality of irrigation valves installed therein. 
         FIG. 13  is a perspective view of an irrigation valve assembly used in embodiments of the present invention. 
         FIG. 14  is a partial perspective view of the base frame of an alternative embodiment of the present invention. 
         FIG. 15  is a schematic showing water passageways through the base frame of an alternative embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to  FIGS. 1 through 5B , wherein like reference numerals refer to like components in the various views, there is illustrated therein a new and improved irrigation system valve manifold vault, generally denominated  100  herein. These views, collectively, show that the inventive apparatus comprises three primary portions, including a support base  110 , a vault enclosure  120 , and a lid  130 . 
     The support frame, or support base,  110  is generally configured in a solid rectangular frame conformation and has sufficient mass to support and secure valve manifolds of the kind typically installed in underground enclosures. It includes four frame members, including a front side  150 , a right side  155 , a back side  160 , and a left side  165 . The front, rear, right and left sides are joined to form a contiguous and substantially co-planar top side  140  and a contiguous and co-planar bottom side  145 . 
     A plurality of valves  170  may then be configured into a valve manifold assembly with conventional connectors, elbows, Ts, and the like, in which the valve is connected to a water supply pipe  180  in the inlet end of the valve and to a plurality of corresponding irrigation pipes at the outlet end of the valve. The assembly can then be mounted onto the top side  140  of the base  110  using pipe U-brackets  195 , in a well known manner. It will be appreciated that the material from which the support base is made is sufficiently dense for the effective use of screws as fasteners, though bolts could be employed when the base is fabricated from lightweight and less sturdy materials. Additionally, it will be appreciated that the water supply pipe could enter the enclosure from underneath the support base, or even through a side of the support base (there being a through hole provided for such an insertion), and the supply could also be mounted to an interior side of the base, rather than to the top side. However, such a configuration does not alter the fundamental structural and operational characteristics of the present invention. 
     The vault enclosure  120  is shaped as a truncated, four-sided pyramid and comprises a left side  200 , a front side  210 , a right side  220 , and a back side  230 . The sides are joined at their respective edges to adjoining sides and angle inwardly toward their upper portions to form an open top  240 , which functions as an access to valve components. The bottom  250  is also open. Knockouts,  260  and  270 , are included on each of the left and right sides, respectively, to provide means to insert inlet pipes through a selected side. The sides terminate at their upper portions in an upper edge  280 , which provides a seat for lid  130 . 
     The bottom portion of the front and back sides, includes a flange  290  having a plurality of holes  300  for securing the vault enclosure proximate the perimeter of the base with fasteners  305  onto the top side of the support base. Alternatively, the vault enclosure may be pivotally attached to one side of the support base with hinges  215 , and then attached to the other side of the support base with permanent fasteners or selectively releasable fasteners, such as cotter pins, clevis pins, or simply a conventional latch. The angle  410  between the front and back sides of the vault enclosure and the top side of the support base can be adjusted for the typical commercial and residential installations such that there is sufficient clearance between the interior walls of the vault enclosure and the valve body to prevent any bending or twisting applied to the enclosed conduits or pressure applied to the valve body. 
     The lid  130  includes an underside  310  and a top side  320 , a back edge  330  and a front edge  340 . A downwardly projecting skirt extends substantially around the underside of the lid, though it is spaced apart from the edge of the underside such that it fits within the opening in the vault. The front side  350  of the skirt includes a through hole  360  that may be aligned with a through hole  370  in the front side of the vault enclosure for securing with a pin  375 . 
     The back side  380  of the skirt includes an angled side  400  that matches the angle of the interior side of the back side  230  of the vault enclosure. This secures the lid snugly onto the top of the vault enclosure while facilitating easy removal for adjustment, replacement, and repair of the valves. Alternatively, the lid may be pivotally attached to the vault enclosure by hinges  105  and secured in its shut position with pin  375 , as described above. 
     As will be appreciated, a fundamental objective achieved by the lid and vault enclosure assembly is to provide rapid access to a clean and well-preserved valve manifold. Underground valve manifolds are notoriously dirty, rusted, bug and spider infested, and frequently submerged under ground water. The lid and vault enclosure combination described herein overcomes these problems by protectively covering a manifold secured on a buried support with a sarcophagus-like structure that extends above ground and above low levels of vegetation or snow. When placed on crushed rock or pea gravel, the support prevents a measure of water intrusion and further prevents infestation by spiders or other insects. 
     From the foregoing description, it will be clear that in its most essential aspect, the present invention is an irrigation system valve manifold vault which includes, at a minimum: a support base, a vault enclosure mounted on the support base, wherein the vault enclosure is a truncated four-sided pyramid having an open top, an open bottom, and four sides; an openable lid which selectively covers the open top of the vault enclosure and providing selective access to the interior of said enclosure; and bracket or other structural means for attaching an irrigation valve manifold assembly onto the support base. 
     While there is provided herein a full and complete disclosure of the preferred embodiments of this invention, it is not desired to limit the invention to the exact construction, dimensional relationships, and operation shown and described. Various modifications, alternative constructions, changes and equivalents will readily occur to those skilled in the art and may be employed, as suitable, without departing from the true spirit and scope of the invention. Such changes might involve alternative materials, components, structural arrangements, sizes, shapes, forms, functions, operational features or the like. 
     Directing attention to  FIG. 6 , in an alternative embodiment similar to vault  100  described above, vault  600  includes lid  610 , compartment  640 , and base frame  680 . Compartment  640  is a sloped, multi-sided structure that sits atop base frame  680  and has side walls that converge to define an area at the top that is covered by lid  610 . In an embodiment, compartment  640  includes lid lock  641 . It is contemplated by the inventor that compartment  640  and base frame  680  are installed below ground level, with lid  610  placed at or near ground level. 
     Base frame  680  includes water inlet  682 , an elongated water passage that feeds water through a plurality of inlet apertures  684  on the interior face of back side  681  ( FIG. 7A ) of base frame  680 . Wire access aperture  683  is located proximate to water inlet  682 , to provide a passage for wiring  685  ( FIG. 7B ) that connects to valves placed between inlet apertures  684  and outlet apertures  686 . Outlet apertures  686  serve as connection points for individual irrigation lines. Returning to  FIG. 6 , optional grate  690  can be configured on the bottom of base frame  680 . 
     It is contemplated that installation of vault  600  is performed in a piecewise fashion. First, base frame  680  is placed at the bottom of a hole in a desired location. Compartment  640 , having a recessed interior surface  700  ( FIG. 8 ) that forms a lip sufficiently dimensioned to span the edges of base frame  680 . This allows compartment  640  to fit snugly on base frame  680  during installation. 
     As shown in  FIG. 9 , in an embodiment, lid  610  has an underframe  614  that has a sloped profile on its rear edge  620 . This rear edge  620  functions as a hinge to allow lid  610  to rotate backward while still placed upon compartment  640 . 
     Directing attention to  FIG. 10 , compartment  640  provides a convenient space in which numerous electronic and mechanical enhancements to a conventional irrigation valve manifold can be stored. For example, on the left side of compartment  640 , battery  642  can be included to power devices located within vault  600 . Communication module  644 , such as a radio receiver or telecommunication receiver, for use with remote control of irrigation valves inside vault  600 . Communication module  644  can also include a transmitter for reporting functions and malfunctions occurring within vault  600 . Thermometer  646  can be located on lid  610 , to provide temperature information that is used to control operation of irrigation valves located within vault  600 . Light bulb  648  can be located underneath lid  610 , or lower, such as on an interior wall of compartment  640  or even on an interior wall  640 , to provide illumination as well as to prevent valves from freezing during cold conditions. Solar panel  650  can be located on lid  610  to charge batter  642 . Solar panel  650  can also be located on a telescoping pole that elevates solar panel above lid  610  or positions solar panel  650  to an optimal azimuth or elevation for charging battery  642 . Moisture sensor  652  can also be located on lid  610 , and is useful for maintaining irrigation valves in a closed position during rain to prevent overwatering. LED display  653  can be located at the top of a sidewall of compartment  640  in instances where compartment  640  protrudes above ground level. Alternatively, LED display  653  can be located on lid  610 . Vent  654  can be located at the top of one or more sidewalls of compartment  640 . Irrigation controller  656  and clock  657  can also be mounted on an interior wall of compartment  640 . While in the preferred embodiment, vault  600  is located beneath ground level, above-ground installations are also contemplated. In such embodiments, if freezing pipes are a concern, an electrical heating element can be incorporated within vault  600 , for example, a heating coil located around the inner circumference of compartment  640  or base frame  680 , or at locations on grate  690 , or other suitable configurations that keep the temperature within vault  600  above freezing. 
     Directing attention to  FIG. 11 , lid  610  can incorporate electrical contact  660  that, when lid  610  is in a closed position, is brought into contact with electrical contact  662 , to provide connection between solar panel  650  and battery  642 . 
     All of the devices described above take advantage of the open space provided by compartment  640 , and mounting them near the top of compartment  640  provides easy access by reaching down through the opening beneath lid  610 , and manipulating the devices from underneath. 
     Directing attention to  FIG. 12 , a plurality of irrigation valves are shown disposed within base frame  680  between inlet apertures  684  and outlet apertures  686 . It is contemplated that these valves are controlled electronically, and function in accordance with the devices described above in  FIGS. 10-11 . In this manner, water flows through inlet  682 , through inlet apertures  684 , through the valves, and out outlet apertures  686 . Individual water lines are attached to outlet apertures  686  to distribute water where desired. 
     In the preferred embodiment, the valves shown in  FIG. 12  are similar to valve assembly  700  shown in  FIG. 13 . Valve assembly  700  includes valve body  710 , coupling  720  fitted on pipe segment  730 , attachment nut  740  that secures waterproof elastomeric cylindrical fitting  750 , which fits tightly around the outer surface of pipe segment  730 , to a threaded connection, typically protruding from inlet apertures  684  and outlet apertures  686 . Through the use of fittings  740  and elastomeric fitting  750 , valve assembly  700  is easily removed from base frame  680  without having to cut and glue PVC pipe, as is typically performed in the repair of a failed valve. As vault  600  is typically located below ground, the use of quick release valve assembly  700  within base frame  680  is a vast improvement over traditional glued irrigation valve manifolds. 
     Directing attention to  FIG. 14 , in an embodiment, valve  800  is provided to release water present in inlet  682  or the upstream side of valve assembly  700 . 
       FIG. 15  shows the path of water through inlet  682 , through feeder pipe  900 , through valve assembly  700 , and out of base frame  680 . In an embodiment, cylindrical stake guides  910  are provided so that metal stakes can be inserted into the ground beneath base frame  700 , to secure base frame  680  on the ground and to provide a grounding source for electronic current passed through the various electronic devices used within vault  600 . Optionally, two-wire decoder  912  can be incorporated with base frame  680 . Two-wire decoder  912  serves as a multiplexer between a plurality of valves  700  and controller  656 , relaying signals to controller  656  that are specific to individual valves. 
     While numerous modifications can be made to the various embodiments of the present invention, the above description and illustrations should not be construed as limiting the scope of the invention, which is defined by the appended claims.