IN-GROUND UTILITY ACCESS BOX AND RELATED METHODS

A utility access system may include a base, a plurality of sidewalls extending vertically upward from the base and connected together to define a cavity therein with an opening at a top thereof and a rim inside the opening, and a lid configured to close the opening when received by the rim. Each of the sidewalls may include a plurality of first and second ribs extending from the base to the rim, with the first ribs extending outwardly away from the rim and the second ribs extending inwardly beneath the rim, at least one first fin on each first rib outside of the rim, and at least one second rib on each second rib beneath the rim and coupled thereto.

TECHNICAL FIELD

The present disclosure generally relates to utility infrastructure, and more particularly to access boxes for utility infrastructure components and related methods.

BACKGROUND

Various types of ground boxes or vaults are used to provide access points in a number of utility infrastructure applications. For example, pull boxes provide access to cables such as electrical or telecommunications lines. Other similar types of boxes provide access to valves, meters, and the like.

Such boxes are typically buried with the top of the box flush with the ground. A removable lid provides access to the infrastructure within when needed, and keeps the infrastructure otherwise closed off and protected when it is not. Various materials are used for such boxes, including concrete and polymer-based materials, for example.

SUMMARY

A utility access system may include a base, a plurality of sidewalls extending vertically upward from the base and connected together to define a cavity therein with an opening at a top thereof and a rim inside the opening, and a lid configured to close the opening when received by the rim. Each of the sidewalls may include a plurality of first and second ribs extending from the base to the rim, with the first ribs extending outwardly away from the rim and the second ribs extending inwardly beneath the rim, at least one first fin on each first rib outside of the rim, and at least one second fin on each second rib beneath the rim and coupled thereto.

In an example embodiment, the first and second ribs may be arranged in an alternating fashion along each sidewall. Also by way of example, the at least one first fin may comprise a pair of spaced apart first fins at a top of each first rib. Similarly, the at least one second fin may comprise a pair of spaced apart second fins. In some embodiments, the first and second ribs may be elongated isosceles trapezoids. Furthermore, the base may comprise a webbed footer surrounding the cavity in an example implementation. In some embodiments, the base and plurality of sidewalls may define a unitary body, and they may comprise high-density polyethylene (HPDE), for example.

A related utility access vault, such as the one briefly described above, and method for making the vault are also provided. The method may include forming a base and a plurality of sidewalls extending vertically upward from the base and connected together to define a cavity therein with an opening at a top thereof and a rim inside the opening configured to receive a lid. Forming the sidewalls may include forming a plurality of first and second ribs extending from the base to the rim, with the first ribs extending outwardly away from the rim and the second ribs extending inwardly beneath the rim, forming at least one first fin on each first rib outside of the rim, and forming at least one second rib on each second rib beneath the rim and coupled thereto.

DESCRIPTION

Example embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which the example embodiments are shown. The embodiments may, however, be implemented in many different forms and should not be construed as limited to the specific examples set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete. Like numbers refer to like elements throughout.

Referring initially toFIGS.1-5, a utility access box or vault30in accordance with an example embodiment is first described. The box30is designed to be flush-mounted in the ground and receive a lid31in the top opening32illustrated inFIG.1, which allows access to a cavity therein where the utility infrastructure is located (e.g., electrical wiring or components, telecommunications components, water/sewer components, traffic light components, meters, valves, etc.). Conventional lids31(e.g., polymer concrete, conventional concrete, etc.) may be used with the illustrated box30, and in the illustrated configuration fits within the rimmed opening or rim33at the top of the box. As seen inFIG.1, the lid31is sized to close the opening32when received by the rim33.

Generally speaking, utility access boxes are positioned in locations where they may be subject to stress and heavy loads, such as along roadways. As such, they need to be sturdy enough to withstand such loads, which is why some of these boxes are made of concrete. However, transportation and storage of the boxes are also significant concerns, and thus lighter weight materials, such as polymer-based materials including high-density polyethylene (HDPE), are also used. A tiered scale is used to rate the strength of utility boxes, with tier 22 being the highest rating meant to withstand extreme loads such as being run over by a semi-tractor trailer.

The configuration of the illustrated box30provides a technical advantage of allowing fabrication from relatively light weight materials, such as HDPE (although other suitable materials may also be used, including concrete and polymer concrete or other polymer-based materials), while also providing enhanced structural stability high enough to achieve a tier 22 rating (although the present configuration may be used for lower-tiered box configurations as well). To achieve its structural rigidity, the box30illustratively includes outer (first) and inner (second) ribs34,35along slanted or flared walls36. In the present example, the exterior and interior ribs34,35have a cross section resembling an elongated isosceles trapezoid (pyramids), although other shapes may be used in different embodiments (e.g., semi-cylindrical, triangular, etc.). As seen inFIGS.1and5, the exterior and interior ribs34,35alternate in an accordion-like or corrugated fashion, such that where the outer ribs protrude the inner ribs are recessed, and vice-versa. Moreover, the outer ribs34have their base (widest portion) at the bottom of the box30, while the inner ribs35have their base at the top of the box (i.e., the exterior and interior ribs34,35are inverted with respect to one another).

The sidewalls36of the box30extend vertically upward from a base37and are connected together to define the cavity therebetween and the opening32at a top of the box, with the rim33inside the opening. The exterior and interior ribs34,35extend from the base37to the rim33. More specifically, the exterior and interior ribs34,35are in contact with and extend from the level of the base37all of the way up at least to the bottom level of the rim33in the illustrated example. Not only does this provide extra support and rigidity all of the way up the sides36of the box30, but it also allows for extra reinforcement of the rim33. Threaded inserts45or other suitable connectors may be included for securing the lid31(e.g., with screws, etc.).

In this regard, one or more exterior (first) fins41are positioned on the tops of the first ribs34, and one or more interior (second) fins are carried on the interior fins35. The exterior fins40are coupled to the sidewalls of the rim33, while the interior fins41are coupled to the bottom of the rim, providing both lateral and vertical support to the rim when the cover31is under load. In the illustrated example, respective pairs of exterior fins40and interior fins41are carried by the exterior ribs34and interior ribs35for extra reinforcement and rigidity, although a single fin (or more than two fins) may be used on the exterior and/or interior in different embodiments. The ribs34,35and fins40,41advantageously provide desired structural stability or rigidity to help prevent excess deformity/bending of the box30under load, and achieve desired load ratings such as those noted above. Moreover, having the fins40,41directly coupled to the ribs34,35extends that structural stability to the rim33as well.

The base37of box30includes a webbed footer or footing42(FIG.4), adding additional structural rigidity while helping to remove material to reduce weight. However, different footer configurations (e.g., solid, etc.) may also be used in different embodiments. It should be noted that the box30in the illustrated example is rectangular, but it may take other shapes (e.g., square, round, etc.) in different embodiments. Moreover, access boxes or vaults are known to come in a variety of different sizes for different applications, and the utility box described herein may be fabricated to accommodate such different sizes as well.

Another significant technical advantage of the utility box30is that it is a one-piece configuration which may be easily stacked for shipping and storage, as shown inFIGS.6-8. The unitary, one-piece configuration is advantageous in that it requires less work to assemble in the field than a two-piece configuration, and may require less time to package for shipping. Moreover, less parts also reduces the chances of pieces getting lost or separated during shipping or storage, for example.

With regard to stacking, the flared walls36allow multiple boxes30to be stacked one on top of another as noted above. In addition, the interior fins41provide a stop that keeps the next box30in the stack from sliding all of the way down along the lower box, which allows the boxes to be more easily separated during unstacking. The above-described configuration, including the pyramid shape of the inner and outer ribs34,35, also helps provide a technical advantage of easier de-molding during the fabrication process, e.g., after injection molding.

A related method for making the box30is now described with reference to the flow diagram90ofFIG.9. Beginning at Block91, the method illustratively includes forming the base37and the plurality of sidewalls36extending vertically upward from the base, at Blocks92-93. As discussed further above, the base36and sidewalls36may be integrally formed as a single, unitary body in a mold (e.g., from HPDE), although in some embodiments they could be formed as separate pieces. After demolding, the box30may be stacked with others for ease of storage and shipping, and its configuration allows for easy unstacking for deployment, as noted above. The method ofFIG.9illustratively concludes at Block94.