Patent Publication Number: US-7591610-B2

Title: Water drain tank or channel module

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application No. 60/771,417, filed Feb. 8, 2006, the entire disclosure of which is hereby incorporated herein by reference. 

   BACKGROUND OF THE INVENTION 
   The present invention relates to water drain tank modules or channel modules, as well as to assemblies of the modules, to temporarily hold or divert water, typically storm water, from erosion paths or areas susceptible to flooding, and to control water drainage at least out of the modules. 
   More particularly, the present invention relates to a module that is easy to manufacture and assemble into an assembly of modules to create a water drain tank or drainage channel for controlling the flow of water at least out of the modules, as well as assemblies made from such modules. 
   The present invention controls the runoff of water from natural runoff areas, as well as construction sites, and other locations, where such runoff otherwise may cause a problem with respect to overflow areas, silt build-up and the like. In addition, the modules, alone or together as an assembly, restrict the entry of sediment into the modules or assembly and control the retention of soil abutting them when they are installed in a trench or otherwise underground. 
   The water drain tank or channel modules of this invention may be manufactured readily, are portable and may be assembled on site. The modules comprise a novel supporting structure to provide versatility in assembling both the modules themselves and assemblies of modules to create effective drainage channels. The modules and assemblies form holding tanks or reservoirs or slow-release tanks, reservoirs or channels to allow controlled release of runoff or storm water. 
   BRIEF SUMMARY OF THE INVENTION 
   One aspect of the present invention relates to a water drain tank or channel module comprising a structure having a top platen and a bottom platen, a plurality of generally vertical support members for supporting at least the top platen, the support members being retained in sockets on at least one of the bottom platen and the top platen, and optional side walls each comprising a water-permeable lattice member that is adapted to support an impermeable membrane or water-permeable geotextile material that is capable of controlling the flow of drain water at least out of the module and restricting sediment from entering the module. 
   Another aspect of the present invention relates to an assembly of modules to create a water drain tank or channel, wherein each module comprises a structure having a top platen and a bottom platen, a plurality of generally vertical support members for supporting the top platen, the support members being retained in sockets on at least one of the bottom platen and the top platen, and side walls as are necessary to form outer peripheral side walls of the assembly, each module side wall comprising a water-permeable lattice member that is adapted to support an impermeable membrane or a water-permeable geotextile material capable of controlling the flow of drain water at least out of the assembly and restricting sediment from entering the assembly, to create a tank or drain channel, and wherein at least the outer peripheral walls of the assembly are at least partially covered with the geotextile material. 

   
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
     The foregoing summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. 
     In the drawings: 
       FIG. 1A  is an isometric view of an assembly of modules according to the present invention forming a water drain tank or channel, with some modules removed for the sake of clarity, schematically showing the location of the assembly within a hole or trench in the ground; 
       FIG. 1B  is a top plan view of a module of the present invention with the top platen and a portion of lattice members in one corner removed to show the support structure of the bottom platen and a water-permeable geotextile material (only a portion of which is shown for the sake of clarity) below the bottom platen; 
       FIG. 2  is a front elevation view of the module of  FIG. 1B , showing the covering of the front wall with a geotextile material and the optional use of a water-impermeable covering that would extend at least partially around the side walls and under the bottom platen, (only portions of both of which are shown for the sake of clarity), such that this module would function as a holding or storage tank or reservoir; 
       FIG. 3A  is a schematic isometric view of a portion of a module according to the present invention with some of the top platen, walls and other details removed for the sake of clarity, and without any covering of the module walls with a water-permeable geotextile material or a water-impermeable covering; 
       FIG. 3B  is a schematic exploded isometric view of an assembly made using two vertically-stacked modules according to the present invention, where portions of the modules are removed for the sake of clarity; 
       FIG. 3C  is an enlarged isometric view of the circled area of  FIG. 3B , showing the use of one exemplary interlocking cylinder to align and interlock the vertically-stacked modules; 
       FIG. 3D  is a schematic isometric view of a portion of another embodiment of an assembly of vertically stacked modules according to the present invention, in which an intermediate platen substitutes for the top and bottom platens as shown in  FIG. 3C  and functions as a common or combined top and bottom platen, such that the intermediate platen includes top and bottom sockets to retain the vertical support members and for interlocking vertically stacked modules; and 
       FIG. 4  is a schematic side elevation view of three modules assembled together front-to-back to form a modular drainage assembly, with the geotextile covering removed for the sake of clarity. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Certain terminology is used in the following description for convenience only and is not limiting. The words “lower,” “upper,” “bottom,” “top,” “front,” “back,” “left,” “right” and “sides” designate directions in the drawings to which reference is made, but are not limiting with respect to the orientation in which the modules or any assembly of them may be used. The terminology includes the words specifically mentioned above, derivatives thereof and words of similar import. 
   As used herein, the article “a” or a singular component includes the plural or more than one component, unless specifically and explicitly restricted to the singular or a single component. 
   As used herein, “sediment” means the sand, gravel, soil, dirt or other solid particles surrounding the module or assembly of modules, which the geotextile material used with the modules and assembly restrict from entering the modules or assembly. 
   Referring to the drawings, where like numerals indicate like elements throughout the several views, there is shown a module  10  either individually or when assembled together as an assembly  11  of modules  10 , that is adapted to be buried in an appropriate location in the ground. The modules  10  of the present invention may be assembled side-to-side, front-to-back, top-to-bottom or in any other combination or alternative arrangement thereof.  FIG. 1A  shows a number of modules  10  formed into a module assembly  11  that is located within a hole or trench  13  in the ground  15 . Details of the modules  10  are explained below, and details of exemplary assemblies  11 , made from modules  10 ,  10 ′ and  10 ″ are explained below with reference to  FIGS. 1A and 4 . The hole or trench  13  has a bottom and walls of appropriate dimensions to hold the assembly  11 . Typically, a module  10 , or an assembly  11  is wrapped with appropriate geotextile material at least partially around the outer peripheral side walls, the top and the bottom of the module  10  or assembly  11  to control the flow of drain water at least out of the module or assembly and to restrict sediment from entering the assembly, thereby creating a drain tank or channel. Optionally, to create a holding or storage tank or reservoir, an impermeable membrane is wrapped at least partially around the outer peripheral side walls, the top and the bottom of the module  10  or assembly  11 . Thereafter, sediment of the appropriate type is backfilled between the walls of the hole or trench  13  and the outer peripheral side walls and the top of the module  10  or assembly  11  to bury the module or assembly, which can thereby control water runoff and draining. 
   With reference to  FIGS. 1B-3A , an embodiment of a module  10  is shown that includes four sides identified as a front  12 , a rear  14 , and first and second opposed sides  16  and  18 , as well as a top platen  20  and a bottom platen  22 . The sides may have optional walls made in a lattice structure or mesh structure (hereinafter referred to as a lattice member)  24 , that may be formed using at least one panel  19 . As shown, each of the front  12  and rear  14  has a wall of two panels  19 , and each of the sides  16  and  18  has a wall of one panel  19 . The panels  19  of the lattice members  24  are water permeable and have an open area of about 20% to about 80%, and in a preferred embodiment have an open area of about 50%. The top platen  20  and bottom platen  22  may have different structures or preferably, the same structure that in use is simply inverted to be the top or bottom platen. The top and bottom platens are also water permeable and have an open area of about 20% to about 80%, and in a preferred embodiment have an open area of about 45%. As noted above and explained in more detail below, the module  10  may be constructed without side walls to form a completely open structure without vertical walls or lattice members  24  or panels  19 . 
   The lattice members  24  may be of any desired configuration or materials, such as, without limitation, a synthetic polymer or fiber-filled polymer, such as polypropylene, a combination of polypropylene and polyethylene, or alternatively, polyvinylchloride (PVC), among others, that may be formed into a lattice by injection molding or other molding method, extrusion or pultrusion, thermoforming or the like, wire mesh of the type used in chain-link fences, that may be galvanized steel or other suitable material, or other materials. The top and bottom platens  20  and  22 , respectively, which preferably have the same structure, may also be of any desired configuration or materials, such as, without limitation, a synthetic polymer or fiber-filled polymer, such as polypropylene, a combination of polypropylene and polyethylene, or alternatively, polyvinylchloride (PVC), among others, that may be formed into a lattice by injection molding or other molding method, extrusion or pultrusion, thermoforming or the like, or metal, such as galvanized steel or other suitable metal, or other materials. 
   Preferably, the top and bottom platens have inner and outer peripheral edge flanges, forming channels to accommodate portions of the lattice member panels  19 . For example as shown best in  FIGS. 1B and 3A , the bottom platen  22  has an upwardly extending outer peripheral edge flange  23  and an upwardly extending inner peripheral flange  25  that define a channel  27  for retaining the lower edges of the panels  19 . There is a similar channel (not shown) in the top platen  20  defined by a downwardly extending outer peripheral edge flange  21  and a downwardly extending inner peripheral flange (not shown) for retaining the upper edges of the panels  25 . The flanges  21  and  23  thus overlap portions of the panels  19  located along the front  12 , rear  14  and sides  16  and  18 , to capture the panels  19  for enhanced structural integrity of the module. As best seen in  FIG. 1B , the panels  19  preferably have beveled vertical edges  29  to abut smoothly with each other in corners and with the structure within the channels  27  of the top and bottom platens  20  and  22 . 
   The top platen  20  is supported by an appropriate number, based on the size and shape of the modules, of support members  26 , preferably in the form of tubes of any convenient cross-section, such as circular, and having any suitable dimensions, which in turn are supported by the bottom platen  22 . It is presently preferred that each module be in a six-sided shape, with the module sides  12 ,  14 ,  16  and  18  and the top and bottom platens  20  and  22  each in a quadrilateral shape, including a rectangular or square shape, as shown in the drawings, with a number of edge support members  26  and some interior support members  26 . For example, the embodiment as shown in  FIGS. 1A ,  1 B,  3 A,  3 B and  4  has eight support members, one in each corner and one in the middle of the front and rear where the panels  19  for the front  12  and the rear  14  are rectangular, and two centered in the interior  29  of the module to equally support any load on the top platen, where the preferred spacing is best shown in  FIG. 1B . If the top and bottom platen plan view dimensions are reduced, only four support members  26  might be used. Further, if the top and bottom platens are made hexagonal or triagonal it would be possible for a construction with only one support member per top and bottom platen. The support members  26  are preferably retained at their tops and bottoms by collars  28  on the top and bottom platens. The collars may be formed integrally and unitarily with the top platen  20  and the bottom platen  22 , or the collars may be separately attached to the top platen  20  and the bottom platen  22  by suitable adhesives, fasteners such as screws, rivets or the like, or in any other suitable manner. 
   The support members  26  are preferably made from PVC pipe, for example without limitation, with a circular cross-section, and a standard outside diameter of about 2.375 inches (6 cm) and an inside diameter of about 2 inches (5.1 cm). This type of PVC pipe is readily available, is inexpensive, strong, durable and is easy to cut to form the desired module height which is preferably about 6 inches (15.2 cm) to about 36 inches (91.4 cm). As best seen in  FIG. 2 , the side panels  19  are optionally, but preferably, marked with a number of horizontal lines  38  and indicating arrows  40  that identify where to cut the panels  19  to pre-selected heights, such lines  38  and arrows  40  being compatible with the cutting of the support members  26  to 6 inch (15.2 cm) incremental module heights. 
   The module  10 , as best seen schematically in  FIG. 3A , forms a water-permeable module with a void space schematically shown as area  31 , but extending everywhere between the walls and in the absence of walls into the adjacent module void spaces. It is important that the structures of the top and bottom platens  20  and  22 , as supported by support members  26 , have sufficient integrity and strength to resist vertical and lateral loading and to support other modules when stacked vertically together, for example as an assembly  11  shown schematically in an exploded view in  FIG. 3B . When stacked vertically as shown in  FIG. 3B , it is especially important to align the vertical support members  26  in the upper modules with the vertical support members  26  in the lower modules. The enlarged partial view of  FIG. 3C  shows a preferred arrangement for aligning and interlocking the upper and lower modules  10 , by using interlocking cylinders  35  that extend through apertures or sockets  36  in the top platen  20  and the bottom platen  22 . 
     FIG. 3D  shows another embodiment of a platen for use in an assembly  11  of vertically stacked modules  10  according to the present invention, in which a single intermediate platen  42  substitutes for the top platen  20  and the bottom platen  22  as shown in  FIG. 3C  and functions as a common or combined top and bottom platen, such that the intermediate platen  42  includes top and bottom sockets  28  to retain the vertical support members  26  in alignment and for interlocking vertically stacked modules. The intermediate platen  42  has a horizontal support surface  44 , and also preferably includes outer edge flanges  43  and inner flanges  45 , both extending upwardly and downwardly from the horizontal support surface  44  to create channels  47  for the upper edges of any panels  19  used in the lower module and for the lower edges of any panels  19  used in the upper module. 
   It is also important that the support structure for lattice members  24 , such as in the form of panels  19 , be capable of supporting water-permeable and sediment restricting geotextile material  30 , shown partially covering the bottom platen  22  in  FIG. 1B , and partially covering the front  12  panels  19  in  FIG. 2 , both for the sake of clarity. Suitable water-permeable geotextile material  30  is typically made from polyester or polypropylene yarns, for example, as is well-known to those skilled in this art and is readily available. The geotextile material  30  withstands extended contact with sediment and water without degrading. Due to the water-permeable characteristics of the geotextile material, it allows water within the void space  31  of the module  19  or assembly  11  to flow out of the module  10  or assembly  11  and into the surrounding environment, typically including layers of gravel, sand or other more water-permeable material than densely-packed soil, such as clay, that may be in the strata surrounding the module  10  or module assembly  11 . The geotextile material  30  allows runoff, storm or other water to flow slowly out of the module  10  or module assembly  11 , and from the void space  31  of the module  10  or module assembly  11 , while inhibiting the entry of sediment into the void space  31  of the module  10  or module assembly  11 . The geotextile material  30  may cover one or more walls of each module  10 . Alternatively, when the modules, such as  10 ,  10 ′ and  10 ″, are assembled together to form one embodiment of a module assembly  11  as shown in  FIG. 4 , the geotextile material  30  may cover some or all of the outside walls to create a water drainage tank or channel formed by the interconnected void spaces  31  of the modules  10 ,  10 ′ and  10 ″. 
   If desired to form a holding tank or reservoir from a module  10  or module assembly  11 , for a water detention purpose, an optional water-impervious covering  32 , best shown in  FIG. 2 , such as various types of synthetic polymeric plastic sheeting, could cover all or a portion, such as the bottom platen  22  and entirely, or as shown, partway up the panels  19  of the lattice members  24  at the front  12 , rear  14 , and sides  16  and  18 . The top portion of the side panels could be covered with the geotextile  30  as shown. When a water-impervious covering is provided, the water is held within the module for storage and subsequent release by pumping or a restricted flow method. 
   With reference to  FIG. 4 , an exemplary, non-limiting embodiment of a module assembly  11  is shown as formed from three modules  10 ,  10 ′ and  10 ″ arranged in a lateral front-to-back alignment. In the module assembly  11  of  FIG. 4 , the interior front and rear walls of the various modules have been eliminated to form a less restrictive flow path or channel for water to flow within the module assembly  11 . The edges of side walls  16  are shown adjacent to each other at the dashed lines  33  in  FIG. 4 . While not necessary, the modules  10 ,  10 ′ and  10 ″ may be held together by clips, staples, wire ties or the like, as shown schematically by reference to fasteners  34  in  FIG. 4 . Thus, in this embodiment, the module  10  has a front  12  with two lattice panels  19  (to the left in  FIG. 4 ), namely a forward panel  19  and a rearward panel (not visible); sides  16  and  18  with lattice panels  19  shown on side  16  (to the rear in  FIG. 4 ), a top platen  20  and a bottom platen  22 . Module  10 ′ has only a top platen, a bottom platen and sides with panels  19 ′ (only the panel  19 ′ on side  16 ′, to the rear in  FIG. 4 , is visible) walls; and module  10 ″ has a top platen, a bottom platen and side walls with panels  19 ″ (only the panel  19 ″ on side  16 ″, to the rear in  FIG. 4 , is visible), as well as a rear  14 ″ with two panels  19 ″, namely a forward panel  19 ″ and a rearward panel (not visible). If the middle module  10 ′ also had another module stacked on top of it, then the top platen of module  10 ′ could be eliminated and the bottom wall of the module stacked on top of module  10 ′ could also be eliminated, or alternatively these top and bottom platens could be replaced by an intermediate platen like intermediate platen  42  as shown in  FIG. 3D . 
   Likewise, module  10 ′ could only have a top platen  20  and bottom platen  22  if it served as a junction module internally within a module assembly such that all four sides of the module  10 ′ were open. 
   As shown best in  FIG. 1A , when two or more modules are formed laterally into a module assembly  11 , there may be at least three types of modules  10 , such as an outer module  10   a  with one side  18   a  having a panel  19 ; an outer module  10   b  with a front or rear, such as front  12   b  having at least one, and preferably two panels  19 ; a corner module  10   c  with one side  18   c  and a front or rear (neither visible in  FIG. 1A ) with one or preferably two panels  19 ; and one or more interior modules  10   d , each having only a top platen and a bottom platen but no panels on its front, rear or sides. 
   Typically, but certainly not exclusively, in one preferred embodiment, the front and rear  12  and  14  of the module  10  are defined as sediment resistant by installation of two identical lattice panels  19 , each panel having dimensions of about 36 inches (91.4 cm) high by about 18 inches (45.7 cm) wide and by laying over the lattice panels a geotextile fabric  30 . In this preferred embodiment, each of the sides  16  and  18  uses only one of the same lattice panels  19  per side having the same dimensions as used for the front  12  and rear  14 . Thus, typically, by way of example and without limitation, for this embodiment, the dimensions of the lattice panels are about 36 inches (91.4 cm) high by about 18 inches (45.7 cm) wide. In this preferred embodiment, each of the top platen  20  and the bottom platen  22  is formed with eight vertical support member sockets unitarily molded in to the platen, such that the typical, but non-limiting plan dimensions for the top and bottom platens of this embodiment would be about 36 inches (91.4 cm) long by about 18 inches (45.7 cm) wide. When fully assembled using a top and bottom platen and six lattice panels, as a single module tank, the dimensions of the preferred module are 36 inches (91.4 cm) from side to side, 36 inches (91.4 cm) in height and 18 inches (45.7 cm) from front to rear. 
   It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.