Cross-Reference to Related Applications

[0001] The present patent application claims the benefits of priority of United States Provisional Patent Application No. 63/117,413, entitled “FOLDABLE WASTEWATER CONDUIT AND MANUFACTURING METHOD THEREOF”, and filed at the United States Patent and Trademark Office on November 23, 2020, the content of which is incorporated herein by reference.

Field of the Invention

[0002] The present invention generally relates to the field of wastewater and sewage treatment and manufacturing, installation and transportation methods thereof. More particularly, the present invention generally relates to a hinged wastewater conduit for use in septic systems and to a method to install a wastewater conduit for use in septic systems.

Background of the Invention

[0003] Septic systems are typically used in areas or countries that are not connected to a sewage system, such as rural areas or undeveloped countries. Consequently, materials and equipment are typically transported long distances before reaching the installation site. As such, transportation costs can represent a substantial expense.

[0004] Moreover, traditional septic systems typically rely on long drainage conduits configured to distribute effluent over the span of a drainage field. These hollow tubes serve crucial role in the treatment of wastewater but can occupy a lot of space prior to installation. As transportation costs are commonly related to the volume of the transported materials, there is therefore continued interest in minimizing the transport size of equipment and, concordantly, transportation costs.

[0005] There is therefore a need for a hinged wastewater conduit capable of opening to occupy less volume during storage and/or transportation.

Summary of the Invention

[0006] The present invention is directed to a foldable wastewater conduit for conveying a fluid, the wastewater conduit comprising first and second portions linked to one another about a folding axis, wherein the first and second portions being placeable in open and closed configurations, the folding axis being along a longitudinal axis of the wastewater conduit, and the wastewater conduit being stackable over or under another wastewater conduit of the same configuration.

[0007] In certain embodiments, the folding axis may comprise a foldable portion between the first and the second portions, the foldable portion comprising a flexible material and wherein the first portion, the second portion and the foldable portion may be unitary. Moreover, a first attachment section of the first portion may be attachable to a second attachment section of the second portion, wherein the first attachment section may be attached to the second attachment section by at least one of welding, sewing, stapling, clamping and gluing.

[0008] In further embodiments, the wastewater conduit may further comprise first and second coupling ends configured to be fluidly affixed to another wastewater conduit of the same configuration, wherein the first and second coupling ends may comprise one of a male connector and a female connector and may comprise ridges.

[0009] In other embodiments still, the wastewater conduit may further comprise one or more textile membranes wrapped around an outer surface of the wastewater conduit and configured to facilitate a leaching of the fluid, wherein the one or more textile membranes are affixed to at least one of the first and second attachment sections. The wastewater conduit may further comprise perforations configured to facilitate a leaching of the fluid, the first and second portions may have similar shapes, and the first and second portions may be mating half tubular sections.

[0010] In another aspect of the invention, a method of installing a wastewater conduit is provided. The method comprises folding a first portion of a conduit assembly over a second portion of the conduit assembly to form the wastewater conduit, the folding being about a folding axis substantially parallel to a flow of the fluid within the formed wastewater conduit, and sealingly attaching the folded first portion to the second portion.

[0011] In certain embodiments, the attaching of the folded first portion to the second portion further may comprise affixing a first attachment section of the first portion to a second attachment section of the second portion. The method may further comprise wrapping a textile membrane around an outer surface of the formed wastewater conduit and affixing the textile membrane to one of the first and second attachment sections.

[0012] In other embodiments, the attaching of the first portion to the second portion may comprise at least one of welding, sewing, stapling, clamping and gluing. The method may further comprise installing the wastewater conduit in a drainage field and fluidly connecting a coupling end of the formed wastewater conduit to another formed wastewater conduit. [0013] The features of the present invention which are believed to be novel are set forth with particularity in the appended claims.

Brief Description of the Drawings

[0014] The above and other objects, features and advantages of the invention will become more readily apparent from the following description, reference being made to the accompanying drawings in which:

[0015] FIG. 1 is a cross-sectional view of an exemplary drainage conduit in an open configuration in accordance with the principles of the present invention.

[0016] FIG. 2 is a cross-sectional view of the drainage conduit of FIG. 1 in a closed configuration.

[0017] FIG. 3 is a cross-sectional view of five drainage conduits as illustrated in FIG. 1 in a stacked configuration.

[0018] FIG. 4 is a side perspective view of the drainage conduit of FIG. 1 in a closed configuration.

Detailed Description of the Preferred Embodiment

[0019] A novel foldable wastewater conduit and manufacturing method thereof will be described hereinafter. Although the invention is described in terms of specific illustrative embodiments, it is to be understood that the embodiments described herein are by way of example only and that the scope of the invention is not intended to be limited thereby.

[0020] The systems and methods described herein incorporate a hinged or foldable wastewater conduit 300 configured to facilitate the storage, transportation and installation of a wastewater treatment system (not shown), such as, but not limited to, a treatment system described in International Patent Publication Nos. WO 2020/041906 and WO 2020/248043. The wastewater treatment system typically comprises an input source, such as an input source or drainage pipe, a tank, such as a septic tank, and a drainage field.

[0021] The drainage pipe may be configured to deliver wastewater to the wastewater treatment system from a water consuming environment (such as a residential dwelling, a commercial space, an industrial space, etc.), typically in areas that are not connected to a municipal or urban sewage system such as, but not limited to, rural areas. The wastewater may comprise any water used from domestic, industrial, commercial or agricultural activities or any combination thereof. [0022] In some embodiments, the drainage pipe may be fluidly connected to the septic tank. The septic tank may comprise an underground chamber (not shown) configured as a watertight container generally made of concrete, fiberglass, plastic or any other suitable material known in the art. The underground chamber may be either partially or entirely buried underneath a surface, such as a finished ground surface. The septic tank may provide a first treatment of the wastewater, the output of which is referred to as effluent.

[0023] In some embodiments, the septic tank may be fluidly connected to one or more drainage fields configured to receive and treat the effluent from the septic tank into treated wastewater. For example, the wastewater treatment system may comprise a drainage field configured to treat the effluent.

[0024] The drainage field may comprise a leach system disposed between a plurality of ground layers. In such embodiment, the drainage field comprises a surface, a covering layer immediately below the surface, a filtering medium, a permeable soil and a bedrock. In some embodiments, one or more of the layers may overlap and combine thereby removing any clear delineation between them.

[0025] In some embodiments, the leach system may be at least partially surrounded by the filtering medium. In yet other embodiments, a portion of the filtering medium may be disposed above the leach system and/or another portion of the filtering medium may be disposed underneath the leach system.

[0026] Referring now to FIG. 1, in some embodiments, the leach system may comprise one or more drainage passages or conduits 300 configured to fluidly receive and treat the effluent. The drainage conduits 300 may comprise pipes configured to carry and distribute the effluent across the drainage field. In some embodiments, the pipes may be perforated pipes. The effluent flowing in the drainage conduits 300 may be conveyed by gravitational forces in tandem with the geometry of the drainage conduits 300. In other embodiments, the effluent flowing in the drainage conduits 300 may be pressurized by a low-pressure distribution system or any other suitable pumping system.

[0027] The effluent treated by microbial water treating bacteria within the leach system and filtered by the filtering medium may be defined as treated wastewater.

[0028] As the treated wastewater exits the filtering medium, the treatment of the wastewater performed by the wastewater treatment system is complete. The treated wastewater may disperse into the permeable soil of the drainage field. In some embodiments, the permeable soil of the drainage field comprises a porous, unsaturated soil capable of absorbing fluids. [0029] The drainage conduits 300 may have any cross-sectional shape adapted to accommodate the volume of water to be disposed supplied by the drainage pipe and/or to accommodate the topographic requirements of the installation site. For example, the drainage conduits 300 may comprise a circular, oval, rectangular or any other suitable shape known in the art.

[0030] The drainage conduits 300 may be made of any semi rigid material. Examples of possible construction materials include, but are not limited to, plastics such as polypropylene and polyethylene or flexible metal. Other polymers, fibrous material, metal, rubber or rubberlike materials may also be used.

[0031] In yet other embodiments, the drainage conduits 300 may have any length or cross- sectional area suitable to accommodate the volume of water to be disposed or supplied by the drainage pipe and/or to accommodate the topographic requirements of the installation site. In some embodiments, the drainage conduits 300 may have a cross-sectional area of 175 cm ² to 2,000 cm ² .

[0032] In yet other embodiments, the drainage conduits 300 may comprise microbes. The microbes may allow an aerobic process to treat the effluent disposed within the drainage conduits 300 by absorbing the organic waste, removing pathogens and breaking down the effluent into soluble by-products. In an embodiment, the drainage conduits 300 are adapted to encourage the development of microbial water treating bacteria responsible for a secondary treatment of the wastewater. In particular, the drainage conduits 300 may be adapted to maintain a controlled flow rate of the effluent suitable for the growth of microbial water treating bacteria and may be geometrically configured to form spaces suitable for the growth of microbial water treating bacteria.

[0033] The drainage conduits 300 may further be corrugated to increase the structural flexibility and structural strength of said drainage conduits 300. Understandably, the corrugation of the drainage conduits 300 may further encourage the growth of microbial cultures and may provide a greater surface area for the development of microbial water treating bacteria and increases the contact surface between the microbial water treating bacteria and the effluent.

[0034] Referring now to FIG. 4, the flow of the effluent within the drainage conduits 300 further defines a stream direction 15 wherein the beginnings of the drainage conduits 300 in the direction of the stream direction 15 are defined as upstream ends 302 and the ends of the drainage conduits 300 in the direction of the stream direction 15 are defined as downstream ends 304. In some embodiments, the downstream ends 304 of the drainage conduits 300 are configured to receive one or more end caps (not shown) which may be detachably affixed to the drainage conduits 300 and may either partially or entirely limit the flow of the effluent outside of the downstream ends 304.

[0035] Referring again to FIG. 1, the drainage conduit 300 comprises a first 310 and a second 320 portion, interconnected by a hinged or folding portion 340. The hinged portion 340 may be configured to allow the first and second portions 310, 320 to pivot about the hinged portion 340 and relative to one another between a closed configuration and an open configuration. The hinged portion 340 may be configured to allow first and second portions 310, 320 to pivot about the hinged portion 340 with limited effort by hand or using a tool, such as but not limited to a handheld tool. Each of the first portion 310 and the second portion 320 are generally shaped to form a closed conduit when the two portions are folded along the hinged portion 340. In certain embodiments, the drainage conduit 300 may comprise more than one hinge portion 340 and additional pivoting portions therefrom.

[0036] Referring now to FIG. 2, an embodiment of the drainage conduit 300 is illustrated in a closed configuration. In such an embodiment, the first and second portions 310, 320 are folded along the hinged portion 340 and form a closed environment within the drainage conduit 300 suitable for channeling the effluent within the drainage field. The two portions 310 and 320 are attached to one another to form the closed environment.

[0037] To that end, each of the two portions 310 and 320 may comprise an outer open extremity adapted to be attached or affixed to the outer open extremity of the corresponding portion 320 and 310. In other embodiments, a first attachment section 312 of the first portion 310 and a second attachment section 322 of the second portion 320 may adjoin at a position other than the hinged portion 340 such as to create the closed environment.

[0038] Referring back to FIG. 1, the drainage conduit 300 is illustrated in an open configuration wherein the first and second portions 310, 320 are away from one another such that the first attachment section 312 and second attachment section 322 do not adjoin and create an open environment within the drainage conduit 300.

[0039] Prior or during installation of the drainage conduits 300 into the wastewater treatment system, it may be desirable to permanently position the drainage conduits 300 in a closed configuration. The first attachment section 312 and second attachment section 322 may therefore be configured to be permanently affixed to one another by any suitable means such as, but not limited, welding, sewing, stapling, clamping and gluing. [0040] The hinged portion 340 may comprise any moving joint or mechanism configured to allow the first and second portions 310, 320 to pivot. For example, the hinged portion 340 may comprise a butt hinge, a spring-loaded hinge, a concealed hinge, an offset hinge, a barrel hinge or any other suitable hinge allowing the first and second portions 310, 320 to create a hermetic seal at their adjoining points. In certain embodiments, the hinged portion 340 may comprise a living hinge made from the same material as the first and second portions 310, 320. To that end, the first portion 310, second portion 320 and hinged portion 340 may form a single unitary piece. In such embodiments, the first and second portions 310 and 320 and the hinged portion 340 may be made of flexible yet resistant material, such as flexible plastic.

[0041] Referring now to FIG. 3, a plurality of an embodiment of foldable drainage conduits 300 in an open configuration are shown stacked on top of one another. In such embodiments, the hinged portion 340 may allow the drainage conduits 300 to be disposed in an open configuration thereby allowing a plurality of drainage conduits 300 to be stacked on top of one another. It may be appreciated that a plurality of drainage conduits 300 may occupy less volume when stacked in an open configuration, as illustrated, as opposed to a closed configuration. In such embodiment, the drainage conduits 300 may be stored and/or transported to an installation site in an open configuration. Once the benefits of an open configuration are no longer required or desirable, the first and second portions 310, 320 may be pivoted into a closed configuration suitable for installation and operation of the wastewater treatment system.

[0042] In certain embodiments, the drainage conduits 300 may have an oval-shaped cross- sectional profile wherein each of the first and second portions 310, 320 may define an arc having the largest radius of curvature being substantially centered between the hinged portion 340 and the first and second attachment sections 312, 322. Configured in this manner, the first and second portions 310, 320 may form elliptically shaped spacings to better receive the first and second portions 310, 320 of a complementary drainage conduit 300 stacked atop it, thus occupying less volume when stored or at least minimizing the empty volume.

[0043] In a further embodiment and as illustrated in FIGS. 2 and 3, the drainage conduits 300 may further comprise perforations 360 adapted to allow a release of the effluent outside of the drainage conduits 300. In a preferred embodiment, the size of the perforations 360, the number of perforations 360 and the distribution of perforations 360 are determined based on the conditions of operation. As an example, the characteristics of the perforations may be determined to ensure a steady release of the effluent, to ensure leaching into the surrounding layers of the drainage field and to distribute the effluent along a substantial portion of the drainage conduits 300 in response to the volume of water to be disposed of by the wastewater treatment system. It may be appreciated that a high number of perforations 360 or perforations 360 having large apertures may cause an undesirable amount of the effluent to be released early on in the drainage conduits 300 as defined by the stream direction 15. Having too many perforation apertures or having large apertures may limit the longitudinal distribution of the effluent to a first section of the drainage conduits 300. Similarly, a number of perforations 360 being too low or perforations 360 having small apertures may prevent a sufficient volume of the effluent to be released from the conduits 300. In some embodiments, having an insufficient release of effluent may cause an undesirable accumulation of the effluent in the drainage conduits 300 or flooding of the drainage conduits 300 and the wastewater treatment system.

[0044] Referring again to FIG. 4, the leach system further comprises one or more layers of porous or filtering textile membranes 365, such as fabric membranes, adapted to wrap the drainage conduits 300 and to facilitate the leaching of the effluent into the filtering medium 430. The membranes 365 may comprise any suitable synthetic media for the leaching of fluids. The membranes 365 may further facilitate the fixation of microbial water treating bacteria supporting treatment of the effluent. The membranes 365 may further support a longitudinal distribution of the effluent along the drainage conduits 300. The filtering membranes 365 may be fastened to the drainage conduits 300 by any suitable means. In certain embodiments, the filtering membranes 365 are affixed to the first and second attachment sections 312, 322 by welding, sewing, stapling, clamping and gluing. In other embodiments, the filtering membranes 365 may be removably disposed about the drainage conduits 300 without any fastening means such as, for example, being wrapped around the drainage conduits 300.

[0045] In some further embodiments, the drainage conduits 300 may be configured in parallel, in series or in any combination thereof, such as with some drainage conduits 300 being positioned in parallel and other drainage conduits 300 being positioned in series.

[0046] When configured in parallel, the drainage conduits 300 may be interconnected by means of a distribution device (not shown) configured to distribute the effluent across the two or more interconnected drainage conduits 300. Similarly, the leach system may comprise a junction pipe configured to fluidly connect the one or more drainage conduits 300 at their downstream ends 304. To that end, the junction pipe may comprise any shape and length necessary to reach the downstream ends 304 of the drainage conduits 300. In some embodiments, the end caps may comprise an opening configured to allow fluid access to the junction pipe.

[0047] When configured in series, the drainage conduits 300 may be interconnected by means of couplers configured to allow a fluid communication between two or more drainage conduits 300. In other embodiments however, the drainage conduits 300 may comprise integrated couplers forming part of the drainage conduits 300 and eliminating the need for any additional coupling means.

[0048] Still referring to FIG. 4, the drainage conduits 300 may comprise first and second coupling ends 382, 384 configured to sealingly affix two drainage conduits 300 positioned in series. In certain embodiments, the first and second coupling ends 382, 384 may take the form of male and female connectors wherein the female connector is configured to receive and hold the male connector. In the embodiment illustrated in FIG. 4, the first coupling end 382 comprises a male connector configured to be received by the female connector of another drainage conduit (not shown) installed in series. Similarly, the second coupling end 384 comprises a female connector configured to receive by the male connector of another drainage conduit (not shown) installed in series. The first and second coupling ends 382, 384 may additionally be configured to receive the distribution device 248 or the end caps 254.

[0049] In certain embodiments, the first and second coupling ends 382, 384 may additionally comprise means for affixing drainage conduits 300 disposed in series. For example, the first and second coupling ends 382, 384 may comprise ridges, threading, adhesive or any other suitable means of restricting motion in a longitudinal direction of the drainage conduits 300. Still referring to FIG. 4, the first and second coupling ends 382, 384 comprise ridges 388 disposed on their outer and inner surfaces, respectively.

[0050] The present invention also provides a method for manufacturing and installing the drainage conduits 300 into the wastewater treatment system. The method generally comprises forming the first and second portions 310, 320 and the hinged portion 340 of the drainage conduit, forming a closed drainage conduits by folding the two portions 310, 320 along the hinged portion 340 and laying the closed conduits 300 on the ground.

[0051] Forming the first and second portions 310, 320 may comprise injecting molten material into a mould having the shape of the first and second portions 310, 320 and of the hinged portion 340. The manufacturing of the open conduit 300 may, in some embodiments, comprise forming distinct first and second portions 310, 320 and attaching the said portion along their length using a hinge 340.

[0052] The method may further comprise stacking a plurality of drainage conduits 300 in an open configuration on top of one another.

[0053] The step of forming a closed drainage conduit by folding the two portions 310, 320 may comprise pivoting the two portions 310 and 320 along the hinged portion 340 and fixing the two portions to one another. Fixing the two portions to one another may comprise attaching the outer extremity 312 and 322 of each portion 310, 320 to one another attachment mean, such as gluing, sewing, clamping, etc. In yet another embodiment, each extremity 312 and 322 may comprise a male and female connector allowing to be mated to one another, such as snapping the two portions together.

[0054] In some embodiments, the step of installing or laying the drainage conduits 300 comprises placing the drainage conduits in a closed position. The installation of the drainage conduits 300 may further comprise affixing the first and second attachment sections 312, 322 prior to installation using any suitable means such as, but not limited, welding, sowing, stapling and gluing.

[0055] The method of assembly may further comprise surrounding the conduit with filtering membranes 365. The method may further comprise affixing the drainage conduits to other drainage conduits in a series by means of the first and second coupling ends 382, 384.

[0056] In some embodiments, the method comprises forming or moulding the first and second portions 310, 320 and the hinged portion 340, stacking the formed conduits on top of one another and transporting the stacked conduits 300 to another location. At such location, the two portions 310, 320 are folded one against the other to form the closed configuration and are attached or sewed to one another. The closed conduit 300 may then be installed or laid on the ground.

[0057] While illustrative and presently preferred embodiments of the invention have been described in detail hereinabove, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art.