Method of constructing septic system including pipe support

This application is a continuation of U.S. patent application Ser. No. 12/025,320 filed on Feb. 4, 2008, entitled PIPE STAND, the entire contents of which are incorporated herein by reference.

The present invention relates to pipe stands, and more particularly relates to pipe stands used to support liquid-filled horizontally-extending pipes supported in a trench above ground, such as are used to convey human waste to drain fields of septic systems, though not limited to only that use.

One type of septic system (sold by Infiltrator Systems, Inc., Old Saybrook, Conn., by Chamber Systems ADS Company, and also by Hancor Company) includes waste-conveying pipes supported above ground and that extend from a septic tank to a drain field. The pipes are positioned in trenches in the ground, and supported under semi-cylindrical chambers, such as by tying the pipes to the chambers by straps or by supporting the pipes on posts that extend into the ground at a bottom of the trenches. In a gravity system, the waste-conveying pipes are generally horizontal but slightly downhill, such that the waste flows from the septic tank by gravity to a dump location in the drain field. In a low pressure system, the waste is communicated under pressure through waste pipes that define several dump locations in the drain field. Both systems require that the waste-conveying pipes be stably supported above the ground in a horizontal position so that low sections are avoided, both at installation and also over time. The avoidance of low sections prevents solid waste from collecting in low sections and thus prevents the collecting waste from stopping flow through the pipe. However, known pipe supports for the above-discussed septic system are deficient in that they require a difficult installation and also they may allow the pipe to sag and form low sections prematurely over time. For example, one system preassembles the pipe to the chambers using tie straps, and then places the pipes and chambers as a unit.

Specifically, the two most common ways of supporting waste-conveying pipes in the above-mentioned septic system include either straps or posts, both of which have significant installation and durability problems. For example, it is difficult to attach straps under the chambers and difficult to assure that the pipes are held in a horizontal position under the chambers with no low sections, since vision and reach are difficult. Further, the straps may break or sag over time (especially since waste-filled pipes are heavy), causing low sections to occur well after the installation, thus requiring maintenance and/or repair. Posts can be installed before the chambers are placed in the trench, such that installation is a bit easier than straps. However, posts tend to tip sideways or sink (or erupt from ground pressure), such that there is a significant risk of low sections forming over time. Also, sometimes it is difficult to drive the posts into the ground deep enough in the location and true-vertical orientation desired.

In one aspect of the present invention, a method of constructing a septic system comprising steps of providing a trench and at least one long section of waste-conveying pipe with apertures therein, providing a plurality of pipe stands, each including at least one panel with a pipe-supporting surface and an edge adapted to stably engage a ground surface, and positioning the pipe stands transversely to the pipe and in a position supporting the pipe above a bottom of the trench, including slipping the pipe stands onto or under the waste-conveying pipe. The method further includes placing components forming an elongated chamber in the trench that at least partially cover the pipe above the bottom with the trench unfilled to form a septic system capable of handling and distributing waste product.

In another aspect of the present invention, a method comprises steps of digging a trench with a bottom, providing waste-dispensing pipe, forming a plurality of pipe stands from sheet material, and supporting the pipe above the bottom of the trench using the pipe stands, with the pipe stands engaging and supporting the pipe at spaced locations, the pipe stands each comprising a body having a pipe-supporting portion. The method further includes placing components forming an elongated chamber in the trench that at least partially cover the pipe above the bottom with the trench unfilled to form a septic system capable of handling and distributing waste product.

In still another aspect of the present invention, a septic system includes an unfilled trench with a bottom, a pipe system for spreading waste along the bottom of the unfilled trench, the pipe system including at least one apertured pipe for conveying and dropping waste located above the bottom, and a plurality of pipe stands supporting the pipe above the bottom of the unfilled trench, each pipe stand comprising a flat sheet having two interconnected panels that define a fold line therebetween so that, when folded along the fold line, the two panels align a pipe-supporting portion on each panel for receiving the pipe, the pipe-supporting portion being spaced above a bottom edge of the panels so that the at least one pipe can spread the waste along the bottom of the unfilled trench.

An object of the present invention is to provide a very simple pipe stand that is durable, long-lasting, and very stable when used to support waste-conveying pipes in the primary environment of a septic system.

An object of the present invention is to provide a pipe stand that promotes an efficient installation of a septic system, and which is intuitive to use, yet flexible in use.

These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.

FIG. 1 is a perspective view of a septic system including the drain field, the drain field being uncovered so that components can be seen, one of the chambers being broken away to reveal the waste-conveying pipe as supported by a pipe support of the present invention.

FIG. 2 is a cross section taken through a chamber in the drain field, showing the chamber, the pipe, and the pipe stand, and

FIG. 3 is a perspective view showing a similar area and components.

FIG. 4 is a perspective view of a long waste-conveying pipe section and with multiple pipe stands for supporting the pipe.

FIGS. 5-6 are plan and side views of a pipe stand blank prior to bending.

FIGS. 7-20 are perspective views of alternative pipe stand constructions, FIGS. 13 and 20 showing installations.

The present pipe stands 20 ( FIGS. 1-4 ) support waste-conveying pipes 21 above a trench-bottom ground surface 22 in a septic system 23 having a septic tank 19 . The illustrated septic system 23 includes semi-cylindrically-shaped chambers 24 that are positioned over the pipes 21 in the drain field 25 thereby defined. Notably, FIG. 1 illustrates the components 20 , 21 , and 24 as positioned in a bottom of trenches 26 . These trenches 26 are filled during a later part of the installation to a level generally equal to the top soil 27 , with the chambers 24 protecting the pipes 21 (and stands 20 ).

The present pipe stands 20 are particularly simple, effective, flexible in use, and easy to install in the present environment of a septic system for a variety of reasons. In regard to their construction, the pipe stand 20 ( FIGS. 4-6 ) is cut from a flat bowtie-shaped sheet (preferably durable polymeric sheet such as high density polyethylene that is about ⅛″ to ¼″ thick, though it could be metal, aluminum, composite, or other structural material). The bowtie shape defines two panels 30 and 31 connected by a narrow region 32 (also called a “fold line” or a “living hinge”). The narrow region 32 of the “bow tie” shape, when folded, forms a living hinge that biases the panels 30 and 31 toward a more planar shape. The fold line can include slits or thinned areas to assist in folding, and to reduce the outward biasing force. This may be desirable when it is unnecessary for the panels 30 and 31 to frictionally engage the pipe 21 . A hole 33 is formed in each panel slight larger than the pipe 21 that it is intended to receive, thus forming a pipe-supporting surface. The holes 33 align when the sheet is folded, thus providing a stable two-point support for a horizontal pipe 21 . In stands where the panels 30 and 31 are biased apart, the stand 20 frictionally engages the pipe 21 . This assists in installation by holding the stands in position on the pipe 21 while the pipe 21 is being manipulated to a final position. Advantageously, the pipe 21 does not have to be tied to the chamber 24 covering it.

Also, when attached to the pipe 21 , each bottom edge 35 and 36 of the panels 30 and 31 rest on the ground. Due to a width of the edges 35 and 36 , they stably engage the ground surface 22 even if there are some variations in the surface 22 . A fold-out foot 37 is formed at the bottom edges 35 and 36 by pairs of slots 38 . The fold-out foot 37 is useful where the ground is soft, since it can be bent to a horizontal position that gives a wider footprint along the bottom edge 35 and 36 . At the same time, the end tabs 39 (outboard of the foot 37 ) extend into the soil of the ground surface 22 , adding further stability to the arrangement.

It is noted that variations can be made in the pipe stand 20 of FIG. 5-6 . For example, pipe stand 20 can be used in a second orientation (i.e. rotated about 100 degrees on the pipe from the orientation shown in FIG. 2-3 ). In this second orientation, the pipe 21 is positioned slightly closer to the ground surface 22 , thus giving the user a height selection capability. Also, the living hinge can be replaced with actual hinges or straps or tethers. Further, the material of the stand 20 can be any structural material, including metal (corrosion-treated steel, stainless steel, aluminum) composites, and other materials. The pipe stand 20 can be injection molded, stamped, CNC cut, saw and drilled, die-cut, water jet cut, routed, or shaped by other known methods.

A number of modified pipe stands are shown in FIGS. 7-20 . In these modified pipe stands, similar and identical components, features and characteristics are identified using identical numbers to those used in FIGS. 1-6 , but with the addition of a letter “A,” “B,” “C,” etc. This is done to reduce redundant discussion. Notably, the various modified pipe stands include the same features and characteristics as the pipe stand 20 unless otherwise noted.

The pipe stand 20 A ( FIG. 7 ) is similar to pipe stand 20 except pipe stand 20 A includes slots 40 A at ends of the fold line 32 A. This reduces an outward bias of the living hinge, thus making it easier to fold the sheet to form the pipe stand 20 A and also reducing a grip of the pipe stand 20 A on the pipe ( 21 ).

The pipe stand 20 B ( FIG. 8 ) includes a hole 33 B and further includes a plurality of circular slits or depressions forming a plurality of punch-out rings 41 B- 43 B of different sizes around the hole 33 B. Each ring 41 B- 43 B can be punched out to form a hole sized for a particular pipe ( 21 ), such as 1¼″, 1½″, 2″, 3″, etc.

The pipe stand 20 C ( FIG. 9 ) includes a notch 33 C instead of a hole ( 33 ). The notch 33 C opens toward the fold line 32 C, thus reducing a strength of the living hinge at the fold line 32 C. Also, there are slits 44 C at outer ends of the fold line 32 C, further weakening the bias of the living hinge. Notably, the edges of the notch 33 C extend vertically, such that it engages a maximum of 180 degrees of the pipe ( 21 ). Note that pipe stands 20 D ( FIG. 10) and 20E ( FIG. 11 ) include inwardly-facing tips 45 D (rounded) and 45 E (relatively pointed) at upper ends of their respective notches 33 D and 33 E. The tips 45 D, 45 E are made to resilient snappingly engage a pipe 21 D, 21 E pressed into the respective notch 33 D or 33 E. Thus, the pipe 21 D, 21 E is retained in the notch ( 33 D, 33 E) even though the notch 33 D, 33 E is upwardly open.

The pipe stand 20 F ( FIGS. 12-13 ) includes slots 40 F at ends of its fold line 32 F (similar to pipe stands 20 A), which shorten its living hinge and the bias of its hinge. Slots 38 F are formed to define a fold-out foot 37 F. The illustrated end tabs 39 F are pointed and stake-simulating, such that they dig into soft ground for retaining the panels 30 F and 31 F in position. Further, the tabs 39 F include a small hole or other feature/structure 47 F for receiving a U-shaped ground-engaging wire stake or pin 48 F that fixedly holds the panels 30 F and 31 F in their respective selected positions.

A U-shaped slot 49 F ( FIGS. 12-13 ) is formed in the panels 30 F and 31 F, defining a fold-out dispersing flange 50 F. In pressurized septic systems, the waste product 51 F is pushed out openings 52 F in the pipe 21 F. When the waste product 51 F is dispensed onto a dispersing flange 50 F, the flange 50 F spreads the waste product 51 F and reduces an impact of the waste product 51 F as it engages a particular area of the ground 22 F.

The pipe stand 20 G ( FIG. 14 ) includes three holes 33 G, 53 G, and 54 G, each sized to receive a different size diameter pipe ( 21 ). Each hole 33 G, 53 G, and 54 G is located in a different corner of the pipe stand 20 G. By positioning the pipe stand 20 G in different orientations (compare FIGS. 14 and 15 ), different holes 33 G, 53 G, 54 G can be positioned at a top of the stand 20 G (i.e., at their preferred height). It is contemplated that more or less holes 33 G, 53 G, 54 G could be used, and also that punch-out rings could be used in combination with multiple holes 33 G, 53 G, 54 G. Also, it is noted that the living hinge of pipe stand 20 G is located at a corner and that the panels 30 G and 31 G are triangularly shaped, such that the living hinge is relatively short without the need for cutting slots into the fold line 32 G.

The pipe stand 20 H ( FIG. 16 ) includes a stabilizer panel 56 H with corners having tabs 57 H configured to frictionally engage the end tabs 39 H. When engaged, the stabilizer panel 56 H holds the panels 30 H and 31 H at a desired spacing, thus adding stability to the pipe stand 20 H without the need for stability to come from the way that the holes 33 engage the pipe ( 21 ). Also, the stabilizer panel 56 H adds considerably to the footprint of the pipe stand 20 H, and can be particularly useful where the soil is particularly soft. Nonetheless, it is noted that care must be taken to not reduce the surface area of the ground surface, since a minimum amount of surface area is required in order to qualify as a drain field for a given septic system.

The pipe stand 20 I ( FIG. 17 ) includes two triangular panels 30 I and 31 I connected by a relatively long fold line 32 I. As noted above, the fold line 32 I can be made easier to fold if necessary, such as by adding perforations, slits, slots, or thinned areas along the fold line 32 I. As illustrated, the holes 33 I are located near the outer corners of the triangular panels 30 I and 31 I. When folded, the long fold line 32 I is positioned at the ground, with the pipe 21 I engaging the holes 33 I at a selected height above the ground and fold line 32 I. Notably, in previous illustrated pipe stands, the fold line was along a top (or side) of the part. In pipe stand 20 I, it is located along its bottom.

The pipe stand 20 J ( FIG. 18 ) includes a panel-shaped structural member 30 J of sufficient strength to support a pipe 21 J in an elevated position above a ground surface 22 J, and includes a pipe receiving feature (hole 33 J and potentially within the hole 33 J a short pipe 33 J′ large enough to receive pipe 21 J) and a ground-engaging stabilizer (foot 37 J) of sufficient width to prevent tip-over. The foot 37 J can be integrally formed as part of the structural member 30 J (and folded outwardly therefrom), or can be a separately formed part attached along a bottom edge of the panel-shaped structural member 30 J.

The pipe stand 20 K ( FIG. 19 ) includes a pair of panel-shaped structural members 30 K and 31 K connected by transverse rib 32 K from their bottom and connected by pipe 21 K at their top, where the pipe 21 K is extended through closely fitting holes 33 K.

The pipe stand 20 L ( FIG. 20 ) is similar to pipe stand 20 , and includes two panels 30 L and 31 L connected at their narrow section (fold line 32 L). The pipe 21 L is extended through holes 33 L. However, the pipe stand 20 L is inverted so that panels 30 K and 31 K can be attached to an overhead beam, such as a ceiling beam or floor joist 60 K. Thus, the present pipe stand is converted into a pipe hanger. This same concept of inverting the component and using it as a hanger can be done using any of the pipe stands shown in FIGS. 6-8 , 10 - 12 , 18 - 19 .

Advantageously, the present pipe stands can be used in low pressure chamber systems, and do not have to be tied to a chamber. This allows the chamber to be installed after the “squirt” test. The present stands are easily installed, including folding and sliding onto the pipe that they support. They ship flat and are low weight, such that they ship at low cost, and are easily shipped and stored. They are easily adjustable to different spacings on a given pipe. Notably, different pipe sizes require different spacings, and the present pipe stands readily fill that need, while providing excellent stability and levelness of the pipe off the ground. In some forms, the pipe stands squeeze the pipe, yet release for adjustment. Some pipe stands cradle and/or snap over the pipe for additional sureness of retention. Others have punch-outs that permit selection of a desired hole size. The present pipe stands are independent from the chamber, and stand alone. They fit multiple sizes of pipes, with holes on one pipe stand fitting more than just one pipe size. Sides of the pipe stands can be fixed in a desired spread condition, either by using a cross piece, or ground-engaging tabs. Further, the sides of the pipe stands can include fold-out feet for increased footprint for loose soil, and also can include fold-out flanges for dispersing waste material dropping from the pipe. The pipe stands include integral hinges that are low-cost, easily bent to a desired shape, and ARE highly efficient and satisfactory for their intended purpose. The pipe stands can be inverted and used as a pipe hanger. They can be made by a variety of processes, such as injection molding, stamping, cutting, forming, sawing/drilling, and the like. They can be made out of many different materials, such as plastic, metal (steel, aluminum) composite, or the like. The present pipe stands can be made to virtually any size or shape, with any desired hole size.

It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.