U.S. patent application number 11/210138 was filed with the patent office on 2006-03-09 for self-cleaning flooring system.
Invention is credited to David L. Christian, James G. MacLean.
Application Number | 20060048469 11/210138 |
Document ID | / |
Family ID | 37770777 |
Filed Date | 2006-03-09 |
United States Patent
Application |
20060048469 |
Kind Code |
A1 |
MacLean; James G. ; et
al. |
March 9, 2006 |
Self-cleaning flooring system
Abstract
A self-cleaning flooring system is provided that includes at
least one module. The module comprises a drain pan, a plurality of
discharge ports, and at least one side wall. The drain may have a
ramp and a drain outlet. The ramp may slope downward towards the
drain outlet. The discharge ports may be disposed about a periphery
of the drain pan and may be directed towards the drain outlet to
direct flushing fluid towards the drain outlet. The side wall may
circumscribe a portion of the periphery of the drain pan and
include a hollow passage and at least one fluid inlet. The fluid
inlet may be in fluid communication with the hollow passage for
delivering flushing fluid to the discharge ports.
Inventors: |
MacLean; James G.; (La
Quinta, CA) ; Christian; David L.; (Rancho Mirage,
CA) |
Correspondence
Address: |
STETINA BRUNDA GARRED & BRUCKER
75 ENTERPRISE, SUITE 250
ALISO VIEJO
CA
92656
US
|
Family ID: |
37770777 |
Appl. No.: |
11/210138 |
Filed: |
August 23, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10282393 |
Oct 29, 2002 |
6941703 |
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11210138 |
Aug 23, 2005 |
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11074814 |
Mar 8, 2005 |
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11210138 |
Aug 23, 2005 |
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Current U.S.
Class: |
52/220.3 |
Current CPC
Class: |
E03F 5/0402 20130101;
A01K 1/0103 20130101; Y02A 30/60 20180101; A01K 1/0151 20130101;
E04F 17/00 20130101; E04F 19/10 20130101 |
Class at
Publication: |
052/220.3 |
International
Class: |
E04C 2/52 20060101
E04C002/52 |
Claims
1. A self-cleaning flooring system including at least one module,
the module comprising: a drain pan having at least one ramp and a
drain outlet, the ramp sloping downwardly toward the drain outlet;
and at least one side wall and one end wall forming at least a
portion of a periphery of the drain pan, the end wall having at
least one fluid inlet, the side wall having at least one discharge
port configured to receive flushing fluid from the fluid inlet and
direct flushing fluid down the ramp toward the drain outlet.
2. The self-cleaning flooring system of claim 1 comprising a
plurality of the modules, each one of the modules being configured
to be connectable to one another in horizontal alignment.
3. The self-cleaning flooring system of claim 1 wherein the side
wall includes a hollow passage extending therethrough, the hollow
passage being in fluid communication with the fluid inlet and being
configured to deliver flushing fluid to the discharge port.
4. The self-cleaning flooring system of claim 1 further including a
removable drain basket positioned adjacent to the drain outlet and
being operative to prevent solid waste from entering the drain
outlet.
5. The self-cleaning flooring system of claim 1 wherein the module
further includes at least one floor grid mounted on the drain pan
and being configured to support personnel standing thereupon and
permitting waste products to pass therethrough.
6. The self-cleaning flooring system of claim 1 wherein the module
further includes at least one strainer tray mounted above the drain
channel and being configured to prevent waste products of a
predetermined size from entering the drain channel.
7. The self-cleaning flooring system of claim 1 wherein the drain
pan includes a perimeter flange extending around the drain pan
periphery and being configured for supporting the drain pan.
8. The self-cleaning flooring system of claim 1 further including
at least one pressure tank in fluid communication with the fluid
inlet and being configured to deliver pressurized flushing fluid
thereto.
9. A self-cleaning flooring system including at least one module,
the module comprising: a drain pan section, comprising: a pair of
ramp sections; and a channel section disposed between the ramp
sections, the channel section being configured to removably
interconnect the ramp sections, the channel section sloping
downwardly toward a drain outlet; wherein each one of the ramp
sections is oriented to slope downwardly toward the channel
section; and at least one discharge port mounted adjacent to the
ramp sections and being operative to spray flushing fluid onto the
ramp sections such that waste products are washed down the ramp
sections toward the channel section and from the channel section
toward the drain outlet.
10. The self-cleaning flooring system of claim 9 wherein the drain
outlet is located adjacent one end of the channel section, the
channel section sloping downwardly toward the drain outlet.
11. The self-cleaning flooring system of claim 9 further
comprising: at least one end plate; wherein each module comprises a
plurality of drain pan sections connected end-to-end and having an
end plate mounted on at least one end thereof.
12. The self-cleaning flooring system of claim 11 wherein the ramp
sections and the channel section are formed as separate
components.
13. The self-cleaning flooring system of claim 9 comprising a
plurality of the modules, each one of the modules being configured
to be connectable to one another end-to-end.
14. The self-cleaning flooring system of claim 9 wherein each one
of the ramp sections includes at least one rib member disposed
thereunder and being configured to support the ramp section above a
substrate.
15. The self-cleaning flooring system of claim 9 wherein the module
further includes at least one floor grid mounted on the drain pan
section and being configured to support personnel standing
thereupon and permitting waste products to pass therethrough.
16. The self-cleaning flooring system of claim 9 wherein the module
further includes at least one strainer tray mounted above the
channel section and being configured to prevent waste products of a
predetermined size from entering the drain channel.
17. A self-cleaning flooring system formed in a substrate,
comprising: a drain pan having a pair of ramps sloping downwardly
toward a drain channel, the drain channel sloping downwardly toward
a drain outlet, the drain pan defining a periphery with a perimeter
flange extending therearound; a manifold extending along a portion
of the drain pan and being disposed above at least one of the
ramps; and a spray nozzle fluidly connected to the manifold and
being operative to spray flushing fluid down the ramp toward the
drain channel and toward the drain outlet.
18. The module of claim 17 wherein the substrate is concrete.
19. The module of claim 17 wherein the drain pan is formed in the
substrate using a removable insert configured as a male mold.
20. The module of claim 17 wherein the insert is a foam material.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of co-pending
U.S. application Ser. No. 10/282,393, filed Oct. 29, 2002, and
co-pending U.S. application Ser. No. 11/074,814, filed Mar. 8,
2005, the entire contents of which are hereby incorporated by
reference.
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] Not Applicable
BACKGROUND
[0003] The present invention relates generally to flooring
protection and, more particularly, to a self-cleaning flooring
system having modules which are interconnectable to horizontally
adjacent modules to form a continuous flooring system for catching
waste products in a variety of applications and industries
including, but not limited to, laundry facilities and food
preparation facilities. The flooring system of the present
invention may also be formed as a permanent installation that is
cast in a concrete floor using removable male mold inserts that
duplicate the shape of a drain pan and over which floor grids may
be installed for supporting personnel standing thereupon.
[0004] Advantageously, the flooring system of the present invention
is adapted for use in dairies, meat processing plants, stables,
poultry operations, machine shops, clean assembly rooms, printing
facilities, and food processing plants. Furthermore, the flooring
system of the present invention may be used in transition areas in
animal processing applications. For example, the flooring system of
the present invention may be used between a feed yard and dairy
milking stations wherein hooves of livestock passing over the
flooring system could be sprayed prior to entering the dairy
milking station such that undesirable residue (e.g., manure) may be
washed from the livestock hooves and into the flooring system for
later retrieval as fertilizer.
[0005] In many industries, cleanliness of certain facilities and
rooms is critical. For example, in the food preparation industry,
sanitation and cleanliness in the kitchen is a major concern. The
kitchen flooring in restaurants, hotels, institutions, and
commercial food vending facilities in general is subject to
frequent spillage from waste products. Such waste products may be
in the form of spilled liquids, semi-solids, and small solids and
may include grease, oil, water, and an infinite variety of food
products. Spilled waste products may create a sanitation hazard as
a hot kitchen is a natural breeding ground for harmful bacteria
that may be caught in tile grout, and around pipes, drains or other
kitchen fixtures. Because of the immovable nature of such kitchen
fixtures, cleanliness is difficult if not impossible to maintain.
Stringent health codes in most states require that kitchens in
commercial food vending facilities receive daily cleaning.
[0006] Daily cleaning of walls, counter tops, appliances and floors
involves a great deal of hand labor consuming a considerable amount
of time. In addition, the waste products may create a health hazard
in that spilled food products are often wet or sticky, creating a
high risk that kitchen personnel may be injured in a fall.
Furthermore, spilled grease or oil creates a fire safety hazard
requiring the cessation of all operations in the kitchen until the
grease or oil is removed from the floor. As may be expected,
shutting down all kitchen operations in a restaurant or hotel may
result in a significant loss of revenue. In addition, current
cleaning methods of facilities such as commercial kitchens may
entail the temporary removal and/or dismantling of certain
equipment and flooring systems followed by lengthy washing with
water. As may be appreciated, such cleaning methods results in the
use of large quantities of water which may increase water
conservation issues in certain locales.
[0007] There is currently known in the prior art flooring systems
that are configured to address sanitation and safety concerns. One
prior art device comprises a washable floor for collecting waste.
The device provides a grid or mesh on which a person may stand, the
grid mounted above a sub-floor onto which waste falls. The
sub-floor is downward sloping towards a drain outlet. Flushing
means are provided for flushing the fluid waste down the sub-floor
towards the drain outlet. The grid is pivotably movable between a
horizontal position and a vertical position and is removable to
facilitate maintenance. Although the device addresses a few safety
and sanitation issues mentioned above in that it provides a
disposal means for fluid waste, the device lacks installation
flexibility in that it must be custom fitted to a particular floor
configuration. In addition, the size of the grids and sub-floor are
such that these components are too heavy and too large to be
individually washed, either by hand or by mechanical means, such as
in a commercial dishwasher.
[0008] Another prior art device provides a supporting surface for
personnel standing thereupon. The device allows water or fluid to
flow through the supporting surface and underneath a modular
flooring member. The device includes a series of cross-channels
forming a gridwork of fluid pads which permit water to flow
underneath the modular flooring. However, a major drawback to the
device is that a large portion of the subsurface of the flooring
member is in direct contact with the moist support floor. Although
this device addresses some safety concerns in that it provides a
non-slip surface upon which personnel may stand, the device is
subject to the problems of mildew and degradation of the subfloor
arising from captured water. Furthermore, the device is not
configured to be easily washable by hand or by mechanical means.
Finally, the above-mentioned devices require the use of large
amounts of water for thorough cleaning thereof.
[0009] As can be seen, there exists a need in the art for a
flooring system for catching waste products that also provides a
non-slip surface upon which personnel may stand to reduce the risk
of injury from slipping. Furthermore, there exists a need in the
art for a flooring system that is self-cleaning such that waste
products may be flushed toward a drain outlet for subsequent
disposal. Additionally, there exists a need in the art for a
flooring system that is light weight and of small size such that it
is removable for easy cleaning by hand or with cleaning equipment
such as a commercial dishwasher as may be found in a commercial
kitchen.
[0010] Also, there exists a need in the art for a flooring system
that is modular such that individual modules may be interconnected
to cover a desired area in a variety of applications and industries
including, but not limited to, laundry facilities and food
preparation facilities such as a cooking line in a commercial
kitchen. Finally, there exists a need in the art for a flooring
system that may be permanently molded into a concrete floor using
removable male mold inserts that duplicate the shape of a drain pan
and over which floor grids may be installed for supporting
personnel standing thereupon. Such a flooring system may be used in
various industries including, but not limited to, dairies, stables
and meat processing plants.
BRIEF SUMMARY
[0011] The present invention specifically addresses and alleviates
the above referenced deficiencies associated with flooring systems.
More particularly, the present invention is an improved
self-cleaning flooring system for catching waste products. In one
embodiment, the flooring system is modular and is configured such
that it may be cleaned using cleaning equipment that is typical of
the industry wherein the flooring system is installed. For example,
if the flooring system is installed in a commercial kitchen, the
flooring system is adapted to be cleaned using commercial
dishwashing equipment. In another embodiment, the flooring system
may be cast-in-place into a concrete substrate using foam inserts
such that upon curing of the concrete, removal of the foam inserts,
installation of plumbing, and laying of floor grids, a durable
flooring system is provided.
[0012] In accordance with an embodiment of the present invention,
there is provided a self-cleaning flooring system for catching
waste products. The flooring system has at least one module
comprised of a drain pan and a floor grid. The drain pan includes a
pair of ramps and a drain channel centrally located between the
ramps. The drain pan may include a pair of side walls and a pair of
end walls. The ramps are disposed on opposite sides of the drain
channel and slope downwardly towards the drain channel. The drain
channel extends between the end walls and slopes downwardly from
one end of the drain pan toward an opposite end of the drain pan
toward a drain outlet. The side and end walls collectively form a
periphery of the drain pan and extend upwardly from the ramps and
drain channel to enclose the drain pan. The side walls and/or ramps
have at least one, and, preferably, a plurality of discharge
mechanisms such as discharge ports and/or spray nozzles for
releasing flushing fluid onto the ramp such that waste products
that fall onto the ramps are washed toward the drain channel.
[0013] The floor grid is configured to support personnel and/or
animals standing upon or moving thereacross while permitting waste
products to pass therethrough. The side wall may include a hollow
passage having a fluid inlet whereby flushing fluid may be
delivered to the discharge ports. The fluid inlet of adjacent ones
of the modules also allows for the flushing fluid to flow
therebetween. The end most one of the modules may be connectable to
the flushing fluid source. The fluid inlet may be connected to a
fluid supply wherein flushing fluid is delivered to the hollow
passage. An overflow passage may be provided near the drain channel
for allowing the flow of flushing fluid and/or liquid waste
products between adjacent modules. The floor grid may comprise a
plurality of abutting floor grids disposed parallel to one another.
The floor grids are sized such that the length of the module
matches the combined length of the abutting floor grids. The module
may include a plurality of dowels with the side walls having
complimentary apertures sized for receiving the dowels for
interconnecting the modules.
[0014] The desired number of drain pans are assembled horizontally
and joined using dowels or other suitable means. The fluid inlets
are connected to the flushing fluid source. During use, the
flushing fluid flows from the fluid inlets into the drain pans. The
flushing fluid may be provided on a periodic basis through the use
of a timed control valve. Alternately, the flushing fluid may be
manually provided as desired when the accumulation of waste
products on the ramps reaches a critical level. Additionally, a
thermal sensor may operate to provide the flushing fluid to the
fluid inlet in the case of a fire. The flushing fluid may be in the
form of water from a tap water source, and is discharged out of the
discharge ports. The flushing fluid may be pressurized and the
flushing fluid may include additives such as degreasers to
facilitate breakdown of certain food substances.
[0015] Waste products that fall through the floor grid are washed
by the flushing fluid down the ramps toward the drain channel. Once
in the drain channel, the flushing fluid then washes the waste
products toward the drain outlet. Removable strainer trays may be
used over the drain channel to prevent waste products from entering
the drain channel. Drain baskets may be installed over the drain
outlet to prevent waste products from washing down the drain
outlet. Floor grids may be installed over the drain pan to support
personnel standing or working above the drain pans. The floor grids
are preferably sized and configured to prevent waste products of a
predetermined size from entering the drain pan.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] These and other features and advantages of the various
embodiments disclosed herein will be better understood with respect
to the following description and drawings, in which like numbers
refer to like parts throughout, and in which:
[0017] FIG. 1 is a perspective view of a first embodiment of a
flooring system illustrating the connective relationship of
horizontally adjacent modules that may make up the flooring
system;
[0018] FIG. 2 is an exploded perspective view of the flooring
system of FIG. 1 illustrating a module and the relationship of a
drain pan and floor grids that make up the module;
[0019] FIG. 3 is a longitudinal sectional view of the module taken
along line 3-3 of FIG. 1 illustrating ramps sloping downwardly
toward a drain channel;
[0020] FIG. 4 is an enlarged partial sectional view of the module
taken from FIG. 3 illustrating the connective relationship of a
spray nozzle disposed within a side wall of the module;
[0021] FIG. 5 is a transverse sectional view of the module of the
first embodiment taken along line 5-5 of FIG. 1 illustrating the
drain channel sloping downwardly toward a drain outlet;
[0022] FIG. 6 is a perspective view of a second embodiment of the
flooring system illustrating the connective relationship of floor
grids and horizontally adjacent drain pan sections that make up a
drain pan assembly;
[0023] FIG. 7 is an exploded perspective view of the flooring
system of FIG. 6 illustrating the connective relationship of a
first and a second ramp section with a channel section that make up
the drain pan section of the second embodiment;
[0024] FIG. 8 is a block diagram of a pressure tank and timer
connected to the modules of the present invention;
[0025] FIG. 9 is a perspective view of the flooring system wherein
the drain pan includes a drain channel that is singly-sloped toward
the drain outlet located at one end of the drain pan;
[0026] FIG. 10 is a cross-sectional view of the module taken along
line 10-10 of FIG. 9 and illustrating a the drain pan installed in
a concrete substrate wherein the drain pan includes a perimeter
flange formed about a periphery of the drain pan to support the
drain pan;
[0027] FIG. 11 is a top view of the module shown in FIG. 9
illustrating an arrangement of the spray nozzles installed in the
ramps;
[0028] FIG. 12 is a side view of the module of FIG. 9 illustrating
the drain channel sloping from one end of the drain pan to the
other toward the drain outlet;
[0029] FIG. 13 is a partial cross sectional view of the flooring
system in a further embodiment wherein the drain pan is
cast-in-place into a concrete substrate and illustrating a manifold
disposed above one of the ramps and to which spray nozzles may be
fluidly connected;
[0030] FIG. 14 is a schematic diagram of a plumbing system in an
embodiment wherein the plumbing system is interconnected to a
series of spray nozzles installed in a single section of the
flooring system; and
[0031] FIG. 15 is a schematic diagram of a plumbing system in
another embodiment wherein the plumbing system is interconnected to
a dual section of the flooring system.
DETAILED DESCRIPTION
[0032] The present invention will now be described in particular
with reference to the accompanying drawings. FIGS. 1 and 2 show a
module 12 of the first preferred embodiment of a flooring system 10
for catching waste products. FIG. 1 is a prospective view of the
first embodiment of the flooring system 10 illustrating the
connective relationships of horizontally adjacently disposed
modules 12 that make up the flooring system 10 illustrating the
module 12 and the relationship of a drain pan 14 and floor grids 24
that make up the module 12 of the first embodiment.
[0033] Although FIGS. 1 and 2 show the module 12 as having three of
the floor grids 24 disposed upon the drain pan 14, it is
contemplated that the module 12 may include at least one or any
number of floor grids 24. Preferably, such floor grids 24 will
collectively be sufficient to cover the drain pan 14. The drain pan
14 is shown in the figures as having a generally rectangular shape.
However, the drain pan 14 may be configured in any number of shapes
and sizes. Preferably, the drain pan 14 is configured such that the
modules 12 may be interconnected to one another in a horizontally
aligned manner. Each one of the drain pans 14 may have a square
shape with the floor grid 24 being sized and configured
complementary to the shape of the drain pan 14.
[0034] Referring still to FIGS. 1 and 2, as can be seen, the drain
pan 14 includes a drain channel 40, a pair of ramps 16, a pair of
side walls 26 and a pair of end walls 42. The ramps 16 are disposed
on opposite sides of the drain channel 40 along the length of the
drain channel 40. As can be seen in FIG. 2, the ramps 16 are
oriented to slope downwardly along a direction indicated by the
arrows (i.e., towards the drain channel 40). The drain channel 40
is interposed between the side walls 26 and extends between the end
walls 42.
[0035] The drain channel 40 itself may be configured to slope
downwardly from one end of the drain pan 14 to the opposite end of
the drain pan 14 toward a drain outlet 18. The drain outlet 18 may
be connected to a drainage or sewage system of the facility within
which the flooring system 10 is installed. A removable drain basket
78 may be provided with the flooring system 10 and may be installed
over the drain outlet 18 for preventing solids or semisolid waste
products of a predetermined size from entering the drain outlet 18.
Alternatively, or in conjunction with the drain basket 78, an
elongate, flat filtering mesh 62 may be provided along the length
of the drain channel 40, (shown only in FIG. 2), to provide an
additional measure of filtering of waste products.
[0036] As shown in FIG. 2, the drain channel 40 may slope
downwardly toward the centralized drain outlet 18 positioned midway
along the drain channel 40. In this regard, the drain channel 40
may have two separate sloping surfaces that slope toward one
another toward the centrally located drain channel 40. However, the
configuration of the drain pan 14 wherein the drain channel 40 has
only the single sloping surface is preferred. In this
configuration, the drain channel 40 slopes downwardly from one of
the end walls 42 of the drain pan 14 toward the other one of the
end walls 42 of the drain pan 14.
[0037] The drain outlet 18 is preferably positioned adjacent to one
of the end walls 42. The end walls 42 as well as the side walls 26
extend upwardly from the ramps 16 to enclose the drain pan 14.
Likewise, the end walls 42 also extend upwardly from the drain
channel 40 to provide enclosure to the drain pan 14. Provided in
each one of the ramps 16 may be a plurality of discharge ports 22
which are specifically configured for releasing or spraying
flushing fluid onto the ramps 16 such that waste products are
washed down the ramp 16 toward the drain channel 40.
[0038] As was earlier mentioned, floor grids 24 may be mounted atop
each one of the drain pans 14. In order to enhance removability and
to facilitate washing and cleaning of the floor grids 24, the floor
grids 24 may be provided in reduced sizes (i.e., widths) such that
a plurality of floor grids 24 disposed in abutting relationship to
one another are required for covering one of the drain pans 14. For
example, as is shown in FIG. 2, three of the floor grids 24 are
required in order to completely cover the drain pan 14.
[0039] The floor grids 24 are preferably appropriately sized and
configured to support personnel, animals or other loads placed
thereupon while permitting waste products to pass therethrough. The
floor grids 24 are supported at the periphery of the drain pan 14
and may be specifically mounted on the side walls 26 such as along
the grid support notches 82 extending along the length of each one
of the side walls 26. In this regard, the floor grids 24 extend
across the ramps 16 and the drain channel 40 and may be supported
by the side walls 26. Optionally, grid support notches 82 may also
be provided along each one of the end walls 42 such that the end
most ones of the floor grids 24 may be supported by the grid
support notches 82 along the end walls 42.
[0040] Although the figures show the drain pan 14 having side walls
26, it is contemplated that the module 12 may be comprised of a
drain pan 14 having a single one of the ramps 16 that extends or
wraps around the drain pan 14. In such an arrangement, the ramp 16
defines the drain pan periphery 20 from where it slopes downwardly
toward the drain channel 40. Alternatively, the drain pan 14 may be
configured such that the ramp 16 slopes downwardly towards the
drain outlet 18. The drain pan periphery 20 may have a plurality of
the discharge ports 22 spaced therealong for spraying flushing
fluid onto the ramp 16.
[0041] In one embodiment, each one of the side walls 26 may include
a hollow passage 28 formed therealong and through which flushing
fluid may flow. A fluid inlet 30 may be provided in at least one of
the end walls 42 as well as in the side walls 26 and is configured
to provide flushing fluid to the ramps 16 via the hollow passages
28. Alternatively, in embodiments that omit the hollow passage 28,
the flushing fluid may enter the fluid inlet 30 and may be provided
directly to the ramps 16. However, the fluid inlet 30 may provide a
conduit through which a manifold 94 may pass and which carries
flushing fluid to the discharge ports 22 or spray nozzles 32.
[0042] As can be seen in FIG. 1, the self-cleaning flooring system
10 of the present invention may be comprised of a plurality of the
modules 12 with each one of the modules 12 being configured to be
connectable to one another in horizontal alignment.
Interconnectablity of the modules 12 is facilitated through the use
of mechanical fixtures such as, for example, a dowel 36 and
aperture 38 system wherein dowels 36 are provided in one of the
modules 12 and into which may be received by apertures 38 formed in
an adjacent one of the modules 12.
[0043] However, it will be appreciated that the module 12 may be
interconnected to one another through a variety of attachment
mechanisms and is not limited by the specific embodiments or
configurations shown and disclosed herewithin. As shown in FIG. 2,
the module 12 may include at least one strainer tray 74 which may
be configured to extend along the length of the drain channel 40
and which may be mounted above the drain channel 40. The strainer
tray 74 is preferably configured to fit within the drain channel 40
and is operative to prevent waste products of a predetermined size
from entering the drain channel 40.
[0044] As can be seen in FIG. 2, the strainer tray 74 extends along
the length of the drain channel 40 and is specifically adapted to
complement the dual sloped surface of the drain channel 40. In this
regard, the strainer tray 74 has a middle thickness which is larger
than the thickness at the free ends of the strainer tray 74. The
strainer tray 74 may additionally include a grate 76 that acts as a
filtering mechanism to prevent waste products from passing into the
drain channel 40. For configurations wherein the drain channel 40
is configured as a single sloping surface sloping downwardly toward
the drain outlet 18 at an end of the drain pan 14, the strainer
channel is preferably configured complimentary thereto. More
specifically, the strainer tray 74 is preferably configured to be
thicker at one end than at an opposite end such that the grate 76
mounted atop the strainer tray 74 is disposed in general horizontal
orientation when installed in the drain channel 40.
[0045] Turning now to FIGS. 9-12, shown is a self-cleaning flooring
system 10 of the present invention in an embodiment that may be
installed on a substrate 88 such as a concrete substrate 88. As can
be seen in FIG. 10, the drain pan 14 may be installed on a setting
bed of dry packed concrete although the drain pan 14 may be
installed on a substrate 88 of any composition. The periphery of
the drain pan 14 may include a perimeter flange 80 extending
therearound which acts as a ledge upon which the drain pan 14 may
be supported. The perimeter flange 80 extends laterally outwardly
from side walls 26 of the drain pan 14. Preferably, the perimeter
flange 80 is installed so as to be even with floor level 86. More
specifically, the perimeter flange 80 of the drain pan 14 is
preferably installed to be flush with an upper surface of the floor
covering 84 at the floor level 86 such as floor tile or other floor
coverings 84.
[0046] As can be seen in FIG. 10, the ramps 16 of the drain pan 14
may be installed on the substrate 88 such as the concrete substrate
88 which may, in turn, be installed over a base surface such as a
grading 90 of earthen or soil. The setting bed then may be in turn
laid atop the concrete substrate 88 and may be comprised of dry
packed concrete. The floor covering 84 such as floor tile may be
then, in turn, installed over the setting bed. The perimeter flange
80 may be installed over the setting bed and is preferably level
with the floor level 86.
[0047] The embodiment of the flooring system 10 shown in FIGS. 9-12
is similar in configuration to that which is shown in FIGS. 1-2 and
which is described above. More specifically, the drain pan 14 as
shown in FIGS. 9-12 may be comprised of a pair of opposing ramps 16
that slope downwardly toward a drain channel 40. However, it is
contemplated that each one of the modules 12 may be comprised of a
drain pan 14 having only one ramp 16 with a drain outlet 18
disposed in a corner of the drain pan 14. The ramp 16 may slope
downwardly toward the drain outlet 18. However, it is believed that
the configuration shown in FIGS. 1 and 2 and FIGS. 9-12 is
preferable wherein the drain pan 14 is comprised of a pair of ramps
16 disposed on opposite sides of the drain channel 40. The drain
channel 40, as described above, is sloped downwardly toward the
drain outlet 18 which is located adjacent to the end wall 42.
[0048] Referring still to FIG. 10, as can be seen, the opening
formed in the substrate 88 and setting bed is sized to be slightly
larger than the drain pan 14. More specifically, the opening
includes areas into which plumbing (such as a manifold 94 for
carrying flushing fluid), may be installed after curing of the
concrete. Once the plumbing is installed, the drain pan 14 can be
installed with portions of the ramp 16 resting upon the substrate
88.
[0049] The drain pan 14 may then be supported at the periphery
thereof by installation of the dry packed concrete which forms the
final setting bed. In this regard, the dry packed concrete fills
voids underneath the side wall 26 and perimeter flange 80. The
drain pan 14 may be checked for levelness to ensure proper
functioning and flowing of the flushing fluid during operation of
the flooring system 10. It is contemplated that reinforcement bar
may be provided to assist in leveling of the drain pan 14 prior to
installation of the setting bed.
[0050] It is contemplated that the drain pan 14 may be installed in
multi-floor buildings wherein steel decking may be utilized as the
substrate 88. In this regard, the drain pan 14 can be accommodated
with appropriate cutouts to allow fitment and support of the drain
pan 14 on the steel decking. The flooring system 10 of the present
invention may be installed similar to the method for installing a
floor sink or trough. Mounting straps may be secured to the decking
prior to pouring of concrete which, in turn, occurs prior to
installation of the drain pan 14. As was earlier mentioned, it is
preferable that the drain pan 14 is checked for levelness prior to
pouring or curing of the concrete.
[0051] Following installation of the manifold 94 and installation
of the drain pan 14, the appropriate number of discharge ports 22
such as spray nozzles 32 may be fluidly connected to the manifold
94 such that flushing fluid passing through the manifold 94 may be
discharged out of the spray nozzles 32. As can be seen in FIG. 11,
three of the spray nozzles 32 are provided on opposite sides of the
drain pan 14 and are extended through the ramp 16 portions thereof.
The spray nozzles 32 may be threadably connected to the manifold
94. Although three of the spray nozzles 32 are shown on each side
of the drain pan 14, any number may be provided.
[0052] Furthermore, although the spray nozzles 32 are shown in FIG.
10 as extending through a crease or slope-change in the ramp 16, it
is contemplated that the spray nozzles 32 may be installed anywhere
along the ramps 16. Furthermore, although the ramp 16 shown in FIG.
10 has a doubly-sloped surface, it is contemplated that the ramp 16
may be provided with a singly sloped surface extending from the
side wall 26 down to the drain channel 40. Additionally, it is
contemplated that the ramp 16 may be curved or have a multiply
angled or sloped surface. However, it is believed that the single
or doubly sloped surface is preferred in order to enhance the
washing of the waste products down the ramp 16 toward the drain
channel 40.
[0053] Referring to FIG. 3, shown is a longitudinal sectional view
of the module 12 taken along line 3-3 of FIG. 1 and illustrating
ramps 16 sloping downwardly toward the drain channel 40. As can be
seen in FIG. 3, the fluid inlets 30 allow for the flushing fluid to
flow between adjacent ones of the modules 12 with the endmost
module 12 in the flooring system 10 being connected to the flushing
fluid source. The fluid inlet 30 may be connected to a fluid supply
wherein the fluid is delivered to the hollow passages 28 or to the
drain pan 14 via a manifold 94 or other similar plumbing system
96.
[0054] The flushing fluid may contain additives such as degreasers
which may be injected into the fluid. The fluid may be water based
or may be comprised of alternative liquids. For example, degreaser
may be provided or injected into the fluid in order to break down
grease that is deposited on the ramp 16. As can be seen in FIG. 3,
the fluid inlets 30 may be disposed on the side walls 26 and/or the
end walls 42 and may be concentric with the hollow passage 28 to
allow fluid to flow therebetween. If the hollow passages 28 are not
included, the fluid inlets 30 may be connected to a manifold 94 or
other plumbing connection wherein the discharge ports 22 and/or
spray nozzles 32 receive flushing fluid therefrom.
[0055] Turning now to FIG. 4, shown is an enlarged partial
sectional view of the module 12 taken from FIG. 3 and illustrating
the connective relationship of the spray nozzle 32 within the side
wall 26. As was earlier mentioned, the spray nozzle 32 or discharge
port 22 may be disposed above or adjacent to the ramps 16. The
discharge ports 22 may be internally threaded for receiving the
spray nozzles 32 which may be included in the module 12. The spray
nozzles 32 may be discharged from the flushing fluid at an elevated
pressure level in order to improve the effectiveness with which the
waste products may be washed down the ramps 16 toward the drain
channel 40. The spray nozzles 32 may be conventional spray nozzles
32 or alternatively, may be water jets that are integrated into the
manifold 94 without separate spray nozzles 32.
[0056] Regarding operation of the discharge ports 22 and/or spray
nozzles 32, it is contemplated that flushing fluid may be
discharged therefrom via manual or automatic activation. For
automatic activation, a timer 70 may be included with the flooring
system 10 in order to periodically or at scheduled intervals,
release flushing fluid into the ramps 16. Furthermore, the spray
nozzles 32 and/or discharge ports 22 may be activated via a thermal
sensor such that flushing fluid may be discharged in case of fire
in the facility in which the flooring system 10 is installed.
Referring still to FIG. 3, the drain pan 14 may include at least
one overflow passage 48 proximate the drain channel 40 to allow for
the flow of flushing fluid and/or liquid waste products between
adjacent ones of the modules 12. The overflow passages 48 may be
formed in the end walls 42 of the drain pan 14 and may be
collocated such that when the modules 12 are connected together,
the passage is provided via the overflow passages 48.
[0057] As is shown in FIG. 4, the drain pan 14 supports the floor
grid 24 via a grid support notch 82 that is formed in the side wall
26. As is shown in FIG. 4, the grid support notch 82 is created via
the formation of the hollow passage 28 which extends along the
length of the side wall 26. Alternatively, as is shown in the
preferred embodiment in FIGS. 9-12, the grid support notch 82 is
formed in the side wall 26 with the edge of the floor grid 24
resting along the grid support notch 82. A lower peripheral edge of
each one of the floor grids 24 is preferably chamfered or radius to
provide a gap between the side wall 26 and the floor grid 24 (i.e.,
the grid support notch 82) such that the floor grid 24 does not
sharply bear against radius corners of the grid support notch 82.
Furthermore, the lower peripheral edge may be chamfered or radius
to provide a gap such that waste products may pass
therebetween.
[0058] Referring to FIGS. 3-5, each one of the drain pans 14 may
comprise or include parallel spaced rib members 46 disposed along a
length of the drain pan 14 between the end walls 42. The parallel
rib members 46 may be disposed widthwise under the ramps 16 and
drain channel 40 for supporting the module 12 in an even fashion on
the sub-floor such as a tile and grout sub-floor that is commonly
found in commercial kitchens and other vending establishments.
Likewise, as was earlier mentioned, the flooring system 10 may be
installed in a variety of applications and industries including,
but not limited to, dairies, meat processing plants, poultry
operations, and stables wherein the rib members 46 may be utilized
to support the drain pan 14 and drain channel 40 in an even
manner.
[0059] The drain pan 14 may be formed of any suitable material
including metallic and non-metallic materials. For metallic
materials, it is contemplated that the drain pan 14 would be formed
of stainless steel or otherwise suitable metallic material that is
resistant to corrosion and or degradation due to the environmental
effects. For non-metallic materials, it is contemplated that a
polymeric material such as polyvinyl chloride (PBC) and/or
polypropylene may be utilized.
[0060] Furthermore, fiberglass may be utilized. In this regard, it
is contemplated that the drain pan 14 may be formed of any material
that is suitable and that is compatible with the elevated
temperatures that the drain pan 14 may encounter during washing
such as during washing in a commercial dishwasher. The drain pan 14
may be formed as a unitary structure by any method such as by
injection molding. More specifically, it is contemplated that the
side walls 26, end walls 42, drain channel 40, ramps 16 and rib
members 46 as well as grid support notches 82 and other features of
the drain pan 14 may be formed via an injection molding process so
that the drain pan 14 is formed as a single unitary structure.
[0061] During fabrication, it is contemplated that all corners may
be radiused in order to reduce the probabilities of stress cracking
that may be induced by localized stresses in corners. Furthermore,
radiused corners facilitate cleaning of the drain pan 14 wherein
waste products that may otherwise gather in nooks and crannies and
otherwise hard-to-reach-corners, are more easily washed and
cleaned. The lower floor grids 24 may be radiused to be
complementary to any radii formed in the grid support notches 82
above the side walls 26a. In this manner, the floor grid 24 lower
surface and substantially abutting contact with the side wall 26
and/or grid support notch 82.
[0062] Turning now to FIG. 5, shown in a transverse sectional view
of the module 12 of the first embodiment taken along line 5-5 of
FIG. 1 and illustrating the drain channel 40 sloping downwardly
toward the drain outlet 18. In FIG. 5, the rib members 46 can be
seen extending vertically downwardly from the ramp 16 lower
surface. Discharge ports 22 can be seen disposed within the side
wall 26 and extending along the length thereof. The discharge ports
22 may be evenly spaced between the end walls 42 although any
spacing is contemplated for the discharge ports 22.
[0063] The strainer tray 74 is shown disposed above or mounted
within the drain channel 40 which extends from end wall 42 to end
wall 42. As was earlier mentioned, the strainer tray 74 includes a
grate 76 which prevents the entry of solid or semisolid waste
products into the drain channel 40 which may otherwise fall into
the drain outlet 18 resulting in clogging thereof. As a final
measure of protection, a removable drain basket 78 may be included
in the drain outlet 18 and disposed thereover in order to prevent
solid waste from falling into the drain outlet 18 and clogging down
stream features such as a grease trap.
[0064] In FIGS. 1-5 as well as in FIGS. 10 and 13, the floor grids
24 are shown formed as an array of spaced parallel grid members 34
that are joined together with the transversely disposed spaced grid
members 34. The spacings of the grid members 34 is preferably such
that passage of semisolid and liquid waste products is allowed
while preventing passage of waste products of a predetermined size.
As was earlier mentioned, the floor grids 24 are sized and
configured to span between the side walls 26 of the drain pan 14.
Similar to the materials used for forming the drain pan 14, the
floor grids 24 may be formed of high strength material.
[0065] For example, the floor grids 24 may be fabricated of
fiberglass material as such material is lightweight to allow easy
removal for cleaning of the flooring system 10 as well as for
cleaning of the floor grid 24 itself, as well as highly
structurally sound in order to support the personnel working and
standing thereupon. It will be understood that the floor grids 24
may be formed of any material and in any configuration sufficient
to prevent passage of waste products of a predetermined size.
Furthermore, it is contemplated that the material used in
fabricating the floor grids 24 is compatible with commercial
cleaning equipment such as commercial dishwashers and therefore is
capable of surviving elevated temperatures. The embodiment of the
floor system 10 may be of any size and shape. However, it is
contemplated that in order to facilitate cleaning of the modules
12, it is contemplated that the width of the drain pan 14 and floor
grid 24 is compatible with cleaning equipment.
[0066] Turning now to FIGS. 6 and 7, shown is a second embodiment
of a self-cleaning flooring system 10 which, as was earlier
mentioned, comprises at least one module 12, but preferably
comprises a series of modules 12 joined end-to-end. Each one of the
modules 12 comprises a drain pan section 66 which is itself
comprised of a pair of first and second ramp sections 50, 52, and a
channel section 54 which is disposed between the first and second
ramp sections 50, 52. As shown in FIGS. 6 and 7, the first ramp
section 50 is joined to the second ramp section 52 which is
interconnected to the channel section 54. The channel section 54 is
preferably configured to removably interconnect the first and
second ramp sections 50, 52 together at a lower side portion 58 of
each one of the first and second ramp sections 50, 52.
[0067] As was mentioned for the configuration in FIGS. 1-5, the
first and second ramp sections 50, 52 slope downwardly toward the
channel section 54. The module 12 shown in FIGS. 6 and 7 is also
comprised of at least one discharge port 22 which is preferably
mounted above or adjacent to the first and/or second ramp sections
50, 52 and which is operative to separate flushing fluid onto the
first and second ramp section 50, 52 such that waste products are
washed down the first and second ramp sections 50, 52 toward the
channel section 54 and then from the channel section 54 toward the
drain outlet 18.
[0068] The configuration of the flooring system 10 shown in FIGS. 6
and 7 is similar to that which is shown and described above in
FIGS. 1-5 except for the drain pan section 66 being comprised of
the first and second ramp sections 50, 52 and channel section 54.
Furthermore, the drain pan section 66 shown in FIGS. 6 and 7 may
further comprise end plates 64 which may be disposed on extreme
ends of each one of the modules 12 after assembly of consecutive
ones of the drain pan sections 66.
[0069] For example, as is shown in FIG. 7, the end plate 64 may be
secured to an extreme end of one pair of drain pan sections 66
which are adjoined end-to-end. Another one of the end plates 64 may
be adjoined to an opposite end of the module 12 which comprises two
of the drain pan sections 66. Each one of the drain pan sections 66
includes the channel section 54 which includes the drain outlet 18
at an end thereof. Preferably, the channel section 54 slopes
downwardly toward the drain outlet 18 but is not necessarily so.
For example, it is contemplated that the channel section 54 may be
formed with no slope and may be horizontally formed.
[0070] Each one of the first and second ramp sections 50, 52 may
include at least one rib member 46 which extends from the side wall
26 of the ramp 16 section toward the drain channel 40. The rib
member 46 is disposed under the ramp 16 section and is preferably
configured to support the ramp 16 section above a substrate 88. As
can be seen in FIG. 7, the first ramp section 50 is of a narrower
width than the second ramp section 52 although the first and second
ramp sections 50, 52 may be equally configured.
[0071] A plurality of discharge ports 22 and/or spray nozzles 32
may be disposed along upper side portions 56 of the first and
second ramp sections 50, 52. At least one strainer tray 74 may be
mounted above the channel section 54 and may be configured to
prevent waste products of a predetermined size from entering the
drain channel 40. Alternatively, a plurality of strainer trays 74
may be connected end-to-end and mounted above each one of the drain
channels 40. Optionally, the strainer tray 74 may be omitted such
that waste products of any size may be flushed down the drain
outlet 18 and may pass into a holding tank.
[0072] Although the drain pan assembly 68 and, more specifically,
drain pan sections 66 of the second embodiment may be of any size
and any shape, it is contemplated that the first ramp section 50 is
sized to be compatible with commercially available cleaning
equipment as well as the second ramp section 52 being likewise
sized to facilitate cleaning. Accordingly, the floor grids 24 are
preferably sized to be compatible with commercial cleaning
equipment. In this regard, depending upon the method of cleaning,
it is contemplated that the drain pan sections 66 and, hence, the
drain pan assemblies 68, may be formed at any size and any
shape.
[0073] As can be seen in FIG. 7, vertically extending grid supports
60 may be provided with the first and second ramp sections 50, 52
in order to support the floor grids 24. For industries where a
person may be standing on the floor grids 24 for an extended period
of time, it is contemplated that such grid supports 60 may be
either limited or all together removed in order to allow some
degree of flexing in the floor grid 24 in order to enhance the
comfort of personnel standing thereupon for extended periods of
time. As can be seen, one of the drain pan sections 66 omits the
use of the grid supports 60 while the other one of drain pan
sections 66 which is joined end-to-end includes the floor grid
support 60 for exemplary purposes only.
[0074] Referring now to FIG. 13, shown is the flooring system 10 in
a further embodiment wherein the drain pan 14 is formed or cast
into a substrate 88 such as a concrete substrate 88. More
specifically, the flooring system 10 shown in FIG. 13 illustrates
the drain pan 14 having the same or similar features as described
above for the flooring systems 10 of FIGS. 1-5 and 9-12. More
specifically, the substrate 88 itself forms the shape of the drain
pan 14 wherein the substrate 88 itself includes a pair of ramps 16
which slope downwardly toward a drain channel 40 with the drain
channel 40 itself sloping downwardly toward the drain outlet 18.
The drain pan 14 defines the periphery thereof with a perimeter
flange 80 being formed around the drain pan 14 for supporting the
floor grid 24 on an upper surface of the substrate 88.
[0075] As shown in FIG. 13, the flooring system 10 further includes
a manifold 94 which may be extended along a portion of the drain
pan 14 and which is formed within a corner of one of the ramps 16.
The manifold 94 extends along a portion of the ramp 16 and is
disposed above the ramp 16 in order to provide flushing fluid to
the ramp 16 for washing waste products down to the drain channel
40. The flooring system 10 further includes a spray nozzle 32 which
may be fluidly connected to the manifold 94 and may be operative to
spray flushing fluid down the ramp 16 toward the drain channel 40.
However, it should be noted that the spray nozzle 32 may be omitted
with apertures 38 instead being formed in the manifold 94 to form
ports through which flushing fluid may be discharged for spraying
flushing fluid down the ramps 16.
[0076] The cast concrete system which forms the flooring system 10
of the present invention may be developed for use in any of the
above-mentioned applications and industries. For example, the cast
concrete system may be used in dairies, meat processing plants,
stables and other facilities and applications that typically endure
heavy wear due to contact with the heavy animals. Other
applications where the cast concrete system for the flooring system
10 shown in FIG. 13 include poultry operations, emergency rooms,
machine shops, clean rooms, printing facilities, food processing
plants and other industrial operations. Furthermore, the flooring
system 10 of the present invention may be used in transition areas
in animal processing applications.
[0077] For example, the flooring system 10 of the present invention
may be used between a feed yard and dairy milking stations. In this
regard, the flooring system 10 may be installed in certain
transition areas and may include an above-ground spray element that
could be triggered by hooves of livestock passing over the flooring
system 10. Once the spray element is triggered, fluid may be
sprayed onto the livestock hooves while such livestock is entering
the dairy milking station such that undesirable residue (e.g.,
manure) may be washed from the livestock hooves and into the
flooring system 10 for later retrieval as fertilizer. It is
contemplated that a triggering mechanism may be included with the
flooring system 10 to activate the spray element. Such triggering
mechanism may be configured as an infrared beam that is triggered
by the livestock hooves.
[0078] Regarding the first above-mentioned application for the cast
concrete system of the flooring system 10, it is contemplated that
the manifold 94 and/or spray nozzles 32 and/or discharge ports 22
that are typically used for washing flushing fluid down the ramps
16, may also be used for spraying animals hooves as they cross over
the flooring system 10. In this manner, unwanted sediments and
manure from stockyards may be washed from the hooves of livestock
to increase the hygiene and cleanliness of the facility into which
the flooring system 10 is installed.
[0079] As was earlier mentioned, in a dairy, it is contemplated
that the flooring system 10 may be configured to spray the hooves
of dairy cows when brought into a milking facility such as into a
rotating milking system. Advantageously, the flooring system 10 as
shown in FIG. 13 is installed as a cast-in-place system wherein the
drain pan 14 itself is formed directly in the substrate 88 such as
the concrete substrate 88. Ideally, the drain pan 14 is located in
the area in which it is to be installed via location of the drain
channel 40 flowing down towards the drain outlet 18. Furthermore,
it is contemplated that the floor grids 24 for such an application
are appropriately sized and configured to handle heavy loads
imposed by large livestock such as cattle. In this regard, it is
contemplated that the floor grids 24 have an increased thickness
such as a two (2) inch thickness for increased load-bearing
capacity. As shown in FIG. 13, floor grid supports 60 may be
included to provide additional support against heavy loads.
[0080] As shown in FIG. 13, the drain pan 14 may be formed in the
substrate 88 using a removable insert which is configured as a male
mold that duplicates the shape of the drain pan 14. FIG. 13
represents one-half of the installation with the other half being
symmetrically formed about the vertical centerline. However, it is
contemplated that the installation of the drain pan may be
asymmetrical. As was earlier mentioned, the male mold will ideally
include the features described above for the drain pan 14 such as
the side wall 26, grid support notch 82, ramps 16, and drain
channel 40.
[0081] The removable insert may preferably be formed as a foam
material which may be shaped as a single unitary piece of foam or
may be shaped as a series of foam inserts 92 which are individual
pieces that collectively define the drain pan 14 shape when
installed prior to flooring of the substrate 88 such as a concrete
substrate 88. Installation of the flooring system 10 is
accomplished by initially laying out and locating the drain pan 14
with reference to the drain outlet 18 such as the drain channel 40
the drain pan 14 is roughly centered on the drain outlet 18.
[0082] The foam may be placed in the shape of the drain pan 14
after which the concrete may be poured underneath around the
insert. Just prior to or after curing of the concrete, the foam
insert 92 may be removed after which the concrete can proceed to
final cure. As can be seen in FIG. 13, a depression may be formed
in the ramp 16 to receive the manifold 94 which may run lengthwise
along the ramp 16. The manifold 94 may be connected to the flushing
fluid source and is operative to spray flushing fluid down the ramp
16. The grid support notch 82 is formed in the side wall 26 and is
specifically shaped and configured to be complementary to the
thickness of the floor grid 24 for support of the floor grid 24
thereupon.
[0083] Referring now to FIGS. 14 and 15, shown therein is a
schematic diagram illustrating a plumbing system 96 as may be
connected to the flooring system 10 of the present invention. FIG.
14 illustrates the plumbing system 96 interconnected to a series of
discharge ports 22 and/or spray nozzles 32 installed in a single
section of the flooring system 10. As can be seen in FIG. 14, the
flooring system 10 includes two modules 12 connected end-to-end
with each module 12 including six discharge ports 22 and/or spray
nozzles 32. The spray nozzles 32 on one side of the flooring system
10 are connected in series. This schematic diagram of FIG. 14
illustrates the proper assembly for flooring system 10
configurations having anywhere from four to sixteen spray nozzles
32.
[0084] FIG. 15 is a schematic diagram of the plumbing system 96 in
a further embodiment wherein a pair of flooring systems 10 is
interconnected to the plumbing system 96 in parallel. More
specifically, the plumbing system 96 supplies flushing fluid to a
first flooring system 10 and a second flooring system 10
illustrated in FIG. 15 as being disposed above one another. As will
be appreciated, the flooring system 10 shown in FIG. 14 is similar
to one of the pairs of flooring systems 10 illustrated in FIG. 15.
It is contemplated that the flushing fluid is provided by a water
supply line 100. Such water supply may be a cold water supply line
100 having a diameter of about 1/2 inch in a standard supply line
100. However, it is contemplated that a 3/4 inch diameter water
supply line 100 may be provided with the plumbing system 96.
[0085] Minimum static pressure for the water supply line 100 is
preferably about fifty-five PSI although the water supply may be
provided in any pressure level. However, it is preferable that
consistent water pressure be provided to the flooring system 10
and, therefore, depending upon the number of spray nozzles 32
and/or discharge ports 22 included within the flooring system 10, a
complementary supply line 100 diameter and pressure level should be
provided. Along these lines, it is contemplated that a pressure
source may be included in the plumbing system 96 such as a pressure
tank 72 in order to add the appropriate amount of pressure to the
flooring system 10 and plumbing system 96. Even further, the
plumbing system 96 may include a pump in order to increase the
pressure level of the flushing fluid supply.
[0086] Referring to FIG. 14, it can be seen that the flushing fluid
may be provided via a supply line 100 which feeds into a shutoff
valve 102 that may be activated under certain circumstances such as
upon loss of power. Also included in the schematic diagram is a
check valve 104 which may be interposed between the pressure tank
72 and the shutoff valve 102 to prevent back flow of flushing
fluid. Downstream of the pressure tank 72, a
solenoid-controlled-valve 106 may be included.
[0087] The valve may be controlled by a timer 70 or by a manual
switch. The supply line 100 leading to the flooring system 10 may
preferably be a 3/4 inch diameter supply line 100 in order to
provide adequate flow of flushing fluid to the flooring system 10.
Each one of the flooring systems 10 may include a header 98
disposed on one end thereof for connection to the plumbing system
96. As can be seen in FIG. 14, each of the spray nozzles 32 on one
of the sides of the flooring system 10 is preferably connect in
series. A cap may be provided at the end of each one of the series
of discharge ports 22 and/or spray nozzles 32.
[0088] Referring now to FIG. 15, shown is the schematic diagram
having a pair of the flooring systems 10 installed in parallel. The
plumbing system 96 provides flushing fluid, such as water, to the
respective ones of the flooring systems 10. The componentry of the
schematic diagram shown in FIG. 15 is similar to that described and
shown in FIG. 14 above. However, a pair of the
solenoid-controlled-valves 106 are included at a split in the
supply line 100. Notably, instead of connecting the discharge ports
22 and/or spray nozzles 32 in series, the schematic diagram of FIG.
15 show an alternative arrangement wherein three of the spray
nozzles 32 are connected to another three of the spray nozzles 32
in parallel with one another. A cap may be provided at an end of
each one of the series of three spray nozzles 32.
[0089] Regarding drainage from the drain outlet 18, it is
contemplated that a three inch diameter connection be utilized in
order to connect a waste conduit of at least three inches in
diameter to each one of the flooring systems 10. As was earlier
mentioned, the drain outlet 18 may lead to a grease trap. Timers 70
and solenoids may optionally be further included in the flooring
systems 10 and may be either manually or autonomously operated. It
is contemplated that the timer 70 system may include a manual
override in order to allow an operator additional control in the
frequency of spraying of the flushing fluid.
[0090] Regarding the pressure tank 72, it is contemplated that each
pressure tank 72 may include the capability for containing about
six gallons of flushing fluid in order to produce about three to
four gallons of flushing fluid that may be pressurized to about
thirty to thirty-five PSI. An additional valve may be included with
the pressure tank 72 in order to provide control over the operating
pressure at which the pressure tank 72 operates. As was earlier
mentioned, commercial degreasing agents and other additives may be
injected into the plumbing system 96 supply line 100 as shown in
FIGS. 14 and 15 as required.
[0091] The operation of the flooring system 10 will now be
described with reference to FIGS. 1-15. The flooring system 10 as
shown in FIGS. 1-2 may be installed initial by placing the drain
pan 14 on the surface to which it is to be mounted. As was earlier
mentioned, such surface may include a concrete flooring substrate
88 or a steel decking arrangement although various other
configurations are contemplated upon which the flooring systems 10
may be installed. The following connection of the plumbing system
96 as illustrated in FIGS. 14-15, the flushing fluid may be
provided to the pressure tank 72 and then to the series of
discharge ports 22 and/or spray nozzles 32 upon activation of the
plumbing system 96.
[0092] Such activation may be autonomous via a timer 70 or via
manual activation by the appropriate personnel. During use, waste
products fall through the floor grids 24 and pass therethrough
landing on the ramps 16. At appropriate intervals or when manually
activated, flushing fluid is discharged onto the ramps 16 washing
the waste products down to the strainer tray 74 if included. The
grating of the strainer tray 74 prevents waste products of a
predetermined size from entering into the drain channel 40. The
flushing fluid causes the waste products to fold toward the drain
outlet 18 wherein the addition of a drain basket 78 further
prevents entering of such waste products into the drain outlet 18
and clogging of the grease trap.
[0093] For the drain pan assembly 68 modules 12 as shown in FIGS.
3-7, following interconnection of the channel section 54 to the
first and second ramp sections 50, 52 and securing of the end
plates 64 upon abutting connection of the drain pan sections 66,
the plumbing may then be interconnected thereto. Operation and
maintenance of the flooring system 10 is similar to that which we
described below with reference to FIGS. 1-2. For the flooring
system 10 illustrated in FIG. 13, installation of the drain pan 14
is effectuated through the use of a foam insert 92 which is set in
place after which concrete substrate 88 is then poured therearound.
Removal of the foam insert 92 and carrying of the concrete
substrate 88 results in the creation of the drain pan 14 having
features similar to that described above for FIGS. 1-7. Following
placement of the floor grids 24 on the side walls 26, waste
products may then fall through the floor grids 24 and are flushed
down into the drain outlet 18 in a manner similar to that described
above.
[0094] Maintenance of the flooring system 10 may be effectuated
wherein the floor grids 24 may be removed and may be manually hosed
off or washed using the cleaning equipment available in the
facility. For example, in a commercial kitchen, it is contemplated
that the floor grids 24 are washed at each days end in a commercial
dishwasher such that such floor grids 24 are ready for
reinstallation. A commercial degreaser may be included with the
flushing fluid and which may be hand sprayed on the grates 76 prior
to washing in order to remove grease build up. Other chemicals and
additives may be injected in the supply line 100 to prevent grease
build up on the ramp 16 and drain channel 40 areas. In this same
manner, the strainer tray 74 as well as the drain basket 78 may be
cleaned and checked.
[0095] It is contemplated that floor grids 24 of different colors
be utilized in order to easily monitor washing cycles and
replacement. For example, one color of the floor grid 24 may be
used for even numbered bays while another color of a floor grid 24
may be utilized for odd numbered bays. During removal of the floor
grids 24, the discharge ports 22 and/or spray nozzles 32 may be
adjusted such that the alignment thereof is checked to ensure that
such spray nozzles 32 are spraying evenly down the ramps 16.
Furthermore, various components of the plumbing system 96 should be
checked such as the pressure tank 72, shutoff valves 102,
solenoid-control-valves 106 and supply lines 100.
[0096] The above description is given by way of example, and not
limitation. Given the above disclosure, one skilled in the art
could devise variations that are within the scope of the invention
disclosed herein. Further, the various features of the embodiments
disclosed herein can be used alone, or in varying combinations with
each other and are not intended to be limited to the specific
combination described herein. Thus, the scope of the claims is not
to be limited by the illustrated embodiments.
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