CA2952389A1 - Trench drain with overmolded frame - Google Patents

Abstract

A trench drain includes an open-faced channel that is polymeric with one or more integral metal frames molded into the sidewall(s) of the open-faced channel.

Description

TRENCH DRAIN WITH OVERMOLDED FRAME
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based on and claims priority to U.S. Provisional Patent Application No. 62/271,078, filed December 22, 2015, the contents of which are incorporated herein by reference in its entirety for all purposes.
TECHNICAL FIELD

[0002] This application relates to modular trench drains used to transport liquid to a drainage sewer.
BACKGROUND

[0003] Trench drains are U-shaped or V-shaped troughs for the collection of liquid, such as rainwater, and can be used to transport the collected water to a sewer or other drainage point. Trench drains are commonly installed in the ground and secured in concrete. In most cases, trench drains also include a grate to prevent large debris from entering the water-conveying channel and to prevent people from stepping or falling into them.

[0004] Historically, concrete trench drain systems used forms. The forms were placed in a ditch dug in the ground.
Concrete was then poured around the forms, which were removed after the concrete has set. Trench drain systems made in accordance with this method or similar methods result in relatively expensive systems due to the cost of installing and removing the forms.

[0005] Many of the expenses associated with these prior art trench drain systems have been overcome by the advent of polymeric trench drains, which can be left in place after the concrete has been poured in place. These polymeric trench QB\43032020.1 - 1 -156214.00527 drains perform two functions. First, the polymeric channel acts as a form for casting the concrete. Second, the polymeric channel acts as a liner such that the water initially comes in contact with the polymeric channel and not in direct contact with the concrete. The manufacture and transportation costs associated with this type of trench drain is significantly less than the other types of trench drains.

[0006] However, trench drain systems made of polymeric channels have problems not associated with the other types of trench drain systems, namely buckling due to the expansion of the trench drains. This typically occurs when the trench drains are installed in colder weather. They then expand in hotter weather due to the polymeric materials' high coefficient of expansion. The embedding concrete prevents the trench drains from expanding in a longitudinal direction. Therefore, the trench drains buckle to compensate for this expansion. Further, the trench drains can deform during installation when wet concrete is poured around the periphery of the trench drains.
This is due to the pressure of wet concrete against the trench drain walls.

[0007] Furthermore, as in all of the above trench drain systems, installing the polymeric trench drains require a substantial amount of hardware, such as nuts and bolts, which adds not only to the cost, but can also result in delays, should the installer run out of this hardware.
SUMMARY

[0008] Various improvements to trench drains are described herein including an improvement relating to the overmolding of metal rails. It will be appreciated that the various improvements could potentially be used separate from one another or in various combinations and permutations with one another.
QB\43032020.1 - 2 -158214.00527

[0009] According to one aspect, a trench drain includes an open-faced channel having spaced-apart sidewalls connected to a bottom wall and extending between a pair of opposing axial ends.
The open-faced channel comprises a polymeric material. The trench drain further includes an integral metal frame having an upper lip portion adapted to support a grate and having a lower embedded portion which is molded into at least one of the spaced-apart sidewalls to secure the integral metal frame to the open-faced channel.

[0010] In some forms, the integral metal frame may include a pair of opposing axial ends and may further include an anchor feature disposed proximate one of the pair of opposing axial ends. The anchor feature may be molded into the polymeric material of the open-faced channel to positionally fix the axial ends of the integral metal frame on which the anchor feature is positioned relative to a respective one of the pair of opposing axial ends of the open-faced channel. During molding, the polymeric material may flows into and/or engages the anchor feature such that, upon cooling, the anchor feature serves as an anchor point for the integral metal frame relative to the sidewall. Because as the integral metal frame and the open-faced channel differentially shrink during cooling, a dimensional shrinkage difference in an axial direction between the integral metal frame and the open-faced channel may then be expressed only on the respective axial ends of the frame and channel not having the anchor feature. In some forms, the anchor feature may be a frame aperture and, during molding, the polymeric material flows into and fills the frame aperture creating a sidewall protrusion. In other forms, the anchor feature may be a frame notch having an axially-facing wall that is embedded in the polymeric material of the open-faced channel.
Still yet, in other forms, the anchor feature may include QB\43032020.1 - 3 -158214.00527 multiple features such as, for example, a frame aperture and a frame notch. It is contemplated that if there is one or more anchor features, that each anchor feature may have a surface that is at least partially facing an axial direction to anchor the end of the integral metal frame relative to the sidewall.

[0011] In some forms, the integral metal frame may further include an intermediate section connecting the upper lip portion to the lower embedded portion. The intermediate section may have at least one exposed surface which is not at an axial end of the integral metal frame and that is not covered by the polymeric material of the open-faced channel. Put another way, the intermediate section may separate inner and outer environments having an inwardly facing surface that defines a portion of the inner channel and outwardly facing surface that is adapted for being cast in concrete or the like. In some forms, the upper lip portion, the intermediate section, and an upper edge of each sidewall may collectively form an outer recess. The outer recess may also be further defined by one or more vertically extending side ribs on the outside of the open-faced channel. The outer recess may be configured to receive concrete.

[0012] In some forms, the lower embedded portion may be an embedded angle including both a horizontal and vertical section molded into the sidewall. The embedded angle may forms a right angle that helps to secure the embedded angle in the polymeric material. To help accommodate the molding of the lower embedded portion in the polymeric material, an upper extent of each sidewall is thickened relative to a lower extend of each sidewall to provide a sufficient thickness of polymeric material to hold the embedded angle of the integral metal frame within the corresponding sidewall (or whatever geometry the lower embedded portion takes).
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[0013] In some forms, the polymeric material may be a resin containing at least one of a fiberglass, nylon, and a polyethylene. In some forms, the polymeric material may include polyethylene and/or polypropylene.

[0014] In some forms, an integral metal frame may each be molded into a respective one of the spaced-apart sidewalls.

[0015] These and still other advantages of the invention will be apparent from the detailed description and drawings. What follows is merely a description of some preferred embodiments of the present invention. To assess the full scope of the invention, the claims should be looked to as these preferred embodiments are not intended to be the only embodiments within the scope of the claims.
BRIEF DESCRIPTION OF THE FIGURES

[0016] FIG. 1 is a top perspective view of a trench drain;

[0017] FIG. 2 is a partial cross-sectional view of the trench drain shown in FIG. 1;

[0018] FIG. 3 is a perspective view of a pair of exploded sections of a trench drain and a gasket used that can be slid into one another to form a connection therebetween;

[0019] FIG. 4 is a top perspective view of a rebar clip attachment mechanism on a lateral side of a trench drain;

[0020] FIG. 5 is a top perspective view of an alternative embodiment of a rebar clip attachment mechanism;

[0021] FIG. 6A is a bottom perspective view of a spacer block for lateral placement across the trench drain;

[0022] FIG. 6B is a top perspective view of a spacer block of FIG. 6A;

[0023] FIG. 7 is a top perspective views of the insertion steps of a spacer block into a trench drain;
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[0024] FIG. 8 is a partial cross-sectional view of the trench drain showing the spacer block shown of FIG. 7;

[0025] FIG. 9 is a partial cross-sectional view of a toggle bolt for securing a grate to a spacer block;

[0026] FIG. 10 is a partial cross-sectional view of a push pin for securing a grate to a spacer block;

[0027] FIG. 11 is a top perspective view of a trench drain cover for a grate;

[0028] FIG. 12 is a top perspective view of a catch basin for use with a trench drain system;

[0029] FIG. 13 is a top plan view of the catch basin of FIG.
12;

[0030] FIG. 14 is a top perspective view of a catch basin with metal rails;

[0031] FIG. 15 is a top perspective view of a catch basin with a removed side wall section;

[0032] FIG. 16 is a top perspective view of another trench drain;

[0033] FIG. 17 is a front elevational view of the trench drain shown in FIG. 16;

[0034] FIG. 18 is a partial cross-sectional view of the trench drain shown in FIG. 16;

[0035] FIG. 19 is a detail view of a rear end of a metal frame of the trench drain of FIG. 16; and

[0036] FIG. 20 is a detail view similar to FIG. 19, shown without the metal frame installed on the trench drain.
DETAILED DESCRIPTION

[0037] FIGS. 1-3 show a U-shaped trench drain 10. In some forms, the trench drain 10 is made of a polymeric or plastic material, such as a resin containing fiberglass, nylon, or a polyethylene and formed in lengths of eighty inches. The trench QB\43032020.1 - 6 -158214.00527 drain 10 weighs considerably less than a comparable concrete or metal trench drain. In general, more polymeric trench drains can be transported per truckload than concrete or metal trench drains because of their light weight.

[0038] The trench drain 10 includes a pair of spaced apart sidewalls 12 connected to a U-shaped bottom wall 14 and define an open-faced channel 15. The sidewalls 12 can either be straight or angled. Likewise, the bottom wall 14 can either be flat, round, or angled so that water or other liquids can be directed from one end to another. In any event, the particular geometry of the trench drain 10 and channel can deviate from that illustrated.

[0039] The trench drain 10 includes a first end or male end 16 and a second end or female end 18 that can be used to connect sections of the trench drain 10 together as best illustrated in FIG. 3. The male end 16 includes a portion of the walls 12 and 14 and the female end 18 defines a recessed portion adapted to matingly receive the male end 16 of an adjacent trench drain. As best illustrated in FIG. 3, a gasket 19 may be seated in the female end 18 of one segment of a trench drain before the reception of the male end 16 of another segment of a trench drain and this gasket 19 can help prevent leaking of fluids between the different sections of the trench drain 10 and accommodate some dimensional adjustment or flexure of the separate drain sections relative to one another.

[0040] Returning now to FIG. 1, a plurality of ribs 20 are integrally formed in the walls 12 and 14 and are spaced along the length of the trench drain 10. The ribs 20 add structural strength to the trench drain 10. A plurality of support ribs 24 (which support rebar clips 26) are also integrally formed in the walls 12 and 14 and are spaced along the length of the trench drain 10. An L-shaped lip 22 is defined at upper ends of Q18\43032020.1 - 7 -158214.00527 respective sidewalls 12. The lips 22 define recesses 23 for receiving a grate 112 (as will be best illustrated in FIG. 11).

[0041] With specific reference to FIG. 2, the sidewalls 12 which may be comprised of high-density polyethylene (HDPE) are molded over an elongated metal frame 56 traversing the axial length of the trench drain 10. The metal frame 56 includes a first vertical wall 58 and a horizontal wall 60 forming lips 22 or an upper lip portion and a second vertical wall 62 embedded within the sidewalls 12 forms a lower embedded portion.

[0042] The metal frame 56 provides significantly improved stability of trench drain 10, thereby allowing longer lengths of the trench drain 10 to be transported long distances without being damaged or deformed during shipping. Being able to transport long lengths of the trench drains 10 (e.g., 80 inch lengths) is especially useful in large industrial applications requiring a significant amount of the trench drains 10 (e.g., gas stations, stadiums, etc.).

[0043] The metal frame 56 additionally provides substantial reinforcement along the length of the trench drain 10 thereby minimizing any deformation of the trench drain 10 during installation when the concrete is poured into the trench. The metal frame 56 further provides a clean edge after the concrete is poured and enhances structural support for the trench grates 112 as best illustrated in FIG. 11.

[0044] It should be appreciated that, while the metal frame 56 is illustrated in FIGS. 1-3 as being molded into the body of the trench drain, the metal frame could potentially be assembled to or connected to the polymeric body in a number of other ways while achieving the same or similar benefits to those described herein. For example, rather than molding the metal frame 56 into the sidewalls 12 of the trench drain 10, the metal frame could be otherwise assembled to the polymeric body of the trench 413\43032020.1 - 8 -158214.00527 drain by fastening (e.g., using threaded screws or other types of fasteners), by snap fit (e.g., designing the frame and body to have interlocking clip features or features the mechanically engage one another), by adhesion (e.g., using adhesive or epoxy to join the metal frame to the polymeric body, although it is noted that such adhesive joining can be difficult given the types of materials involved), slotted engagement (e.g., sliding the metal frame into a slot formed in the body or vise-versa) or such other joining techniques.

[0045] Turning now to FIG. 4, detail of the U-shaped rebar clip 26 is illustrated showing the attachment of the rebar clip 26 to a rebar support 42. The U-shaped rebar clip 26 includes a first section 34 opposite a second section 36 and a rebar clip engagement surface 38 defining an annular hole 40 passing therethrough. The rebar support 42 passes through the hole 40 and is frictionally held in place against the rebar clip engagement surface 38 with a fastening tool 44 when the fastening tool 44 is used to draw the first section 34 and the second section 36 together. The fastening tool 44 is manufactured using a glass filled composite or metal materials and includes a threaded end 46 and an L-shaped toggle arm 48.
The threaded end 46 of the fastening tool 44 is received through a first hole 50 in the second section 36 and into a second hole 52 in the first section 34. It is contemplated that the tool 44 could be pre-assembled to the trench drain 10 or installed by the installer during installation. With the tool 44 generally in place, the L-shaped toggle arm 48 can be rotated approximately 180 degrees in a clockwise direction to drive the threaded end

46 through a first hole 50 in the second section 36 and into a second hole 52 in the first section 34, thereby drawing the sections 34 and 36 towards one another to close the gap therebetween and secure in position trench drain 10 to rebar QB\43032020.1 - 9 -158214.00527 support 42. The diameter of the holes 50 and 52 are smaller than a flange or headed portion 54 of the threaded end 46 of the fastening tool 44 and thus the flange can draw the sections 34 and 36 together as the fastening tool 44 is tightened.
[0046] After the trench drain 10 has been positioned in the trench and attached to the rebar support 42 by the rebar clips 26, the drain 10 may still be vertically adjusted by rotating the toggle arm 48 in a counter-clockwise direction by approximately 180 degrees to slight remove the threaded end 46 from the holes 50 and 52 and remove the clamping force applied by the clip 26 on the rebar support 42, thereby temporarily allowing movement of the rebar clip 26 along the rebar support 42, moving the trench drain to a desired position, and then refastening the rebar clips onto the rebar 42 by rotating the toggle arm 48 in a clockwise direction again.

[0047] It should be appreciated that the L-shape of the toggle arm 48 offers easy and reversible tightening or loosening of the clips 26 to the rebar support 42. Moreover, the tool 44 has a low profile and does not require much space to the lateral sides of the trench drain 10 to use. Thus, difficulty of using a power tool to drive a fastener on a lateral side of the trench drain 10 can be avoided. It should further be appreciated that, later during installation of the trench drain 10, the fastening tool 44 can be cast right into the surrounding concrete with the trench drain 10.

[0048] FIG. 5 shows an alternative embodiment of a rebar clip 63 that includes a top cap 64, a base 66 and a tapered cone portion 72. A slot 68 formed in the top cap 64 mates with an extension 70 formed in the base 66. Opposite the base 66 is the cone portion 72 that includes a first arced arm 74 and a second arced arm 76 which partially angularly surround the rebar support 42 and have a slight gap therebetween their respective QB\43032020.1 - 10 -158214.00527 ends permitting their flexure towards another. A vertical surface 78 of the first arced arm 74 and the second arced arm 76 is tapered and the top cap 64 matingly fits over the tapered cone portion 72 to secure the base 66 onto the rebar 42 and compress the arced arms 74 and 76 towards one another.

[0049] The top cap 64 is further affixed to the base 66 with a screw 80 that is threaded from the top surface of the cap 64 through a first hole 82 in the cap 64 and a second hole 84 in the base 66. During installation, the top mounting of the screw 80 (as opposed to a lateral approach) is easily accessed to allow convenient repositioning of the trench drain 10 secured to the rebar 42. The top cap 64 is preferably made of a rigid material and the base 66 is preferably made of high-density polyethylene.

[0050] FIGS. 6A and 6B show spacer blocks 86 that, as shown in FIGS. 7 and 8, are adapted to be received in a plurality of opposing pairs of recesses 88 defined between the sidewalls 12 of the trench drain 10 and the metal frames 56. These spacer blocks 86 provide widthwise extending cross-supports that keep the sidewalls 12 evenly spaced apart over the length of the trench drain 10 and further provide a point for attachment for a grate 112 using a fastener in a hole 90.

[0051] As best illustrated in FIGS. 6A and 6B, each spacer block 86 can be made of a glass filled composite and has an upward-facing longitudinal slot 92 that receives a downturned portion 94 of the metal frame 56. The blocks 86 have an integrally formed spring clip 96 that locks the spacer block 86 in place by applying downward pressure against a bottom surface 98 of the recess 88 thereby biasing upward-facing longitudinal slot 92 into the downturned portion 94 of the metal frame 56.
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[0052] With respect to FIG. 7, it is illustrated how the spacer block 86 can be twisted into place to secure the spacer block 86 into the opposing pairs of recesses 88.

[0053] With additional reference to the detailed view of FIG.
8, to secure the spacer block 86 in place in the recesses 88, downward pressure is applied on the spacer block 86 against the bias of the spring clip 96 to allow enough clearance to disengage the downturned portion 94 of the metal frame 56 from the slot 92 and twisting the spacer block in a counter-clockwise direction to remove it from the recess 88. As noted above, the spacer block 86 also prevents deformation and collapse of the trench drain 10 when the trench drain 10 is shipped to a job site for installation.

[0054] FIG. 9 shows an improved quarter turn toggle bolt 100 with a pair of wings 102 that is received in the bolt hole 90 of the spacer block 86 to lock the grate 112 in place. The toggle bolt 100 has a spring 101 that biases a bolt head 103 in an upward direction away from the grate 112. The head is depressed and the bolt head is rotated a quarter turn to disengage the wings 102 from the bottom surface of the spacer block 86 thereby releasing the bolt 100 securing the grate 112 on the trench drain 10.

[0055] FIG. 10 shows an alternative embodiment to lock the grate 112 in place on the trench drain 10 by providing a push-pin locking mechanism 104 received within a body portion 106 wherein the body portion 106 is installed in the spacer bar 86.
In the open position, the grate 112 is easily inserted or removed because the diameter of a hole 105 in the grate 112 is larger than a movable top portion 108 of the body 106. To lock the grate 112 in place, the push-pin locking mechanism is depressed causing an engagement surface 109 of the top portion 108 to mate within a recess 110 thereby increasing the diameter Q13\43032020.1 - 12 -158214.00527 of the top portion 108 so that it is larger than the diameter of the hole 105 in the grate 112. The grate 112 is removed by pulling the push-pin locking mechanism 104 away from the grate 112 to disengage the engagement surface 109 of the top portion 108 from the recess 110.

[0056] In either fastener design, with the grate 112 removed, this spacer block 86 is easily removed to allow cleaning of the trench drain 10.

[0057] Turning now to FIG. 11, a grate cover 114 is shown that fits over the exposed top surface of the grate 112. The grate cover 114 is preferably manufactured from an inexpensive plastic and thrown away after the concrete is poured into the trench. The grate cover 114 protects the trench drain 10 and the grate 112 from accidental debris and concrete being spilled thereupon during the pouring of the concrete during the installation of the trench drain 10.

[0058] FIGS. 12-15 show a catch basin trench drain module 116 that includes a catch basin 118, a pair of molded female ends 18, and integral rebar clips 26. A top edge 120 of the catch basin trench drain module 116 can be cut to match the size of the opening of the mating male ends 16 of the trench drains 10.
As best illustrated in FIG. 14, a set of metal rails 122 can be affixed to a top edge 124 of the catch basin 116 which has been already cut using a plurality of screws 126 inserted into a hole 128 in the top edge 124 and a hole 130 in the top edge 124 of the catch basin 116. A metal insert 132 is inserted into a recess 134 and adapted to receive the spacer block 86. As best shown in FIG. 15, excessive sidewall material 131 is cut to accommodate the size of the mating male ends 16 of the trench drains 10. Alternatively, the excessive sidewall material 131 is perforated at predetermined intervals to allow portions of the sidewalls 12 to be snapped off along the perforations to Q13\43032020.1 - 13 -158214.00527 match the size of the opening of the mating male ends 16 of the trench drains 10.

[0059] FIGS. 16-20 show another embodiment of a U-shaped trench drain 210. The trench drain 210 is similar to the trench drain 10 and, as such, like features will be labeled with like numbers in the 200 series (e.g., sidewalls 12 and sidewalls 212, metal frame 56 and metal frame 256, etc.). A description of the trench drain 210 will be provided below which will, in part, highlight differences between the trench drain 10 and the trench drain 210.

[0060] In some forms, the trench drain 210 is made of a polymeric or plastic material, such as a resin containing fiberglass, nylon, or a polyethylene and formed in lengths of eighty inches. In some other forms, the trench drain 210 is made of high density polyethylene (HDPE), polypropylene (PP), or any other suitable material. Being made of a polymeric or plastic material, the trench drain 210 weighs considerably less than a comparable concrete or metal trench drain. As such, in general, more polymeric trench drains can be transported per truckload than concrete or metal trench drains because of their light weight.

[0061] The trench drain 210 includes a pair of spaced apart sidewalls 212 connected to a U-shaped bottom wall 214 and defines an open-faced channel 215. The sidewalls 212 can either be straight or angled. Likewise, the bottom wall 214 can either be flat, round, or angled so that water or other liquids can be directed from one end to another. In any event, the particular geometry of the trench drain 210 and channel can deviate from that illustrated.

[0062] The trench drain 210 includes a first axial end 216 and a second axial end 218 that can be configured to connect sections of the trench drain 210 together, similar to the first QB\43032020.1 - 14 -158214.00527 end 16 and the second end 18 of the trench drain 10, or using alterative mechanisms.
[00631 As shown in FIG. 16, a plurality of ribs 220 are integrally formed in the walls 212 and 214 and are spaced along the length of the trench drain 210. The ribs 220 add structural strength to the trench drain 210. A plurality of support ribs 224 (which support rebar clips, not shown, in FIG. 16, but which may be similar to the clips in the first embodiment, for example) are also integrally formed in the walls 212 and 214 and are spaced along the length of the trench drain 210. An L-shaped lip 222 is defined at an upper ends of each respective sidewalls 212. The lips 222 define recesses 223 for receiving a grate, similar to the lips 22 of the trench drain 10.
[0064] Referring now to FIGS. 16 through 18, the sidewalls 212, which are preferably comprised of HDPE or PP, are molded over an elongated, integral metal frame 256 traversing the axial length of the trench drain 210. Each metal frame 256 extends from a first frame axial end 255 disposed adjacent to the first axial end 216 of the channel 215 of the trench drain 210 to a second frame axial end 257 disposed adjacent to the second axial end 218 of the channel 215 of the trench drain 210.
Additionally, each metal frame 256 includes a first vertical wall 258 and a first horizontal wall 260 forming lips 222 in an upper lip portion of the frame 256 and a second vertical wall 262 providing an intermediate portion of the frame 256 that extends to a lower embedded portion.
[0065] Unlike the metal frames 56, the second vertical walls 262 of the metal frames 256 (or the intermediate portion) are not fully embedded within the sidewalls 212. Instead, the second vertical walls 262 are only slightly inset into the sidewalls 212 within the open faced channel 215, such that each second vertical wall 262 is flush with the corresponding QB\43032020.1 - 15 -158214.00527 sidewall 212 within the open faced channel 215. This leaves one non-axial surface non-contacted by the polymeric material of the channel 215.
[0066] Additionally, each metal frame 256 further includes a second horizontal wall 265, extending from a lower end of the corresponding second vertical wall 262, and a third vertical wall 267 which, as illustrated define the lower embedded portion. Each second horizontal wall 265 further extends horizontally into the corresponding sidewall 212 and each third vertical wall 267 extends downwardly from an embedded end of the corresponding second horizontal wall 265. As such, the second horizontal walls 265 and the third vertical walls 267 are embedded within the sidewalls 212 to define the lower embedded portion, forming embedded right angles 269, which secure the metal frames 256 within the sidewalls 212. The embedded right angles 269 further aid in preventing the metal frames 256 from being inadvertently pulled out from the sidewalls 212 during transport.
[0067] Similar to the metal frame 56, the metal frame 256 provides significantly improved stability of trench drain 210, thereby allowing longer lengths of the trench drain 210 to be transported long distances without being damaged or deformed during shipping. Being able to transport long lengths of the trench drains 210 (e.g., 80 inch lengths) is especially useful in large industrial applications requiring a significant amount of the trench drains 210 (e.g., gas stations, stadiums, etc.).
[0068] The metal frame 256 additionally provides substantial reinforcement along the length of the trench drain 210 thereby minimizing any deformation of the trench drain 210 during installation when the concrete is poured into the trench. The metal frame 256 further provides a clean edge after the concrete is poured and enhances structural support for the trench grates.
QB\43032020.1 - 16 -158214.00527 [0069] Referring now to FIG. 18, the first horizontal wall 258, the second vertical wall 262, and an upper edge 271 of each sidewall 212 collectively form an outer recess 273. Each outer recess 273 is configured to receive concrete during installation. As such, once the concrete has set, any grate received by the recesses 223 is supported by the first horizontal walls 260, which are further directly supported by concrete. Additionally, each sidewall 212 of the channel 215 is thickened proximate the upper edge 271 to provide sufficient material to hold the corresponding metal frame 256 within the sidewall 212.
[0070] Referring now to FIGS. 19 and 20, the second frame end 257 of one of the metal frames 256 is shown molded into the second end 218 of the sidewalls of the channel of the trench drain 210 at one or more anchor features (shown with the frame 256 in place in FIG. 19 and with the frame 256 omitted in FIG.
20 to show only the molded portion of the channel).
Additionally, a frame notch 275 is formed in the second vertical wall 262 at the second frame end 257 which is axially offset from the axial end of the sidewall of the channel.
[0071] While the sidewalls 212 are molded over the metal frames 256, the polymeric or plastic material flows into and fills the frame aperture 273, forming a sidewall protrusion 277, and also flows around the frame notch 275, engaging these anchoring features and fixing the axial end of the frame 256 at this anchoring point in the sidewall of the channel. Notably, after the molded polymeric or plastic material forms the sidewalls 212 and begins to cool, the sidewalls 212 tend to shrink more than the metal frames 256 due to a higher coefficient of thermal expansion of the polymeric or plastic material as compared to the coefficient of thermal expansion of the metal. As such, the frame aperture 273 and the frame notch QB\43032020.1 - 17 -158214.00527 275 provide anchor points, such that the plastic material shrinks in a single direction from the first end 215 of the trench drain 210 towards the second end 218 of the trench 210.
With the frame 256 being fixed or staked at one axial end of the trench, this means that all of the dimension difference as the result of differential shrinking occurs at the non-fixed axial end. Accordingly, the entire difference as the result of differential shrinkage occurs at that one side, which can be cut at that axial end, and that end only.
[0072] It should be appreciated that various other modifications and variations to the preferred embodiments can be made within the spirit and scope of the invention. Therefore, the invention should not be limited to the described embodiments.
To ascertain the full scope of the invention, the following claims should be referenced.
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Claims (17)

What is claimed is:

1. A trench drain comprising:
an open-faced channel having spaced-apart sidewalls connected to a bottom wall and extending between a pair of opposing axial ends, wherein the open-faced channel comprises a polymeric material; and an integral metal frame having an upper lip portion adapted to support a grate and further having a lower embedded portion which is molded into at least one of the spaced-apart sidewalls to secure the integral metal frame to the open-faced channel.

2. The trench drain of claim 1, wherein the integral metal frame includes a pair of opposing axial ends and further includes an anchor feature disposed proximate one of the pair of opposing axial ends in which the anchor feature is molded into the polymeric material of the open-faced channel to positionally fix only the one of the pair of the opposing axial ends of the integral metal frame on which the anchor feature is positioned relative to a respective one of the pair of opposing axial ends of the open-faced channel.

3. The trench drain of claim 2, wherein, during molding, the polymeric material flows into and engages the anchor feature and, upon cooling, the anchor feature serves as an anchor point for the integral metal frame relative to the sidewall, such that, as the integral metal frame and the open-faced channel differentially shrink during cooling, a dimensional shrinkage difference in an axial direction between the integral metal frame and the open-faced channel is expressed only on the respective axial ends not having the anchor feature.

4. The trench drain of claim 2, wherein the anchor feature is a frame aperture and wherein, during molding, the polymeric material flows into and fills the frame aperture creating a sidewall protrusion.

5. The trench drain of claim 2, wherein the anchor feature is a frame notch having an axially-facing wall that is embedded in the polymeric material of the open-faced channel.

6. The trench drain of claim 2, wherein the anchor feature includes multiple features.

7. The trench drain of claim 6, wherein the multiple features include a frame aperture and a frame notch each having a surface that is at least partially facing an axial direction to anchor the end of the integral metal frame having the multiple features relative to the sidewall.

8. The trench drain of claim 1, wherein the integral metal frame further includes an intermediate section connecting the upper lip portion to the lower embedded portion in which the intermediate section has at least one exposed surface which is not at an axial end of the integral metal frame and that is not covered by the polymeric material of the open-faced channel.

9. The trench drain of claim 8, wherein the upper lip portion, the intermediate section, and an upper edge of each sidewall collectively form an outer recess.

10. The trench drain of claim 9, wherein the outer recess is further defined by vertically extending side ribs on the outside of the open-faced channel.

11. The trench drain of claim 9, wherein the outer recess is configured to receive concrete.

12. The trench drain of claim 1, wherein the lower embedded portion is an embedded angle including both a horizontal and vertical section molded into the sidewall.

13. The trench drain of claim 12, wherein the embedded angle forms a right angle.

14. The trench drain of claim 12, wherein an upper extent of each sidewall is thickened relative to a lower extend of each sidewall to provide a sufficient thickness of polymeric material to hold the embedded angle of the integral metal frame within the corresponding sidewall.

15. The trench drain of claim 1, wherein the polymeric material is a resin containing at least one of a fiberglass, nylon, and a polyethylene.

16. The trench drain of claim 1, wherein the polymeric material is at least one of polyethylene and polypropylene.

17. The trench drain of claim 1, wherein an integral metal frame is each molded into a respective one of the spaced-apart sidewalls.