Abstract:
A device and method for the creation of a water proof component void form unit to create space between concrete structures and expansive soil for the passage of plumbing lines, electrical lines and other utility conduit lines is described. The unit includes a plurality of panels interlocked with one or more connectors. The panels are aligned opposite one another and are configured to abut one another to create a route. The panels are located in a trench and configured to define a void space underground for the passage of the utility conduit lines. A top cap overlays across the panels. Utility conduit lines are routed within the void space and adjusted according to needs. The unit is configured to resist soil expansive forces so as to protect the placement and integrity of the utility conduit lines.

Description:
CLAIM OF PRIORITY 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 62/298,769, filed 23 Feb. 2016. The information contained therein is hereby incorporated by reference. 
     
    
     BACKGROUND 
       [0002]    1. Field of the Invention 
         [0003]    The present application relates generally to construction products, and in particular to an apparatus for a water proof component void form to create space between concrete structures and expansive soil for the passage of plumbing lines, electrical lines and other utility conduit lines. 
         [0004]    2. Description of Related Art 
         [0005]    A plurality of structures are built on and in expansive soils. Most buildings require one or more plumbing lines to provide clean water and remove waste water. Unprotected plumbing lines in the ground are subject to stresses from expansive soil. Often the stresses are great enough to break the pipes, push plumbing lines through the slab, damage other plumbing apparatuses or even cause damage to adjacent structures. Once this occurs, the lines leak and can cause excessive saturation under a foundation. This saturation may lead to foundation cracking and further soil expansion. It is often desired to isolate plumbing lines from direct contact with expansive soil in order to minimize potential damages. This is not always easy. 
         [0006]    A few different types of methods have been developed. For example, one type of method involves the use of a metal wire mesh formed into a volumetric shape. The idea being that as the soil pushes on the wire mesh, the mesh will deform or the soil will push through the mesh. While in theory this may work, it is often not feasible and has many disadvantages. Metal cages are difficult to manipulate and contour to the path of the plumbing. Additionally, cutting and shaping the mesh can be very difficult and time consuming. Cut wires are sharp and can lead to injuries. Likewise, soil passes easily through the gaps in the mesh. 
         [0007]    Although great strides have been made with respect to protecting underground plumbing lines from expansive soil, considerable shortcomings remain. A new type of system is needed that prevents damage to buildings, plumbing lines and other conduit from soil expansion. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0008]    The novel features believed characteristic of the application are set forth in the appended claims. However, the application itself, as well as a preferred mode of use, and further objectives and advantages thereof, will best be understood by reference to the following detailed description when read in conjunction with the accompanying drawings, wherein: 
           [0009]      FIG. 1  is a perspective view of a plumbing void construction unit according to an embodiment of the present application; 
           [0010]      FIG. 2  is an exemplary front view looking down the length of the plumbing void construction unit of  FIG. 1  in finished form; 
           [0011]      FIGS. 3-22  are exemplary perspective views illustrating the method of construction of the plumbing void construction unit of  FIG. 1 . 
       
    
    
       [0012]    While the device and method of the present application is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the application to the particular embodiment disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the process of the present application as defined by the appended claims. 
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0013]    Illustrative embodiments of the preferred embodiment are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developer&#39;s specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. 
         [0014]    In the specification, reference may be made to the spatial relationships between various components and to the spatial orientation of various aspects of components as the devices are depicted in the attached drawings. However, as will be recognized by those skilled in the art after a complete reading of the present application, the devices, members, apparatuses, etc. described herein may be positioned in any desired orientation. Thus, the use of terms to describe a spatial relationship between various components or to describe the spatial orientation of aspects of such components should be understood to describe a relative relationship between the components or a spatial orientation of aspects of such components, respectively, as the device described herein may be oriented in any desired direction. 
         [0015]    The apparatus and method in accordance with the present application overcomes one or more of the above-discussed problems commonly associated with underground plumbing lines, electrical lines and other conduit. Specifically, the unit of the present application is configured to eliminate costly damage to buildings and broken plumbing under, and above, concrete slabs due to the effects of expansive soil. In particular, the unit of the present application is configured to provide a void space within the ground that is formed from a collection of solid surfaced members. The unit of the present application is configured to provide temporary support to under-slab plumbing and suspend lateral pipes in a protected containment void area. The unit is easily customizable and can adjust to changes in plumbing routes. These and other unique features of the device are discussed below and illustrated in the accompanying drawings. 
         [0016]    The apparatus and method will be understood, both as to its structure and operation, from the accompanying drawings, taken in conjunction with the accompanying description. Several embodiments of the device may be presented herein. It should be understood that various components, parts, and features of the different embodiments may be combined together and/or interchanged with one another, all of which are within the scope of the present application, even though not all variations and particular embodiments are shown in the drawings. It should also be understood that the mixing and matching of features, elements, and/or functions between various embodiments is expressly contemplated herein so that one of ordinary skill in the art would appreciate from this disclosure that the features, elements, and/or functions of one embodiment may be incorporated into another embodiment as appropriate, unless otherwise described. 
         [0017]    The apparatus of the present application includes a unit having a plurality of members that when used in combination, creates a self-contained void space for the safe routing of plumbing lines, electrical lines and other conduit underground. The unit includes a plurality of selectively arrayed panel sections coupled together to form a routing path. The panel sections are supported with a plurality of braces/connectors for stability. Additional panels may be added over the top of the panel sections so as to enclose the space. Pipe is laid within the space and elevated as necessary to ensure proper drainage. Elevation is secured through the use of a clevis bracket and threaded rod configured to extend out through the space and panel sections. A fastener and washer combination is used to provide temporary support for the pipe, being supported by the braces/connectors. By modifying the panel sections, routes may be customized to accommodate plumbing needs. Additional features and functions of the device are illustrated and discussed below. 
         [0018]    Referring now to the drawings wherein like reference characters identify corresponding or similar elements in form and function throughout the several views.  FIG. 1  illustrates a sample configuration for a plumbing void construction unit  101  according to the present application. Unit  101  is depicted below ground level within a trench, wherein the wall of the trench closest in the view is removed for clarity purposes. Unit  101  is configured to provide a modular and fully customizable routing void space below ground level in which to run any number of utility lines, such as plumbing lines, electrical lines, gas lines and so forth. Unit  101  is configured to provide a fully enclosed space designed to withstand soil pressures. Unit  101  is also configured to protect the utility lines from expansive soil movements. 
         [0019]    Referring now also to  FIG. 2  in the drawings, a front view looking down the length of unit  101  is illustrated. Unit  101  includes a plurality of side panels  103  coupled together through one or more braces/connectors  105 . The combination of panels  103  in communication with one another form a channel for the laying of piping. It is understood that any type of lines may be run within the void space generated by unit  101 . For purposes of explanation, reference will be given to that of plumbing lines and associated piping. Unit  101  further includes a top cap configured to overlap the side panels and enclose the void space from the backfill and soil. The side panels  103  and top cap  107  are configured to resist inward movement of the soil into the void space. 
         [0020]    As seen in  FIG. 2 , unit  101  is located within the ground and surrounded by backfill or soil when fully assembled. Initially unit  101  is located within a trench for assembly purposes. A hanger  109  and rod  111  are also shown for supporting the plumbing lines. Unit  101  may further include fastener system  113  to provide support for hanger  109  and rod  111  prior to being fully secured by the substrate above ground. The other depicted portions of  FIG. 2  illustrate contextual references and show an exemplary manner in which unit  101  may be utilized in a more specific application. As seen, unit  101  is located within the ground and rod  111  protrudes forth out of the ground into a substrate  115  such as concrete. A void producing structure  117  may be utilized between the substrate and the ground. 
         [0021]    Referring now also to  FIGS. 3-22  in the drawings, the method of use and components of unit  101  are illustrated. As stated previously, unit  101  is configured to create and maintain a contained void space separating underground plumbing lines, electrical lines and other conduit from expansive soil which may cause damage to the lines and adjacent structures. Unit  101  temporarily provides support for under-slab plumbing by suspending them off the ground. A void space area is provided in which expansive soils may expand without damaging plumbing lines. As seen in  FIG. 1 , unit  101  is located in a trench (see also  FIG. 3 ) and is used to surround the plumbing lines. The inner wall of the trench is not show in order to visually display unit  101  (see  FIGS. 4-20 ). The sequential alignment of panels  103  are shown. It is understood that the various members and parts of unit  101  are customizable to permit routing having any number of bends, changes in elevation, and more than one plumbing pipe, electrical line or conduit contained within. It is recommended that the trench be wider than the necessary void space area in order to have room for adjusting the sections when needed. This also applies to the depth of the trench in the case that a granular material is selected as a bottom layer. 
         [0022]    In  FIG. 4  two side panels  103  are illustrated within the trench. The panels  103  are placed at the base of the trench and are located in a side by side manner being separated by a gap. The gap is determined by the needed spacing requirements of the project these are used in conjunction for. Gap distances could be 24 inches or 18 inches for example. Panels  103  can be manufactured and used in various manners and forms. A top view of panel  103  is illustrated in  FIG. 6 . As seen, panel  103  is preferably formed as a ribbed plastic panel. The plastic material has perpendicular supports  119  connecting the exterior surfaces/faces  121  in order to form a supportive sheet/panel. Ideally, panel  103  is a solid member without perforations or holes along its main surfaces  121 . This prevents soil from passing through the panel. A conceivable material would be polypropylene plastic. Panels  103  may be found in different sizing. A common sizing may be that of: height approximately 18″ to 36″; width approximately 12″ to 24″; and length approximately 48″ for example. In these depictions, panels  103  are parallel to one another. It is understood that some instances may necessitate the angling of the panels  103  in a non-parallel orientation. 
         [0023]    Panels  103  are coupled together via connectors  105 . Connectors  105  are configured to interlock the plurality of panels  103  together. Panels  103  will be aligned opposite one another, as seen in  FIGS. 4 and 5 , and also in an abutting fashion along the same relative line, as seen starting in  FIG. 9 . Therefore connectors  105  are used to couple panels  103  together in both situations. Connectors  105  can be seen in communication with panels  103  in  FIG. 5 . 
         [0024]      FIGS. 7A and 7B  illustrated two basic types of connectors  105 . Connector  105   a  is illustrated in  FIG. 7A . Connector  105   b  is illustrated in  FIG. 7B . Each connector has a plurality of legs  123   a/b  and a bridge portion  125   a/b.  Bridge portion  125   a/b  is configured to extend between legs  123   a/b.  Its length may be any that is necessary to accommodate the spacing of panels  103 . In particular, connector  105   a  is configured to couple abutting panels  103 . Given that these panels abut one another, bridge portion  125   a  is relatively small and almost insignificant. Connector  105   b  is configured to extend between opposing panels across from one another and provide lateral support from the forces incurred through soil expansion. In this instance, bridge portion  125   b  is lengthened accordingly. Both types of connectors are seen in  FIG. 5 . It is important to note that legs  123   a/b  are configured and sized so as to translate within slots  127  formed between surfaces  121  and supports  119 . Other manners of coupling are considered, and in no way are connectors  105  limited to this particular manner of coupling. An example of connectors  105  could be rebar selectively bent, cut, and/or welded into shape. 
         [0025]    In  FIG. 8 , the connected section of panels  103  shown in  FIG. 5  is flipped over and aligned within the trench. An advantage of unit  101  is that it is ideally suited for simplified and easy construction, and can adapt to any routing configurations. In the flipped orientation, connectors  105  are located along the bottom of the panel sections. The constructing of them first with the connectors at the top and then flipping it over is found to be the simplest manner of construction. In  FIG. 9 , a second panel section unit is constructed and connected to the first panel section unit. The second unit abuts the first panel section unit. These panel sections are coupled to corresponding connectors  105   a,  both at the top and the bottom at this stage of construction so as to maintain their relative alignment during the remaining construction process. This same process is applicable for the constructing of all other panel sections. 
         [0026]    As stated previously, panels  103  are configured to adapt to different routing paths, where the paths do not necessarily follow a straight line.  FIGS. 10 and 11  illustrates a panel section that incorporates a “T” in the routing. Panel  103  is configured to accept scoring along surfaces  121 . When scored along the slots  127  of the ribbing through only a single face  121 , the remaining face  121  acts as a pivot point or folding joint to allow the face  121  to be angled as desired. In the depicted example, the face is oriented to form a perpendicular routing. Corresponding panels  103   b  are found opposite each other at the “T” intersection. 
         [0027]    Finally in  FIG. 12 , another panel section is included to form the initial routing. At this stage, when the routing is completed, utility lines may be added (see  FIG. 13 ). These lines are run/placed within the gap between panel sections. Naturally, the type of utility lines may dictate the how, where, and in what manner they are located within the gap. For purposes of explanation, unit  101  is shown with plumbing lines. Unit  101  may include a hanger  109  and a threaded rod  111  for the locating of plumbing lines. Hanger  109  and corresponding rods  111  are spaced as needed along the length of the plumbing lines. An exemplary distance of spacing may be that of four feet. 
         [0028]    Corresponding connectors  105  are located along the top surface of panels  103 / 103   b  in a manner and spacing similar to that described previously (see  FIG. 14 ). Ideally it is conceived that the spacing would be approximately 12″ on center, however the precise spacing requirements may depend on design constraints and environmental considerations. At this stage, connectors  105  are located along the top surface and the bottom surfaces of panels  103 . They are also located at the abutting ends of each panel. By laying the utility lines prior to locating the top layer of connectors, it is easier for a worker to maneuver and operate. 
         [0029]    The plumbing lines are needing to be located and/or suspended within the gap of panels  103 . Additional connectors  105   c  are located across panels  103  and on either side of rod  111  (see  FIGS. 15 and 16 ). Connectors  105   c  are similar in form and function to that of connectors  105   b.  System  113  is in threaded communication with rod  111  and is configured to rest on top of connectors  105   c.  The elevation of hanger  109  at each rod  111  is set by adjusting the amount of rod  111  that is threaded above and below system  113 . Therefore, by extending more of rod  111  above panels  103 , less is left within the gap. Although is it known that system  113  may take many types of forms, a simplistic configuration would be that of a single nut fastener and a washer. The washer would be configured to extend out away from rod  111  sufficiently to overlap connectors  105   c.  The fastener would permit the relative adjustment of rod  111 , with the washers supporting the weight of the plumbing lines across connectors  105   c.  System  113  is configured to temporarily locate and support the plumbing lines until the top end of rod  111  is secured within the substrate. Manipulation of each rod  111  within the routing allows workers to set a proper slope in the plumbing lines. Another feature to note is the use of connector  105   d.  Connector  105   d  is similar in form and function to that of connectors  105   b  except that the bridge portion is extended to permit a non-perpendicular alignment to panels  103 . 
         [0030]    Upon completion of unit  101 , the soil will be backfilled against panels  103 . Unit  101  may further include a retainer spacer  129  in communication with parallel panels on directly opposing sides of the gap (see  FIG. 17 ). Spacer  129  is configured to provide additional lateral support against stress induced flexure of panels  103  from the backfill of soil and potential subsequent expansion of said soil. Spacer  129  is made of similar material and structure as that of panel  103 . Slots similar to slots  127  are present and configured to accept one or more connectors. Spacer  129  is adhered to an interior surface  121  of panels  103 . A connector similar to that of connectors  105   b  are inserted into spacers  129  on corresponding sides of panels  103  (across the gap). Spacers  129  are typically installed after the locating of the utility lines so as not to interfere or cause an obstruction. The particular shape of spacers  129  are not herein limited to that which is depicted. 
         [0031]    In  FIG. 18 , unit  101  is illustrated with the inclusion of a top cap  107 . Cap  107  is configured to overlay across the tops of panels  103 / 103   b.  Cap  107  extends between rods  111 , such that rods  111  pass beyond cap  107  without the need to puncture cap  107 . Cap  107  is formed by taking a panel  103  and aligning the slots within the panel in a crosswise (side to side) orientation. Cap  107  may be scored in a manner to allow a portion of cap  107  to fold over and along the exterior surface  121  of both panels  103 . Connectors  105   e  are included over the top of cap  107  and are configured to pass through a portion of the scored flap sections. If the slot orientation is crosswise, the slots would be oriented in a vertical manner ready to accept connectors  105   e.  Connectors  105   e  are similar in form and function to that of connectors  105   b.  At intersection points, it may be necessary to trim portions of cap  107  to accommodate the inclusion of route branches.  FIG. 19  shows the inclusion of an end cap  131  adjacent panels  103   b.  End caps  131  are used to seal off open ends of each route to prevent soil from entering the void space. 
         [0032]    In particular to  FIG. 20 , a seam pad is illustrated. Unit  101  may further include the use of a seam pad  133 . Pads  133  pass around rods  111  and overlap the joints of caps  107 . Additionally, pads  133  are trimmed to wrap around any piping that may extend above caps  107 . In  FIG. 21 , once unit  101  is constructed, the soil is backfilled into the trench. The soil covers a portion of unit  101 . Ideally in most circumstances it is conceived that the backfill of soil will cover all of unit  101  except the extension of rods  111 , which will rise above the soil surface (see  FIG. 22 ). 
         [0033]    Referring again to  FIG. 2  in the drawings, rod  111  extends above the surface of the soil and is configured to couple to or within the substrate  115 . The substrate provides the final secure holding of rod  111  and therefore the plumbing lines within the void space located between panels  103  and cap  107 . System  113  is still operative at this time. System  113  is configured to flex under stresses induced by soil expansion so as to minimize the transfer of stress loads to the plumbing line. As soil expands, it may shift unit  101 . System  113  is configured to traverse along the tops of connectors  105   c  with lateral load shifts. Additionally, the washer is configured to flex or bend as soil induces a vertical load upwards on unit  101 . The composition of the washer is such that flexure is induces under particular loading. Under extreme conditions, the flexure of system  113  is sufficient to result in the washer passing between connectors  105   c.  This avoids rod  111  being loaded in a manner that would alter the slope of the plumbing lines. 
         [0034]    The current application has many advantages over the prior art including at least the following: (1) lightweight and easily portable; (2) collapsible; (3) easy to install procedural components; (4) connector supports approximately 12″ on center to resist lateral soil pressures; (5) all plastic or metal components that are impervious to water degradation; and (6) method of suspending the utility lines in a temporary fashion that is also configured to flex and minimize the transfer of loads in a manner to disrupt the plumbing lines. 
         [0035]    The particular embodiments disclosed above are illustrative only and are not intended to be exhaustive or to limit the invention to the precise form disclosed, as the embodiments may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. It is therefore evident that the particular embodiments disclosed above may be altered or modified, and all such variations are considered within the scope and spirit of the application. Accordingly, the protection sought herein is as set forth in the description. It is apparent that an application with significant advantages has been described and illustrated. Although the present application is shown in a limited number of forms, it is not limited to just these forms, but is amenable to various changes and modifications without departing from the spirit thereof.