Abstract:
A prefabricated one-piece metal frame and funnel drain is constructed for curb and gutter use. The frame may be constructed in a number of styles, with a particular style selected to match the desired curb form. The funnel drain also includes a variety of styles in order to accommodate different drain pipe orientations and configurations. When welded together, the frame and funnel drain may be mounted within any standard curb and gutter form such that curb and gutter installation and drain pipe installation may be accomplished simultaneously, without any preparatory concrete work required for placement of the frame and funnel drain.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to drain outlets for public streets and roadways. More particularly, the present invention relates to a curb and gutter frame and funnel drain structure that may be installed in conjunction with standard concrete curb and gutter forms and that can be adapted to accommodate a variety of underground drain pipe configurations. 
     2. Description of the Related Art 
     In the prior art representatively shown in FIGS. 1 and 2, standard cast iron grates  100  and frames  102  are installed with curbs and gutters in a two-step process. Prior to the pouring of the curb  104 , brick masons construct a masonry chimney  106  directly over the drain pipe  108  for each frame and grate. When the appropriate elevation of each masonry chimney  106  is reached, a cast iron frame  102  and grate  100  is mounted thereon. When this work is completed, the standard curb and gutter forms are set around the frame and grate. Because this work is done in two steps, it is difficult to match the elevations of the masonry work with the drain slopes. 
     Furthermore, when pouring the concrete in the curb form, a section of the form must be left open on either side of the frame and grate due to the fact that a standard curb and gutter paving machine cannot pave over the previously installed cast iron frame and grate. As a result, the sections  110  on either side of the frame  102  and grate  100  must be hand troweled in by a later process. This not only incurs additional labor and expense, but also creates an expansion joint  112  in the paving near the grate. This joint near the grate is often a weak area that may separate under heavy loads. 
     Representative prior art is shown in U.S. Pat. Nos. 329,404, 783,740, 1,473,551, 1,664,853, 2,537,654, 2,809,414, 4,610,566, and 4,986,693. 
     SUMMARY OF THE INVENTION 
     In view of the foregoing, it is an object of the present invention to provide a one-piece curb and gutter frame and funnel drain that can be installed directly in a standard concrete curb and gutter form with the frame having the same upper profile as the form, enabling a standard curb and gutter paving machine to pour the curb with the frame and funnel drain in place in the form, thus eliminating the need to hand trowel on either side of the curb and gutter frame. 
     Another object of the invention is a frame and grate that may be installed without prior concrete work or preparation, and which can be installed concurrently with pouring of the curb and gutter. 
     A further object of the invention is a curb and gutter funnel drain oriented in non-vertical alignment with the frame and grate, allowing future repair to the drain without disturbance to the adjacent street and curb. 
     A still further object of the invention is a frame and funnel drain structure that can be adapted to accommodate a variety of drain pipe connection configurations. 
     In accordance with the foregoing and other objects, the present invention comprises a metal frame and funnel drain fabricated into a single welded structure. The funnel drain can be constructed in a number of ways so as to accommodate any type or shape of curb and gutter funnel outlet. The funnel drain is compatible with a full line of bolt-on attachments, including elbows, funnel extensions and saddle fittings, which connect to each other with standard corrugated metal pipe hugger bands. Through selection and adjustment of these attachments, the funnel drain may be effectively connected to a variety of drain pipe configurations, including those offset so as to be out of vertical alignment with the frame. 
     In addition to the adaptability of the configuration of the one-piece frame and funnel drain to fit various pipe orientations, the one-piece frame and funnel drain of the present invention also offers advantages in installation. The one-piece frame and funnel drain may be installed within any standard curb and gutter form. When installed in a curb and gutter form of the same style as the frame, a standard curb and gutter paving machine can pave directly up to the side panels of the frame. Furthermore, no preparatory concrete work is required to install the frame and funnel drain unit. Instead, concrete is poured with the one-piece unit in the form, so that curb and gutter installation and drain pipe installation may be accomplished simultaneously, saving both time and money over prior art methods. 
     These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a top view of a prior art cast iron grate and frame as installed in a curb; 
     FIG. 2 is a cross-sectional view along line  2 — 2  in FIG. 1 showing the prior art brick masonry base as built upon a drainage pipe to support the iron grate and frame; 
     FIG. 3 is a top view of a one-piece frame and funnel drain in accordance with the present invention, as installed in a standard curb with a grate in place; 
     FIG. 4 is a cutaway side view along line  4 — 4  in FIG. 3 showing the one-piece frame and funnel drain as installed, with a funnel extension connected to a drainage pipe with a saddle fitting; 
     FIG. 5 is a cutaway side view along line  4 — 4  in FIG. 3 showing the one-piece frame and funnel drain as installed, with an alternate funnel extension orientation; 
     FIG. 6A is a cutaway side view along line  4 — 4  in FIG. 3 showing another alternative construction of the one-piece frame and funnel drain as installed, the frame having an extendable rectangular sleeve fitting welded thereto which is connected to a drainage pipe with a saddle fitting; 
     FIG. 6B is a side view of the alternative construction of the one-piece frame and funnel drain of FIG. 6A; 
     FIG. 6C is a front view of the alternative construction of the one-piece frame and funnel drain of FIG. 6B; 
     FIG. 7A is a top view of a second alternative construction of the one-piece frame and funnel drain of the present invention, shown with a grate and mounted in a curb and gutter form; 
     FIG. 7B is a side elevational view along line  7 B— 7 B in FIG. 7A, showing a 900 circular funnel drain designed to fit in the lid of a pre-cast concrete junction box; 
     FIG. 8A is a top view of the one-piece frame and funnel drain shown in FIG. 7A, without the grate; 
     FIG. 8B is a cross-sectional view along line  8 B— 8 B in FIG. 8A, showing the steps on the inner surface of the circular funnel drain; 
     FIG. 9 is a front perspective exploded view of the one-piece frame and funnel drain of FIGS. 7A-7B, with the pre-cast concrete junction box and lid; 
     FIG. 10 is a front perspective view of the one-piece frame and funnel drain of the present invention shown in FIGS. 3-5 but without a grate; 
     FIG. 11A is a front perspective view of a 90° 2′6″ frame style in accordance with the present invention, shown without concrete; 
     FIG. 11B is a front perspective view of the 90° 2′6″ frame style of FIG. 11A, shown with concrete; 
     FIG. 12A is a front perspective view of a shoulder berm frame style in accordance with the present invention, shown without concrete; 
     FIG. 12B is a front perspective view of the shoulder berm frame style of FIG. 12A, shown with concrete; 
     FIG. 13A is a front perspective view of an “S” style transversible curb frame style in accordance with the present invention, shown without concrete; 
     FIG. 13B is a front perspective view of the “S” style transversible curb frame style of FIG. 13A, shown with concrete; 
     FIG. 14A is a side view of a standard 90° 2′6″ curb and gutter form; 
     FIG. 14B is a side view of a 36″ shoulder berm gutter form; and 
     FIG. 14C is a side view of an “S” style transversible curb form. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In describing preferred embodiments of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. 
     Referring now more specifically to the drawings, FIGS. 3 and 4 illustrate a preferred embodiment of the one-piece curb and gutter frame and funnel drain of the present invention, generally designed by the reference numeral  10 . A frame, generally designated by the reference numeral  12 , is fixedly connected to a funnel drain, generally designated by the reference numeral  14 . In each of the preferred embodiments discussed herein, the frame  12  and funnel drain  14  are preferably constructed of welded steel with a galvanized coating to ensure long life. As used herein, “funnel drain” is intended to refer generally to any drain which may be welded to the frame in accordance with the present invention and thus is not limited to drains having a customary “funnel” shape. 
     The frame  12  has a front panel  16 , two side panels  18  and a rear panel  20 . The rear panel  20  is taller than the front panel  16  in order to form a curb. Each side panel  18  rises upwardly near the rear panel  20 ; the slope of the rise varies depending on the curb form being matched by the frame  12 . A curb hood  22  is formed between the uppermost rear surfaces of each side panel  18  and the top of the rear panel  20 , extending toward the front panel, and having a shape and curvature consistent with the style of curb within which the particular one-piece unit  10  is intended to be installed. 
     The front panel  16  abuts the road surface  24  and gravel base  26  being drained by the one-piece frame and funnel drain  10 . A connecting structure such as a plurality of reinforcement studs  28  extend outwardly from each side panel  18  of the frame  12  in order to secure the frame  12  to the concrete paving  30 . In the preferred embodiments, these studs  28  comprise welded rebar pegs; however, other connecting elements can be used in accordance with the present invention. While not shown in FIG. 4, the frame also preferably includes a plurality of dowels  32  extending outwardly from the front panel  16  and the rear panel  20  of the frame for securing the frame to a curb and gutter form when pouring the concrete. Other structures for securing the frame in the form could also be used. 
     A grate  34  may be installed on the upper side of the frame  12 . Alternatively, the upper side of the frame  12  may be contoured with concrete as described more fully hereinafter. In the embodiment shown in FIGS. 3 and 4, the bottom of the frame has a sloped drain surface  82 , to the rear of which is a frame drain opening  84 . The frame drain opening  84  is accessible to the funnel drain  14  below and is normally directly above the top of the funnel drain  14 . In this embodiment, no concrete contouring is necessary and the upper side of the frame supports the grate  34 . 
     The funnel drain  14  shown in FIG. 4 is a sloped and tapered funnel drain that extends downwardly and rearwardly from the underside of the frame  12  into the supporting earth  36 . The upper end of the funnel drain  14  is fixedly connected to the underside of the frame  12 . Points of connection with the underside of the frame  12  preferably include the lower edge of the rear panel  20 , lower edge portions of the side panels  18 , and/or the bottom surface  82 . The funnel drain  14  is connected to the underside of the frame preferably by welding, but other suitable techniques for joining metal objects can also be used. During manufacture, the funnel drain can be welded to the frame at any angle to accommodate particular construction needs. Alternatively, the frame  12  and funnel drain  14  can be manufactured separately and then bolted together prior to or during installation in the field. With such a bolting arrangement, variation in the angle between the frame and the funnel drain can be accommodated through alternative bolt positions. 
     A particular advantage to the sloped and tapered funnel drain  14  is that it allows the drain pipe to be out of vertical alignment with the frame and funnel drain  10  and associated concrete paving. By offsetting of the drain pipe, the funnel drain may be connected to the drain pipe after the curb has been poured. In addition, many future repairs to the drain system may be effected without disturbing the adjacent street and curb. 
     A funnel extension  38  is coupled to the lower end of the funnel drain  14  with a connector band  40 . The other end of the funnel extension  38  is connected to a drainage pipe  42  using a saddle fitting  44 . Variation in the positioning of the drainage pipe  42 , shown by dotted lines as drainage pipe  42 ′, may be accommodated by orienting the funnel drain  14  differently, relative to the frame  12 , when initially connecting the drain  14  to the frame  12  to construct the one-piece frame and funnel drain  10 . Drainage pipe  42 ′ may also be accommodated through the use of a variety of funnel extensions and attachments, such as shown in FIG.  5 . 
     Looking now to FIG. 5, an elbow fitting  46  may be connected between the lower end of the funnel drain  14  and the funnel extension  38 , and secured with hugger bands  48 . Other structures suitable for connecting the fitting and drain structures may also be used. 
     An alternative embodiment of the one-piece frame and funnel drain  10  is shown in FIGS. 6A-6C. An extendable rectangular sleeve fitting, generally designated by the reference numeral  50 , is welded to the frame  12  and acts as the funnel drain. The extendable rectangular sleeve  50  has an inner portion  52  and an outer portion  54 . The outer portion  54  is sized to receive the inner portion  52  and includes a slot  56 . 
     In this alternative embodiment, the inner portion  52  is welded to the underside of the frame  12 , preferably at an angle approximately perpendicular thereto. The outer portion  54  tapers at the bottom and is connected to the drainage pipe  42  with a saddle fitting  44 . The depth of insertion of the inner portion  52  within the outer portion  54 , and hence the distance between the underside of the frame  12  and the drainage pipe  42 , is adjustable. When the inner portion  52  is at the desired insertion depth, the bolt  58  that passes through the slot  56  is tightened to secure the inner portion  52  against the outer portion  54 . 
     A second alternative embodiment is shown in FIGS. 7A-7B. FIG. 7A shows a top view and FIG. 7B shows a side elevational view of the frame and funnel drain  10  with a circular drain  68  as installed in a curb and gutter form, generally designated by the reference numeral  60 . The curb and gutter form  60  includes front and rear longitudinal members  62  joined by cutter plates  64 . The cutter plates  64  are used to form expansion joints in the poured concrete. The shape of the cutter plates  64  determines the contour of the concrete when it is poured, as further illustrated in FIGS. 14A-C. Before the concrete is poured, the form  60  is anchored to the ground using metal rods or stakes (not shown) through anchor loops  66 . 
     The frame and funnel drain  10  is mounted in the form  60  using the dowels  32  which are inserted through holes in the longitudinal members  62 . After the concrete paving  30  sets, the cutter plates  64  are removed and the longitudinal members  62  are pulled outwardly off the dowels  32 . The frame is secured to the set concrete paving  30  on either side by the reinforcement studs  28 . A grate  34  is placed over the frame  12  to cover the top of the circular drain  68 . In this second alternative embodiment, the lower end of the circular drain  68  is designed to fit into a pre-cast concrete box lid  70  for a concrete junction box  72 , as shown in FIG.  9 . 
     In FIGS. 8A and 8B, top and cross-sectional views, respectively, of the frame and funnel drain of FIG. 7A are shown with the grate  34  removed. Mounted on the inner surface of the circular drain  68  are preferably a plurality of manhole steps  74 . When the grate is removed, these manhole steps  74  allow entrance into the concrete junction box  72  located beneath the drain  68 . Side support shelves  76 , located on the inner surface of each side panel  18  of the frame, as well as a front support shelf  78  on the inner surface of the front panel  16 , support the grate  34  when installed. In a preferred embodiment, each side support shelf  76  includes an upwardly extending rear stop  80  (see FIG. 10) that prevents the grate from moving too far rearward, ensuring that the front edge of the grate remains immediately adjacent the front panel  16  of the frame  12  and supported on shelf  78 . 
     FIG. 9 shows a front perspective view of the frame  12  with circular drain  68 , according to the second alternative embodiment. As shown, the circular drain  68  is sized to fit within the circular opening  73  of the pre-cast concrete box lid  70  and can be rotated within such lid. This rotational capability allows the present invention to accommodate a curb and gutter arrangement that is not parallel with the concrete junction box  72 , offering a significant advantage over the prior art bricked masonry chimney technique. A center area  71  of each of the four sides of the concrete junction box  72  can be punched out to access drain lines from four directions. 
     Looking now to FIG. 10, a front perspective view of the embodiment of the frame and funnel drain  10  shown in FIGS. 3-5,  10  as adapted for use with a grate, shows the sloped drain surface  82  of the frame  12 . When the frame and funnel drain  10  has been installed, the grate  34  is placed over the sloped drain surface  82  and supported on either side by side support shelves  76 . The grate is prevented from moving rearward by the upwardly extending rear stops  80 . Drainage water flows through the frame drain opening  84 , at the rear of the sloped drain surface  82 , in the bottom of the frame, where it is directed through the funnel drain  14 . The curb hood  22  prevents debris or other materials from falling directly into the frame drain opening  84  from above. 
     The embodiments depicted in FIGS. 4,  6 A- 6 C and  7 A- 7 B represent three preferred embodiments of the frame and funnel drain  10  of the present invention. In the figures illustrating each of these embodiments, the frame  12  is shown as a 90° 2′6″ frame, with the style of the funnel drain  14  varying and thus distinguishing the three embodiments. However, each of the funnel drain styles shown could be paired with an alternative frame style, according to particular need. For example, the sloped and tapered funnel drain  14  of FIG. 4 could be combined with a shoulder berm frame style or with an “S” frame style. Similarly, the extendable rectangular sleeve  50  of FIGS. 6A-6C could be combined with a shoulder berm frame or with an “S” style curb frame, and so on. A particular frame style is selected on the basis of the curb form within which the frame and funnel drain is to be installed, while the choice of drain style is dependent upon the drainage pipe configuration or other considerations. The present invention includes any combination of frame and drain styles, welded together to form a one-piece steel structure. The frame and funnel drain combinations shown herein are thus illustrative only and are intended to demonstrate some of the many constructions that are possible. 
     Looking in greater detail at particular frame styles, FIGS. 11A and 11B are front perspective views of a 90° 2′6″ frame  12  according to the present invention, as constructed for concrete contouring; the funnel drain  14  is not shown. As shown by the frame  12  without concrete in FIG. 11A, the bottom  86  of the frame includes an upwardly and rearwardly extending rear edge  88 . On the top of each side of the upwardly extending rear edge  88 , there preferably is an upwardly extending fin  90  that abuts the respective side panel  18  and slopes downwardly toward the center of the rear edge  88 . A plurality of reinforcement rods  92  extend laterally between the side panels  18 . Concrete is poured into the frame and contoured to be flush with the top edges of the front panel  16  and side panels  18 , sloping downward toward the middle of the rear edge  88 , as shown in FIG. 11B; preferably, the slope is approximately 2:1. The fins  90  ensure a downward slope is achieved from the top edge of either side panel  18  toward the middle of the rear edge  88 . The concrete, when set into the contoured concrete drain surface  94 , is strengthened by the reinforcement rods  92 . When installed, the top edges of the side panels  18  and front panel  16  are flush with the surrounding paving. This allows the water to flow directly into the contoured concrete drain surface  94  from three sides, and also allows wheeled vehicles, including bicycles, to ride over the depression created by the drain surface without losing control. Reinforcement studs  28  secure the frame  12  to the paving. The curb hood  22  matches the shape and curvature of the curb within which the one-piece frame and gutter drain is installed. 
     A second frame style in accordance with the present invention for use with a shoulder berm gutter form, as constructed for concrete contouring, is shown in FIGS. 12A and 12B. As shown by the frame without concrete in FIG. 12A, the bottom  96  of the frame is essentially perpendicular to the side panels  18 , and has a back rear edge  98  adjacent the frame drain opening  84 . On each side of the back rear edge  98 , there preferably is an upwardly extending fin  91  that abuts the respective side panel  18  and slopes downwardly toward the center of the rear edge  98 . The height of the side panels  18  where they abut the front panel is typically somewhat greater than the height of the side panels at the front edge of the curb hood  22 . A plurality of reinforcement rods  92  extend laterally between the side panels  18 . Concrete is poured into the frame and contoured to be level with the top edge of the front panel  16 , sloping downwardly toward the back rear edge  98 , as shown in FIG. 12B; preferably, the slope is approximately 2:1. The concrete, when set into the sloping concrete drain surface  100 , is strengthened by the reinforcement rods  92 . When installed, the top edges of the side panels  18  and front panel  16  are flush with the surrounding paving. This allows water to flow directly into the sloping concrete drain surface  100  from three sides, and also allows wheeled vehicles, including bicycles, to ride over the depression created by the drain surface without losing control. Reinforcement studs  28  secure the frame to the paving. The curb hood  22  matches the shape and curvature of the curb within which the one-piece frame and gutter drain is installed. 
     A third frame style in accordance with the present invention for use with an “S” style transversible curb and gutter form, as constructed for concrete contouring, is shown in FIGS. 13A and 13B. As shown by the frame  12  without concrete in FIG. 13A, the bottom  120  of the frame includes an upwardly extending rear edge  122 . Near the midpoint between the side panels  18 , the top of the rear edge  122  is approximately parallel to the bottom  120  of the frame and has relatively little vertical height. Moving outward from the midpoint toward each side panel  18 , the rear edge  122  slopes upwardly so that, when the rear edge  122  abuts the side panels  18 , the top of each side of the rear edge  122  is approximately flush with the top edge of the respective side panel  18 . A plurality of reinforcement rods  92  extend laterally between the side panels  18 . Concrete is poured into the frame and contoured to be flush with the top edges of the front panel  16  and side panels  18 , sloping downward toward the middle of the rear edge  122 , as shown in FIG. 13B; preferably, the slope is approximately 2:1. The upwardly sloping sides of the rear edge  122  ensure a downward slope is achieved from the top edge of either side panel  18  toward the middle of the rear edge  122 . The concrete, when set into the contoured concrete drain surface  124 , is strengthened by the reinforcement rods  92 . When installed, the top edges of the side panels  18  and front panel  16  are flush with the surrounding paving. This allows the water to flow directly into the contoured concrete drain surface  124  from three sides, and also allows wheeled vehicles, including bicycles, to ride over the depression created by the drain surface without losing control. Reinforcement studs  28  secure the frame  12  to the paving. The curb hood  22  matches the shape and curvature of the curb within which the onepiece frame and gutter drain is installed. 
     The three most common curb forms are shown in profile or side view in FIGS. 14A-C. The form in FIG. 14A is a standard 90° 2′6″ curb and gutter form and represents the style of curb within which the frame depicted in FIGS.  10  and  11 A- 11 B is intended to be installed. The form in FIG. 14B is a  36 ″ shoulder berm gutter form and represents the style of curb within which the frame shown in FIGS. 12A-12B is intended to be installed. The form in FIG. 14C is an “S” style transversible curb and gutter form and represents the style of curb within which the frame shown in FIGS. 13A-13B is intended to be installed. Other curb styles are also possible and may be easily accommodated through adjustment in frame construction. 
     To install the curb and gutter one-piece frame and funnel drain  10 , the desired curb form  60  is installed to the desired elevation. A hole must be dug into the supporting earth  36  at the desired drain location. Then the one-piece frame and funnel drain  10  is mounted directly in the curb form  60  using the dowels  32 , with the funnel drain  14  extending downwardly into the hole in the ground. Once the frame and funnel drain  10  is mounted in the form  60 , the concrete paving  30  can be poured by a standard slip form curb and gutter paver. The frame and funnel drain  10  can be mounted directly in the curb form  60  and “paved over” because the side panels of the frame  12  are the same shape as the cutter plates  64  within the curb form  60 . As a result, curb and gutter installation and drain pipe installation can be done simultaneously instead of in the two steps that are otherwise necessary to complete the open sections of paving in the portion of the curb that contains the frame. 
     Once the concrete paving sets, the cutter plates  64  are removed and the longitudinal members  62  are pulled outwardly off the dowels  32 . The frame  12  is secured to the set concrete paving  30  by the reinforcement studs  28 . Using funnel attachments, such as elbows  46 , funnel extensions  38  and saddle fittings  44 , the final connection between the funnel drain  14  and the drain pipe  42  can be made then or at a later time. 
     The foregoing descriptions and drawings should be considered as illustrative only of the principles of the invention. The invention may be constructed in a variety of configurations and is not limited to the configurations shown in the preferred embodiments. Therefore, it is not desired to limit the invention to the specific examples disclosed or the exact construction and operation shown and described. Rather, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.