Patent Publication Number: US-9885165-B2

Title: Deck drain and method of manufacture

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. Provisional Application No. 61/794,991, filed Mar. 15, 2013, entitled “Deck Drain and Method Manufacture,” the contents of which is hereby incorporated by reference in its entirety. 
    
    
     BACKGROUND 
     Conventional drainage channels typically comprise a hollow molded concrete member with the channel being defined by the contours of the concrete member. Such drainage channels are difficult to shape to varying drainage paths, do not scale efficiently and are difficult to ship. Accordingly, there is a long-held but unmet need for drainage channels that are adaptable, scalable and easy to transport. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following detailed description of embodiments refers to the accompanying drawings which illustrate specific embodiments of the disclosure. Other embodiments having different structures and operations do not depart from the scope of the present disclosure. 
         FIG. 1  shows a top elevation view of an embodiment of the present invention. 
         FIG. 2  shows an elevation view of the proximal end of the drainage channel formed by joining the first half member and second half member of an embodiment of the present invention. 
         FIG. 3  shows an elevation view of a side of the drainage channel formed by joining the first half member and second half member of an embodiment of the present invention 
         FIG. 4  shows an elevation view of the distal end of the drainage channel formed by joining the first half member and second half member of an embodiment of the present invention. 
         FIG. 5  shows an elevation view of the bottom of a drainage channel formed by joining the first half member and second half member of an embodiment of the present invention. 
         FIG. 6  shows a perspective view of an embodiment of the present invention. 
         FIG. 7  shows a perspective view of a half member of an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION 
     Embodiments of the present invention address the above needs by providing an improved deck drain and method of manufacturing and installing the same. Referring to the drawings, where like reference numerals refer to the same or similar parts,  FIG. 1  provides a top elevation view of an embodiment of the present invention. As shown, the drainage channel is comprised of two half members  102  and  114 . A projection  104  extends longitudinally from the proximal end of the first half member  102 . A depression (see  FIG. 4  at  106 ) corresponding to the size and shape of the projection  104  is located on the distal end of the first half member  102 . The first half member  102  features an overhang  108  extending away from the first half member  102  along the length of the first half member  102  adjacent to the top of the first half member  102 . The overhang  108  is interrupted at regular distances by alternating protrusions  110  and recesses  112 . The second half member  114  is a mirror image of the first half member  102 . The second half member  114  features a projection  116  extending longitudinally from the distal end of the second half member  114 . A depression (see  FIG. 2  at  118 ) corresponding to the size and shape of the projection  116  is located on the proximal end of the second half member  114 . The second half member  114  features an overhang  120  extending away from the second half member  114  along the length of the second half member  114  adjacent to the top of the second half member  114 . The overhang  120  of the second half member  114  is interrupted at regular distances by alternating protrusions  122  and recesses  124 . The protrusions  122  of the second half member occur at the same longitudinal distances from the proximal end of the second half member  114  as the recesses  112  of the first half member  102 . The recesses  124  of the second half member  114  occur at the same longitudinal distances from the proximal end of the second half member  114  as the protrusions  110  of the first half member  102 . 
       FIG. 2 , shows an elevation view of the proximal end of the first half member  102  and second half member  114  joined together. As shown, the projection  104  is located adjacent to the top of the first half member  102  and the depression  118  is located adjacent to the top of the second half member  114 . The overhang  108 , which as shown, extends inwardly, away from the first half member  102  and is located adjacent to the top of the first half member  102 . The overhang  120  of the second half member  114  similarly extends inwardly away from the second half member  114  and is located adjacent to the top of the second half member  114 . The two overhangs  108  and  120  meet to form a nearly solid member. The base  126  of the first half member  102  and the base  128  of the second half member  114  also extend inwardly and meet to form a nearly solid member. The contour formed by the interior edges of the first half member  102  and the second half member  114  define a channel  129 . 
       FIG. 3  is an elevation view of a side of the drainage channel formed by joining the first and second half members. Inasmuch as the first and second half members are mirror images of the each other, both half members will feature similar elements to those shown in  130 . As shown, the half member features a groove  132  running longitudinally adjacent to the top of the half member. The projections  104  and  116  can be seen at the distal and proximal ends of the drainage channel. 
       FIG. 4  is an elevation view of the distal end of the first half member  102  and second half member  114  joined together. As shown, the projection  116  is located adjacent to the top of the second half member  114  and the depression  106  is located adjacent to the top of the first half member  102 . The overhang  120 , which as shown, extends inwardly, away from the second half member  114  and is located adjacent to the top of the second half member  114 . The overhang  108  of the first half member  102  similarly extends inwardly away from the first half member  102  and is located adjacent to the top of the first half member  102 . The two overhangs  108  and  120  meet to form a nearly solid member. The base  126  of the first half member  102  and the base  128  of the second half member  114  also extend inwardly and meet to form a nearly solid member. The contour formed by the interior edges of the first half member  102  and the second half member  114  define a channel  129 . It will be understood that the size of the channel  129  can be made larger or smaller by changing the size of the first and second half members and/or the contours formed by the interior edges of the first and second half members. 
       FIG. 5  is an elevation view of the bottom of a drainage channel formed when the first half member  102  and second half member  114  are joined together. As shown, the base  126  of the first half member  102  and the base  128  of the second half member  114  extend inwardly and meet to form a nearly solid member. The projection  104  can be seen extending from the proximal end of the first half member  102  and the projection  116  can be seen extending from the distal end of the second half member  114 . 
       FIG. 6  is a perspective view of the drainage channel formed when the first half member  102  and the second half member  114  are joined together. The first half member  102  is joined to the second half member  114  when the protrusions  110  of the first half member  102  are received by the recesses  124  of the second half member  114  and the protrusions  122  of the second half member  114  are received by the recesses  112  of the first half member  102  and the respective overhangs  108 , 120  are directly adjacent to each other creating a seal between the first half member  102  and the second half member  114 . As the top portions of the first half member  102  and second half member  114  come together the base  126  of the first half member  102  meets the base  128  of the second half member  114  and also forms a seal. The contour formed by the interior edges of the first half member  102  and the second half member  114  define a channel  129 . 
     As shown, when the first and second half members are joined together, in some embodiments, an indentation  134  is defined by the contours of the top of the first and second half members and the upward facing surface created by the joined overhangs. This indentation  134  runs longitudinally along the top of the drainage channel. 
     In use, surface water or water from other drains will be directed into the channel  129  and water will flow the length of the channel formed by the two half members. Multiple sections of drainage channel can be joined together by inserting projections  104  and  116  into depressions  106  and  118 . When the depressions receive the projections a nearly solid member is formed. The drain is formed by removing soil to form a sloping trench along the intended path of the drain. Lengths of drainage channel are placed along the path and are joined together as described above. Concrete is then poured around the drainage channel. The concrete fills in the groove  132  on the sides of the first and second half members and the indentation  134  running along the top of the drainage channel. As the concrete hardens the resulting forces apply inward pressure along the drainage channel further strengthening the seal of the first and second half members. Water is funneled to the first opening of the drainage channel by means of slot drains, natural run-off or other known methods of redirecting water. The water then travels through each section of drainage channel to its intended destination, such as the sewer system, a drainage pond and the like. 
     Referring now to  FIG. 7 , which shows a perspective view of a half member  200  of an embodiment of the present invention. As shown, a projection  202  extends from the proximal end of the half member  200 . Adjacent to this projection is the outline of a groove  204  the runs longitudinally along the back of the half member  200 . The edges of the interior of the half member  200  define a cavity  206  that travels longitudinally along the length of the half member  200 . In certain embodiments, the height of the cavity  206  is approximately two thirds of the total height of the half member  200 . Adjacent to the top of the cavity  206  is a surface  208  running the length of the half member  200  and forming the interior edge of the top portion of the half member  200 . At regular distances along this surface  208  are protrusions  210  extending away from the surface. At the distal end of the half member  200  is a recess  212 . The other half member (not shown) is a mirror image of the half member  200  illustrated in  FIG. 7  and includes recesses to receive the multiple protrusions  210  of the illustrated half member  200  and a protrusion to be received by the shown recess  212 . The other half member  200  also features a cavity that mirrors the cavity  206  of the illustrated half member  200 . When the two halves are joined together the top surfaces of the half members create a seal and the two cavities define a channel. 
     The drainage channels described and anticipated herein can be manufactured by forming a mold for each half member. In some embodiments a polymer concrete is poured into the molds creating the half members described above. However, concrete, plastics and other materials suitable for transporting water can be used. By forming the drainage channel from half members less polymer concrete (or other material) can be used to form the respective halves than would be required to mold a solid drainage channel. It will be understood that the size of the mold can be changed to create larger (or smaller) drainage channels without deviating from the primary features described herein. Similarly, the length of each section of drainage channel can be adjusted as needed for a particular use. 
     Inasmuch as the drainage channels are formed in half members the components of the drainage channel are smaller and can be transported more easily. For instance, half members of the drainage channel may be stacked one on top of the other without damaging to the drainage channel whereas previously the size and weight of a fully formed channel may have prevented stacking in shipment. 
     This application is intended to cover any adaptations or variations of the present disclosure. The following claims are in no way intended to limit the scope of the disclosure to the specific embodiments described herein.