Abstract:
A drainage system for draining a fluid from a hardenable material as the fluid flows through an aperture formed in the hardenable material includes a conduit and a catch. The conduit has an outer surface defining an inner chamber. The catch is supported by the outer surface of the conduit for directing the fluid from the aperture into the inner chamber. The catch includes a first tab and a second tab that extend along a portion of the length of the conduit, and the second tab is spaced from the first tab. Both the first tab and the second tab are inserted into the hardenable material about opposing sides of the aperture to prevent a collapsing of the conduit and to maintain a flow of the fluid from the aperture into the inner chamber.

Description:
CROSS REFERENCE TO RELATED APPLICATION  
       [0001]     This application claims the benefit of application Ser. No. 60/756,156 filed Jan. 4, 2006, which is hereby incorporated by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The subject invention relates to system and method for draining a fluid from a hardenable material as the fluid flows through an aperture formed in the hardenable material.  
         [0004]     2. Description of the Prior Art  
         [0005]     Drainage systems are important when working with concrete surfaces. Specifically, drainage systems may be used to move a fluid from an expansion joint between two concrete surfaces. As the fluid flows into the expansion joint, changes in temperature cause the fluid to expand and contract, which can crack the concrete surfaces. Therefore, it is necessary to move the fluid away from the concrete surface to reduce the fluid in the expansion joint.  
         [0006]     Various drainage systems are known in the art. One such drainage system is disclosed in U.S. Pat. No. 5,908,266 to Miller (the &#39;266 patent). The &#39;266 patent discloses a drainage system for draining a fluid from a hardenable material as the fluid flows through an aperture formed in the hardenable material. The drainage systems of the prior art include a conduit that has an outer surface that defines an inner chamber. The conduit has a length that extends between distal ends of the conduit and an axis that extends along the length. The drainage systems of the prior art also include a catch disposed on the outer surface of the conduit for directing the fluid from the aperture into the inner chamber.  
         [0007]     Although the drainage systems of the prior art move the fluid away from the hardenable material, there remains an opportunity to improve upon the prior art drainage systems to prevent the conduit from collapsing and to maintain a flow of the fluid from the aperture into the inner chamber.  
       SUMMARY OF THE INVENTION AND ADVANTAGES  
       [0008]     The invention provides for a drainage system for draining a fluid from a hardenable material as the fluid flows through an aperture formed in the hardenable material. The system includes a conduit having an outer surface defining an inner chamber and a length extending between distal ends with an axis extending along the length. A catch is supported by the outer surface of the conduit for directing the fluid from the aperture into the inner chamber. The catch includes a first tab extending along a portion of the length of the conduit and a second tab extending along a portion of the length of the conduit with the second tab radially spaced from the first tab about the axis for insertion into the hardenable material about opposing sides of the aperture to prevent collapsing of the conduit and to maintain a flow of the fluid from the aperture into the inner chamber.  
         [0009]     The invention further provides for a method of making a drainage system. The system includes a hardenable material for forming a hardened layer, a conduit having an outer surface defining an inner chamber, and a catch having a first tab and a second tab. The method includes the steps of disposing the catch on the outer surface of the conduit, applying the hardenable material over the conduit and the catch, curing the hardenable material to form the hardened layer for embedding the first tab and the second tab within the hardened layer, and cutting the hardened layer to form an aperture. The method further includes the step of cutting the outer surface of the conduit between the first tab and the second tab to form a drainage opening simultaneously with the forming of the aperture and with the drainage opening in fluid communication with the aperture.  
         [0010]     The invention further provides for a catch for a conduit for draining a fluid from a hardenable material. The catch includes a base defining a length with the base being adapted for mounting to the conduit. The catch further includes a first tab extending from the base along the length and defining a first plane. In addition, the catch includes a second tab extending from the base along the length spaced from the first tab and the second tab defining a second plane angled relative to the first plane for inserting the first tab and the second tab into the hardenable material to prevent collapsing of the conduit and to maintain a flow of the fluid into the conduit. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]     Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:  
         [0012]      FIG. 1  is a perspective view of a first environment utilizing a drainage system in accordance with the subject invention;  
         [0013]      FIG. 2  is a perspective view of a second environment utilizing the drainage system in accordance with the subject invention;  
         [0014]      FIG. 3  is a perspective view of a conduit and a catch used with the drainage system in accordance with the subject invention;  
         [0015]      FIG. 4  is a cross-sectional view of the conduit and the catch used with the drainage system of  FIG. 3  in accordance with the subject invention;  
         [0016]      FIG. 5  is a perspective view of an end cap used with the drainage system in accordance with the subject invention;  
         [0017]      FIG. 6  is a perspective view of the conduit, the catch, an the end cap as shown in  FIG. 5  assembled in accordance with the subject invention;  
         [0018]      FIG. 7  is a side view of the drainage system disposed below a hardened layer in accordance with the subject invention;  
         [0019]      FIG. 8  is a perspective view of the drainage system disposed below the hardened layer and having an aperture, a fluid passage, and a drainage opening in accordance with the subject invention;  
         [0020]      FIG. 9  is a side view of one embodiment of the drainage system as shown in  FIG. 8  in accordance with the subject invention;  
         [0021]      FIG. 10  is a side view of another embodiment of the drainage system as shown in  FIG. 8  in accordance with the subject invention;  
         [0022]      FIG. 11  is a side view of the drainage system disposed below the hardened layer in accordance with the subject invention;  
         [0023]      FIG. 12  is a perspective view of the drainage system having at least one drain hole formed in the hardened layer in accordance with the subject invention;  
         [0024]      FIG. 13  is a perspective view of the drainage system having at least one slot formed in the hardened layer in accordance with the subject invention; and  
         [0025]      FIG. 14  is a perspective view of the drainage system having a combination of the at least one drain hole and the at least one slot formed in the hardened layer in accordance with the subject invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0026]     Referring to the Figures, wherein like numerals indicate corresponding parts throughout the several views, a drainage system  20  is disclosed generally at reference numeral. As shown in  FIGS. 1 and 2 , the drainage system  20  is used below a hardenable material  22 , such as a concrete driveway or sidewalk. Referring to  FIGS. 3 and 4 , the drainage system  20  includes a conduit  24  having an outer surface  26  defining an inner chamber  28 . A length extends between distal ends of the conduit  24  with an axis A extending along the length. A catch  30  is disposed on the outer surface  26  of the conduit  24  and extends along at least a portion of the length of the conduit  24 . The catch  30  includes a first tab  32  having a first tab length that extends along the catch  30 . In one embodiment, the first tab  32  defines a first plane P 1  that extends through the first tab  32  and through the axis A. The catch  30  also includes a second tab  34  having a second tab length equal to that of the first tab length. Like the first tab  32 , the second tab  34  defines a second plane P 2  that extends through the second tab  34  and through the axis A. It is within the scope of the subject invention that the second plane P 2  extends from the length angled relative to the first plane P 1 , causing the first plane P 1  and the second plane P 2  to intersect, and the axis A may be defined by where the first plane P 1  and the second plane P 2  intersect.  
         [0027]     A base (not shown) may be located on the outer surface conduit  24 , generally opposite the catch  30 . The base may have a shape similar to the catch  30 , and the first and second tabs  32 ,  34 , but is not limited so such shape. The base acts to increase the stability of the drainage system  10 .  
         [0028]     In addition, at least one of the first tab  32  and the second tab  34  may extend from the outer surface  26  of the conduit  24  perpendicularly to the outer surface  26 . Alternatively, at least one of the first tab  32  and the second tab  34  may extend from the outer surface  26  of the conduit  24  obliquely. Since it is within the scope of the subject invention that the first plane P 1  and the second plane P 2  not intersect, the axis A is then defined by conduit  24 . In addition, the first tab  32  may extend continuously along the portion of the length of the conduit  24  parallel to the second tab  34 . In yet another alternative, the catch  30  may include a base  36  that is disposed on the outer surface  26  of the conduit  24  that extends along the portion of the length of the conduit  24  to interconnect the first tab  32  and the second tab  34 . The length of the base  36  may be greater than or equal to the first tab length and the second tab length. It should be understood that the first tab  32  and the second tab  34  may have different shapes or be arranged differently with respect to one another. For instance, the first tab  32  and the second tab  34  may be curved.  
         [0029]     Furthermore, the base  36  is shaped or adapted to mount onto the outer surface  26  of the conduit  24 . For example, if the conduit  24  is a pipe having a cylindrical cross-section, the outer surface  26  is rounded, and therefore, the base  36  of the catch  30  has an arcuate cross-section to fit onto the conduit  24 . It should be understood that the conduit  24  may have alternative cross-sections as is known in the art.  
         [0030]     The second tab  34  extends along the portion of the length of the base  36  and is radially spaced from the first tab  32  about the axis at an angle θ relative to the first tab  32 . The angle θ is less than 90 degrees, however, it should be understood that the angle θ may be any angle. Additionally, as shown in  FIGS. 5 and 6 , end caps  38  may be disposed on the conduit  24  that are transverse relative to and extend between the first tab  32  and the second tab  34  and parallel to one another. With the end caps  38 , the first tab  32  and the second tab  34  enclose the portion of the length of the conduit  24 .  
         [0031]     The catch  30 , which includes the first tab  32 , the second tab  34 , the end caps  38 , and alternatively, the base  36 , may be disposed on the conduit  24  in various ways. For example, the base  36  may be adhered to the conduit  24  with an adhesive  40  or a fastener. Alternatively, the catch  30  may be integrally formed with the conduit  24  so that the conduit  24  and the catch  30  are formed from a single piece of material. In yet another alternative, the catch  30  may simply rest on the conduit  24 . It should be understood that these and other alternatives for disposing the catch  30  on the conduit  24  are within the scope of the subject invention.  
         [0032]     Referring to  FIG. 7 , after the catch  30  has been disposed on the outer surface  26  of the conduit  24 , the conduit  24  and the catch  30  are partially buried in a ground layer  42 . It should be understood that the conduit  24  may be partially placed in the ground layer  42  before disposing the catch  30  on the outer surface  26  of the conduit  24 . Once the catch  30  and the conduit  24  are placed in the ground layer  42 , the hardenable material  22  is applied over the entire catch  30  and over the portion of the length of the conduit  24  such that the first tab  32  and the second tab  34  extend into the hardenable material  22 . The hardenable material  22  may be sloped toward the catch  30  and the conduit  24 . After the hardenable material  22  is applied to the conduit  24  and the catch  30 , the hardenable material  22  is cured to a sufficient hardness. Once cured, a hardened layer  44  is formed and the first tab  32  and second tab  34  are embedded in the hardened layer  44 .  
         [0033]     Next, referring to  FIGS. 8-10 , the hardened layer  44  is cut to form an aperture  46 . Simultaneously, the conduit  24  is cut to form a drainage opening  48 . If the catch  30  includes the base  36  as previously described, then the base  36  is simultaneously cut with the conduit  24  and the hardened layer  44  to form a fluid passage  50 . The aperture  46 , the fluid passage  50 , and the drainage opening  48  may be cut to form at least one slot  52 , such as an expansion joint. An expansion joint filler  54  may be placed in the at least one slot  52  as is known in the art. Alternatively, at least one drain hole  56  may be drilled through the hardened layer  44 , the catch  30 , and the conduit  24  to form the aperture  46 , the fluid passage  50 , and the drainage opening  48 , respectively. A drain cap  58  may be placed over the at least one drain hole  56 . Furthermore, as shown in  FIG. 7 , the drainage opening  48  in the conduit  24  is defined by the outer surface  26  between the first tab  32  and the second tab  34  of the catch  30 , and the drainage opening  48  is in fluid  60  communication with the aperture  46 . The base  36  of the catch  30  defines the fluid passage  50 , which is in fluid  60  communication with the aperture  46  and the drainage opening  48 .  
         [0034]     Referring specifically to  FIG. 9 , the fluid passage  50  and the drainage opening  48  may be cut or drilled to an equal width as the aperture  46 . In an alternative embodiment, as shown in  FIG. 10 , the aperture  46  has a first width while the fluid passage  50  and the drainage opening  48  have a second width that is smaller than the first width. It should be understood that the width of the aperture  46 , the fluid passage  50 , and the drainage opening  48  may be a diameter if the aperture  46 , fluid passage  50 , and the drainage opening  48  are circular in shape, such as the at least one drain hole  56 .  
         [0035]     As previously shown in  FIG. 4 , cutting the conduit  24  may cause the conduit  24  to collapse and close the drainage opening  48 . However, by inserting the first tab  32  and the second tab  34  into the hardenable material  22  and embedding the first tab  32  and the second tab  34  into the hardened layer  44 , the catch  30  can prevent the conduit  24  from collapsing. Although the hardenable material  22  need not be completely cured before cutting through the hardened layer  44  to form the aperture  46 , when the drainage opening  48  is cut in the conduit  24 , the first tab  32  and the second tab  34  must be embedded in the hardened layer  44  and the hardened layer  44  must be strong enough to hold the drainage opening  48  open. If the hardened layer  44  has not cured enough to hold the drainage opening  48  open, the conduit  24  may collapse and close the drainage opening  48 .  
         [0036]     Referring now to  FIG. 11 , the aperture  46  is formed in the hardened layer  44 , the drainage opening  48  is formed in the conduit  24  in fluid  60  communication with the aperture  46 , and the fluid passage  50  is formed in the base  36  of the catch  30  in fluid  60  communication with the aperture  46  and the drainage opening  48 . Now, a fluid  60  can flow from the hardened layer  44  and through the aperture  46 , the fluid passage  50 , and the drainage opening  48  into the inner chamber  28  of the conduit  24 . The first tab  32  and the second tab  34  embedded in the hardened layer  44  hold the drainage opening  48  open and help reduce the fluid  60  from flowing between the hardened layer  44  and the conduit  24  through capillary action. The conduit  24  then carries the fluid  60  away from the hardenable material  22 . It should be understood that the conduit  24  may be any fluid-carrying device known in the art such as, but not limited to, a pipe or tube. In addition, the conduit  24  may be made of any material known in the art capable of carrying the fluid. Such materials include polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), or Acrylonitrile Butadiene Styrene (ABS). It should be understood that conduits  24  made of other materials are within the scope of the subject invention.  
         [0037]     Referring to  FIGS. 12-14 , the aperture  46 , the fluid passage  50 , and the drainage opening  48  may be various shapes. In  FIG. 12 , the aperture  46 , the fluid passage  50 , and the drainage opening  48  are the at least one drain hole  56 . As shown in  FIG. 13 , the aperture  46 , the fluid passage  50 , and the drainage opening  48  are the at least one slot  52 . As shown in  FIG. 14 , the aperture  46 , the fluid passage  50 , and the drainage opening  48  are a combination of the at least one drain hole  56  and the at least one slot  52 .  
         [0038]     Obviously, many modifications and variations of the present invention are possible in light of the above teachings, and the invention may be practiced otherwise than as specifically described within the scope of the appended claims.