U.S. patent application number 11/767999 was filed with the patent office on 2008-07-10 for drain installation kit.
This patent application is currently assigned to The Tile Shop, LLC. Invention is credited to Fumitake Nishi.
Application Number | 20080163419 11/767999 |
Document ID | / |
Family ID | 39592992 |
Filed Date | 2008-07-10 |
United States Patent
Application |
20080163419 |
Kind Code |
A1 |
Nishi; Fumitake |
July 10, 2008 |
DRAIN INSTALLATION KIT
Abstract
The present invention provides a drain installation kit adapted
to maintain alignment of the center of a sloping floor aperture
with the center of a drain throughout the construction process. In
a preferred embodiment, the kit includes an upper flange that is
rigidly connectable to a drain base and multiple sloping guide bars
that are rigidly connectable in a radial fashion to the upper
flange. A user can use this preferred embodiment by assembling it,
adding cementitious material between the guide bars, and making an
upper surface of the cementitious material flush with a top edge of
the guide bars. Embodiments of the present invention provide a
variety of advantages over conventional drain installation kits.
For example, many embodiments provide improved functionality, many
embodiments are easier for do-it-yourselfers to use, and many
embodiments can be manufactured more efficiently.
Inventors: |
Nishi; Fumitake;
(Minnetonka, MN) |
Correspondence
Address: |
INTELLECTUAL PROPERTY GROUP;FREDRIKSON & BYRON, P.A.
200 SOUTH SIXTH STREET, SUITE 4000
MINNEAPOLIS
MN
55402
US
|
Assignee: |
The Tile Shop, LLC
Plymouth
MN
|
Family ID: |
39592992 |
Appl. No.: |
11/767999 |
Filed: |
June 25, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60884124 |
Jan 9, 2007 |
|
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Current U.S.
Class: |
4/613 |
Current CPC
Class: |
A47K 3/40 20130101 |
Class at
Publication: |
4/613 |
International
Class: |
A47K 3/40 20060101
A47K003/40 |
Claims
1. A drain installation kit for constructing a sloped floor that is
made of cementitious material and adapted to drain liquid into a
drain, the kit comprising: a plurality of guide bars, each guide
bar having a leading end and a trailing end, the leading end (a)
being configured to rigidly connect to an upper flange that is
rigidly connected to a drain base and (b) having a smaller height
than the trailing end; and instructions for using the drain
installation kit.
2. The drain installation kit of claim 1, further comprising a
plurality of members adapted to assist in rigidly connecting the
guide bars to the upper flange.
3. The drain installation kit of claim 2, wherein each guide bar
has a guide bar recess, and each member is adapted to be inserted
partially into the guide bar recess and partially into one of a
plurality of flange recesses of the upper flange.
4. The drain installation kit of claim 2, wherein the members are
pins.
5. The drain installation kit of claim 1, wherein each guide bar
includes top and bottom edges, the bottom edge being wider than the
top edge.
6. The drain installation kit of claim 1, wherein each guide bar
includes trusses that define a plurality of openings adapted to
allow cementitious material to pass through the guide bar.
7. The drain installation kit of claim 1, wherein the trailing end
of a first of the plurality of guide bars is configured to connect
with the leading end of a second of the plurality of guide
bars.
8. The drain installation kit of claim 7, wherein the first guide
bar includes a first top edge extending at a first angular slope
between the leading and trailing ends of the first guide bar and
the second guide bar includes a second top edge extending at a
second angular slope between the leading and trailing ends of the
second guide bar, the first angular slope being substantially equal
to the second angular slope.
9. The drain installation kit of claim 1, wherein, when a drain
plate housing is adjustably connected to the upper flange, the
rigid connection between the guide bars and the upper flange does
not obstruct adjustment of the height of the drain plate
housing.
10. A method of assisting a user in constructing a sloped floor
that is made of cementitious material and adapted to drain liquid
into a drain, comprising: providing a drain installation kit that
includes a plurality of guide bars, each guide bar having a leading
end and a trailing end, the leading end having a smaller height
than the trailing end; and instructing the user to: (a) install a
drain base within a support area, (b) rigidly connect an upper
flange to the drain base, (c) position at least some of the
plurality of guide bars radially about the drain base, (d) rigidly
connect the at least some of the plurality of guide bars to the
upper flange, (e) add cementitious material to the support area,
and (f) make an upper surface of the cementitious material flush
with the top edges of the plurality of guide bars.
11. The method of claim 10, wherein instructing the user to rigidly
connect one of the plurality of guide bars to the upper flange
comprises instructing the user to insert a member partially into a
flange recess of the upper flange and partially into a guide bar
recess of the guide bar.
12. The method of claim 10, further comprising instructing a user
to optionally connect the leading end of at least one guide bar to
the trailing end of at least one of the guide bars that is to be
rigidly connected to the upper flange.
13. The method of claim 10, further comprising instructing a user
to connect a drain plate housing to the upper flange and to adjust
the height of the drain plate housing, wherein the rigid connection
between the guide bars and the upper flange does not obstruct
adjustment of the height of the drain plate housing.
14. A drain installation kit for constructing a sloped floor that
is made of cementitious material and adapted to drain liquid into a
drain, the kit comprising: a drain base configured to be installed
in a support area; an upper flange having a plurality of attachment
points, the upper flange being configured to rigidly connect to the
drain base; a drain plate housing adapted to connect to the upper
flange, the height of the drain plate housing when connected to the
upper flange being adjustable; and a plurality of guide bars, each
guide bar having a leading end and a trailing end, the leading end
(a) being configured to rigidly connect to the upper flange at any
one of the plurality of attachment points and (b) having a smaller
height than the trailing end.
15. The drain installation kit of claim 14, wherein the upper
flange has a first surface and each of the plurality of attachment
points includes a flange recess formed in the first surface of the
upper flange.
16. The drain installation kit of claim 15, wherein the flange
recess extends partially through the upper flange.
17. The drain installation kit of claim 15, further comprising a
plurality of members, wherein each guide bar includes a guide bar
recess proximate the leading end and each member is configured to
be partially inserted into one of the flange recesses and partially
into one of the guide bar recesses for rigidly connecting the
leading end of the guide bar to the upper flange.
18. The drain installation kit of claim 17, wherein the member is a
pin.
19. The drain installation kit of claim 15, where each guide bar
includes a protrusion proximate the leading end configured to be
received within one of the flange recesses for rigidly connecting
the leading end of the guide bar to the upper flange.
20. The drain installation kit of claim 14, wherein the plurality
of attachment points are spaced equidistantly from the center of
the upper flange.
21. The drain installation kit of claim 14, wherein each guide bar
includes top and bottom edges, the bottom edge being wider than the
top edge.
22. The drain installation kit of claim 14, wherein each guide bar
defines a plurality of openings adapted to allow cementitious
material to pass through the guide bar.
23. The drain installation kit of claim 22, each guide bar includes
top and bottom edges and the top edge or the bottom edge has at
least one opening.
24. The drain installation kit of claim 22, wherein each guide bar
includes trusses that define at least some of the plurality of
openings.
25. The drain installation kit of claim 14, wherein the trailing
end of a first guide bar is configured to connect with the leading
end of a second guide bar.
26. The drain installation kit of claim 25, wherein the first guide
bar includes a first top edge extending at a first angular slope
between the leading and trailing ends of the first guide bar and
the second guide bar includes a second top edge extending at a
second angular slope between the leading and trailing ends of the
second guide bar, the first angular slope being substantially equal
to the second angular slope.
27. The drain installation kit of claim 14, wherein the rigid
connection between the guide bars and the upper flange does not
obstruct adjustment of the height of the drain plate housing.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C. .sctn.
119(e) to U.S. Provisional Application No. 60/884,124, filed Jan.
9, 2007, which is hereby incorporated by reference.
TECHNICAL FIELD
[0002] This disclosure relates to construction techniques and, more
particularly, to constructing sloped concrete floors.
BACKGROUND
[0003] Many skilled craftspersons can construct sloped floors
(e.g., made of concrete) using techniques that are well-known in
the field. Sloped floors are often desirable for draining water or
other liquids. However, even the most skilled craftsperson can have
trouble reproducing the same, evenly sloped floor on all occasions.
A floor that is unevenly sloped, sloped too steeply, or conversely,
not steeply enough, can drain poorly and/or be uncomfortable to
walk on. For example, an unevenly sloped shower pan can drain
poorly and can be uncomfortable for a person to stand on.
[0004] Do-it-yourselfers sometimes desire to install sloped
surfaces without the expense of hiring a skilled craftsperson. A
drain installation kit can help an unskilled person construct a
sloped surface leading to a drain, such as a shower pan. A
conventional drain, once assembled, usually includes a number of
components. Although an unskilled person may be able to assemble
the needed parts, constructing an evenly sloped floor having an
aperture for the drain can be more challenging. Some installation
kits include a number of sloped form members that can be positioned
radially around the center of the drain to assist in aligning the
center of the sloping floor aperture with the center of the
drain.
[0005] Unfortunately, form members in such conventional kits can be
inadvertently moved during the construction process, meaning that
the center of the sloping floor aperture can become misaligned from
the center of the drain. Such misalignment can result in improper
drainage, which can lead to water pooling and other adverse
effects. Water pooling, in particular, can lead to structural
damage, microorganism incubation, and is at least aesthetically
displeasing.
SUMMARY
[0006] The present invention provides a drain installation kit
adapted to maintain alignment of the center of a sloping floor
aperture with the center of a drain throughout the construction
process. In a preferred embodiment, the kit includes an upper
flange that is rigidly connectable to a drain base and multiple
sloping guide bars that are rigidly connectable in a radial fashion
to the upper flange. A user can use this preferred embodiment by
assembling it, adding cementitious material between the guide bars,
and making an upper surface of the cementitious material flush with
a top edge of the guide bars.
[0007] Some embodiments of the present invention provide
significant functional advantages over conventional drain
installation kits. In some embodiments, the drain installation kit
allows for greater adjustability of the height of the drain plate
housing than in conventional drain kits. In some embodiments, the
drain installation kit provides a fixed attachment point while
still providing adjustability of the drain plate housing height,
whereas attachment points in conventional drain installation kits
are fixed only when the drain plate housing is adjusted tightly
downwards in order to sandwich the attachment points against the
drain assembly. In some embodiments, the drain installation kit
provides independent and unconnected attachment points for each
guide bar, so that movement of one guide bar does not automatically
move another guide bar as in conventional drain installation kits.
Some guide bar embodiments can provide a greater degree of
stability, thereby inhibiting any tendency of the guide bar to
tilt.
[0008] Some embodiments of the present invention provide similar
functionality as conventional drain installation kits, but with
substantially greater ease for the unskilled person. In some
embodiments, the drain installation kit allows the construction of
a concrete floor with a consistent slope. In such embodiments, the
construction can be substantially performed without skilled labor.
In some embodiments, the drain installation kit allows the
construction of a sloping floor without regard to the dimensions or
shape of the installation area. In some embodiments, the drain
installation kit allows for an extension of a sloped surface by
combining multiple instances of the same component, wherein
conventional drain kits, specially designed extension components
were required. In some embodiments, the drain installation kit
centrally anchors sloping guide bars without additional structure
used in conventional drain kits.
[0009] Some embodiments of the present invention can be
manufactured significantly more efficiently. In some embodiments,
the drain installation kit is less expensive to produce because it
includes fewer components than conventional installation kits. Some
guide bar embodiments can be manufactured more uniformly and/or
using less material, while maintaining sufficient structural
integrity. Additional advantages provided by some embodiments of
the present invention will be apparent from the following
description.
BRIEF DESCRIPTION OF THE FIGURES
[0010] The following drawings are illustrative of particular
embodiments of the present invention and therefore do not limit the
scope of the invention. The drawings are not to scale (unless so
stated) and are intended for use in conjunction with the
explanations in the following detailed description. Embodiments of
the present invention will hereinafter be described in conjunction
with the appended drawings, wherein like numerals denote like
elements.
[0011] FIG. 1 is a top plan view depicting an illustrative drain
installation with a plurality of illustrative guide bars having
their respective leading ends attached to an upper flange;
[0012] FIG. 2a is a side elevational view of an illustrative guide
bar;
[0013] FIG. 2b is a side elevational view of an illustrative guide
bar;
[0014] FIG. 2c is a side elevational view of an illustrative guide
bar;
[0015] FIG. 3a is a top plan view of a shower drain and adjacent
flooring built in accordance with an illustrative drain
installation kit;
[0016] FIG. 3b is a top plan view of the illustrative shower drain
of FIG. 3a without the adjacent flooring;
[0017] FIG. 4 is a side elevational, partially sectional view of
the parts depicted in FIG. 3a;
[0018] FIG. 5 is a top perspective view of an illustrative upper
flange;
[0019] FIG. 6a is a perspective view depicting the trailing and
leading ends of illustrative guide bars;
[0020] FIG. 6b is a side elevational view depicting the joinder of
two illustrative guide bars;
[0021] FIG. 6c is a top plan view of the illustrative guide bars
depicted in FIG. 6b;
[0022] FIG. 7 is a top plan view of an illustrative drain
installation made by interconnecting multiple guide bars together
in end-to-end relation to one another;
[0023] FIG. 8 is a perspective view of one illustrative drain
installation kit application;
[0024] FIG. 9 is a side elevational, sectional view of one
illustrative drain installation kit application; and
[0025] FIG. 10 is a perspective view of one illustrative drain
installation kit application.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0026] The following detailed description is exemplary in nature
and is not intended to limit the scope, applicability, or
configuration of the invention in any way. Rather, the following
description provides practical illustrations for implementing
exemplary embodiments of the present invention. Constructions,
materials, dimensions, and manufacturing processes suitable for
making embodiments of the present are known to those of skill in
the field of the invention. Those skilled in the art will recognize
that many of the examples provided have suitable alternatives that
can be utilized.
[0027] Throughout the following description, the term recess is
used to denote an opening. Recess is used to describe both openings
that extend partially through a surface and openings that may
extend fully through a surface. Moreover, as used in this
description, an object's height refers generally to its extent in
direction T of FIGS. 2b-2c, an object's length refers generally to
its extent in direction L of FIGS. 2b-2c, and an object's width
refers generally to its extent in direction W of FIG. 3a.
[0028] FIG. 1 shows a top plan view of an illustrative assembled
drain installation kit 10. A drain installation kit can include a
plurality of guide bars 12, having their respective leading ends 13
detachably attached to an illustrative upper flange 14 about a
drain plate 18. Their respective trailing ends 15 can abut an
upstanding wall 16 that defines the outermost boundaries of the
shower, swimming pool, or other sloped floor to be constructed.
Guide bars 12 are often supported by a substantially flat support
surface 11, which, in one embodiment, would be the slab of the
structure within which the sloped surface is being built.
[0029] Embodiments of a drain installation kit are not restricted
to sloped floors of rectangular configuration only. The guide bars
12 may be used to build sloped floors of any predetermined
geometric configuration. For example, a guide bar 12 may be cut at
any location along the length thereof to conform it to the size of
a space having an extent less than the length of an uncut guide bar
12, and the leading end 13 of one or more additional guide bars may
be attached to the trailing end 15 of one or more installed guide
bars to enable use of the guide bars in spaces having an extent
greater than the length of a single guide bar.
[0030] FIG. 2a shows an illustrative guide bar 12 that has a height
extent at its leading end 13 that is less than its height extent as
its trailing end 15. Accordingly, when its bottom wall or bottom
edge 17 rests atop the substantially flat support surface 11 and
when its leading end 13 is attached to the upper flange 14, the top
wall or top edge 19 of the guide bar will be disposed relative to a
horizontal plane at a predetermined angular slope defined by the
height difference. In some embodiments, the guide bar 12 may have a
trailing projection 44 which extends from its trailing end 15 as
shown in FIG. 2a. In additional embodiments, the guide bar 12 can
have a leading projection 46, which extends from its leading end 13
as shown in FIG. 2a.
[0031] The openings 42 of FIG. 2a are defined by trusses, which
comprise the support structure of the guide bars 12. Guide bars
with truss support structures are often made of a smaller quantity
of material, while maintaining sufficient structural integrity. The
smaller quantity of material often leads to a guide bar that is
less expensive to manufacture and lighter, making it easier for an
installer to handle. In some instances, the openings 42 in each
guide bar 12 enhance the bond between the guide bar and a suitable
cementitious mixture that is used to form the sloped floor. The
illustrative openings 42 depicted in FIG. 2a advantageously allow
more cementitious mixture to pass through the guide bar 12 than in
conventional drain kits, providing for a stronger bond than in
conventional applications.
[0032] In many instances, guide bars with truss support structures
can be manufactured more uniformly. The cross-sectional area of
each of the trusses can be approximately equal. In guide bars made
of plastic, every truss having approximately equal cross-sectional
areas can finish cooling at roughly the same time, thereby
minimizing imperfections (e.g., bending and/or cracking due to
stress). This provides a distinct advantage over support structures
that define circular openings.
[0033] FIGS. 2b and 2c show additional embodiments of the guide bar
12 in which the openings 42 of FIG. 2a can be replaced and/or
supplemented by additional structural features. For example, FIGS.
2b and 2c show embodiments in which the guide bar 12 can have one
or more openings 118 in its bottom edge 17 or top edge 19. In
embodiments in which the bottom edge 17 has openings 118, the
bottom edge 17 would not be supported along its entire extent by
the slab 11. In embodiments in which the top edge has openings 118,
cementitious mixture would not be made flush with the entire top
edge 19 of the guide bar 12 when added. These openings 118 allow
for additional cementitious mixture to pass through the guide bar
12, thus strengthening the bond between the mixture and the guide
bar 12. Those skilled in the art will appreciate that the openings
118 can take a variety of shapes and configurations, and are not
limited to those shown in the embodiments present here. For
example, both the bottom edge 17 and the top edge 19 may contain
the openings 118. In some embodiments, the width of the bottom edge
17 can be greater than that of the top edge 19, thereby increasing
the stability of the guide bar 12.
[0034] FIGS. 3a, 3b, and 4 show one illustrative drain installation
kit assembled with components of a drain assembly 22. A
conventional drain assembly can include a drain pipe 24, a drain
base 25 with a drain base flange 28, and an upper flange. FIGS. 3a,
3b, and 4 show the conventional upper flange replaced by one
embodiment of the upper flange 14 included with an illustrative
drain installation kit. As with a conventional drain assembly, the
illustrative upper flange 14 can be secured to the drain base
flange 28 by a plurality of screws 20. The upper flange 14 is
internally threaded and threadedly receives an externally threaded
conventional post 30. The post 30 is integrally formed with a
housing 32, which receives a drain plate 18.
[0035] FIGS. 3a and 3b further show the leading end of one guide
bar 12 attached directly to the upper flange 14. In the embodiment
depicted, the upper flange 14 has multiple attachment points, which
in this embodiment include a plurality of flange recesses 34. The
flange recesses 34 can be adapted to receive a portion of a member
(e.g., a pin, a screw, a bolt, a nail, or other similar members).
Each guide bar can have a leading projection 46 as shown in FIG.
2(a)-(c). A guide bar recess 52 can pass through the leading
projection from top to bottom, for receiving the member. FIG. 3b
shows one embodiment where a guide bar 12 is detachably attached to
the upper flange 14, with guide bar recess 52 aligned with flange
recess 34.
[0036] As is known, attachment of the guide bar 12 to the upper
flange 14 can be achieved in a variety of ways, and is not limited
solely to the embodiment described above. Although a detachable
attachment may be preferable in some applications where the guide
bar may need to be repositioned, the attachment need not be
detachable. The guide bar may be permanently attached to the upper
flange, especially in applications where the guide bar 12 can be
left in place after it has been attached. The guide bar 12 may
similarly be permanently attached in a variety of ways, as is known
in the art. As just one example, the guide bar may be permanently
attached with an adhesive. Additionally, in some applications, the
upper flange 14 may not be necessary, and the guide bar 12 may be
attached directly to a conventional upper flange included in a
conventional drain assembly.
[0037] FIG. 4 shows a side elevational view of an illustrative
guide bar 12 attached to the upper flange 14. The leading
projection 46 of the guide bar 12 sits atop the upper flange 14 and
is detachably attached to the upper flange 14 in accordance with
the description provided above. In one illustrative embodiment, the
leading projection 46 extends inwardly towards the drain only as
far as the edge of the drain plate 18. When all guide bars are
attached in such a manner, space is maintained between the upper
flange 14 and the housing 32. The space in this embodiment allows
the height of the drain plate to be freely adjusted without
interference from the guide bars 12 or any other part of the drain
installation kit. In this way, the drain plate 18 can be positioned
without regard to the structure that attaches the guide bars 12 to
the upper flange 14. In an illustrative embodiment, the height of
the drain plate 18 is adjusted after the cementitious mixture is
added, but before it dries. Being able to adjust the position of
the drain plate 18 at this time can be important in order to make
the tile and the drain plate 18 as level as possible.
[0038] FIG. 5 shows one embodiment of an upper flange 14 configured
for use in the embodiments depicted in FIGS. 3a, 3b, and 4. The
upper flange 14 in this embodiment has multiple flange recesses 34
radially spaced about a center drain opening 35. The drain opening
35 can be configured to receive the conventional post 30 and drain
plate housing 32 shown in FIG. 4. In the embodiment shown, the
drain opening 35 includes partial internal threading 36 for
threadedly receiving a corresponding post. The upper flange 14 may
be attached to the drain base 25 of FIG. 4 with the screws 20
previously described inserted through one or more openings 37 on
the upper flange 14. Weep holes 38 may also be included in the
upper flange to allow moisture to seep down into the drain.
[0039] FIG. 6a shows one embodiment of a connection between
multiple guide bars 12, 112. In the embodiment shown, a trailing
projection 44 extends from the trailing end 15 of one guide bar 12.
A guide bar recess 54 can pass through the trailing projection 44
from top to bottom, for receiving a member 56. An additional guide
bar 112 has a leading projection 46 with a guide bar recess 52. The
member 56 can join the guide bars 12, 112 when it is inserted into
both guide bar recesses 52, 54. Each guide bar 12, 112 can have the
same predetermined slope, with the trailing and leading projections
dimensioned and placed to maintain a substantially even slope from
the leading end of one guide bar, through the joinder of the bars,
and extending to the trailing end of a second guide bar.
[0040] FIG. 6b shows a side elevational view in which two of the
same illustrative guide bars 12 are connected together in one
embodiment to extend a predetermined slope. The guide bars 12 are
positioned so that the guide bar recess 52 in the first guide bar's
leading projection 46 is aligned with the guide bar recess 54 in
the second guide bar's trailing projection 44. In this embodiment,
the corresponding guide bar recesses can align along axis 50, and a
pin or other suitable member can be inserted to secure both guide
bars together. FIG. 6c shows a top plan view of the guide bars in
FIG. 6b. In some embodiments, the first guide bar 12 is unsupported
along its bottom edge 17 by the slab 11. In some instances,
cementitious material can be added to the space between the bottom
edge 17 and the support surface to assist the respective members
and upstanding wall in maintaining the first guide bar in position.
In some embodiments, a shim made from some kind of scrap (e.g.,
wood, drywall, etc.) can rest on top of the slab and provide
additional support to the bottom edge 17.
[0041] FIG. 7 shows the use of multiple guide bars 12 enabling the
building of larger sloped floors. An illustrative drain
installation kit may have any number of guide bars 12, which can be
connected as needed to extend the overall effective length of a
single guide bar 12. In addition, any guide bar 12 can also be cut
to a shorter length whenever required. In most embodiments, the top
surface of the leading end 13 of an additional guide bar is
positioned at a height substantially equal to the height of the top
surface of the trailing end 15 of a guide bar 12 to which it is
connected, in linear or end-to-end relation.
[0042] With reference to FIGS. 3a, 3b, and 4, to install one
illustrative drain kit, the drain pipe housing 32 is first
unscrewed from a conventional drain assembly and the illustrative
upper flange 14 is attached in place of the conventional upper
flange. The respective leading ends 13 of the guide bars 12 are
then secured to the drain by attaching the leading projection 46 of
each guide bar to the upper flange 14. The guide bars are attached
by aligning each leading projection guide bar recess 52 with a
respective flange recess 34 of the upper flange 14 and inserting a
pin or other suitable member. The height of the drain plate 18 can
then be adjusted to a desired height depending upon the thickness
of the surface 21, to provide a flush joint with the surface.
Additional guide bars 12 can be used if required by the
application. For example, additional guide bars 12 can be used if
the sloped floor is oversized (relative to the length of guide bars
12) as depicted in FIG. 7 or if the sloped floor has an "L"-shaped
or other relatively unusual geometric configuration.
[0043] When all guide bars have been installed, the cementitious
mixture (e.g., mud) is introduced into the area bordered by
upstanding side walls 16 and divided by the upstanding guide bars
and the cementitious mixture is spread throughout the area,
including within the opening maintained between the housing 32 and
the upper flange 14, which solidly secures the drain plate housing
32 once the cementitious mixture dries. The cementitious mixture is
spread flush with the top edge 19 of each guide bar 12 along its
extent. Excess cementitious mixture is removed and the surface is
smoothed by conventional, well-known concrete working techniques.
The surface 21, such as tiling, is then installed atop a relatively
thin layer of cementitious material that overlies the cementitious
mixture in the well-known way and the drain plate 18 is finally
adjusted before the cementitious mixture dries in order to provide
a flush joint between the top of the drain plate and the surface
21. When the surface 21 is tiling, the job is completed by filling
the cracks between the tiles with grout in the well-known way. In
this way, the center of the radially-positioned guide bars 12 can
be nearly perfectly aligned with the center of the drain.
Misalignment can lead to water pooling, and pooling can be
aesthetically displeasing and can cause structural damage.
[0044] It should be apparent that an unskilled laborer can measure
the guide bars 12 and cut them to length if required, or connect
additional guide bars and cut them to length if required, and
position the guide bars atop the slab 11 with the respective
leading ends 13 thereof secured to the upper flange 14. No special
skills are then required to introduce a cementitious mixture into
the area bounded by the upstanding walls 16 and to smooth the
cementitious material until it is flush with at least part of the
guide bars' top edges, thereby ensuring an optimal slope in the
finished sloping floor. In this way, sloping floors are provided in
showers or other rooms having floors that slope to a drain,
swimming pools, and the like. Significantly, the slope will be
duplicated each time the drain installation kit is used and the
steps of installation are followed, even if the sloping floor is
built by unskilled laborers.
[0045] FIG. 8 shows another embodiment of a drain installation kit.
The guide bars 12 in this embodiment can be attached directly to
support surface 11 to provide a sloped surface leading to an
aperture 60 in the support surface 11. Each illustrative guide bar
can include a guide bar recess 62 which can pass through the
leading end 13 of each guide bar 12. The guide bars 12 can be
positioned radially about the aperture 60 as desired and attached
to the support surface 11 by inserting a pin or other suitable
member through the guide bar recess 62 and connecting it with the
support surface. For example, a nail can be inserted into the guide
bar recess 62 and driven into the support surface 11. As those in
the art will appreciate, the attachment can be detachable or may
not be detachable. Cementitious material can then be spread in
between the guide bars to form a sloped surface leading to the
aperture 60.
[0046] FIG. 9 shows one embodiment of an installed drain kit
similar to the embodiment depicted in FIG. 8. The guide bars 12 can
be positioned around an aperture 60, which in one embodiment can be
a sump well. The guide bars 12 can be attached to the support
surface 11 in accordance with the description provided above, and a
sloped surface can be constructed with cementitious mixture in the
usual way.
[0047] FIG. 10 shows another embodiment of an installed drain kit.
The guide bars 12 in this embodiment can be positioned in a
substantially parallel formation 68. In this embodiment, the
trailing edge 15 of each guide bar 12 can be attached to a support
wall 66. A cementitious mixture can be spread in between and flush
with the guide bars 12 to form a sloped, substantially planar
surface. An outer surface, such as tiling, can be installed atop
the substantially planar surface in the usual way. Upon complete
installation, this embodiment advantageously provides a sloped,
substantially planar drain for urging water away from the support
wall 66. As seen in FIG. 10, this embodiment can be implemented
around the foundation of a building 72. In addition, the
illustrative guide bars can also be positioned in a radial
formation 70, which as shown in FIG. 10, can be used to create a
drain surface around the corner of the building 72.
[0048] Embodiments of the present invention may include one or more
of the following features. The upper flange may be configured to
connect to a drain plate housing. In some drain installation kits,
the upper flange may be internally threaded in order to threadedly
receive a drain plate housing. The multiple attachment points on
the upper flange may be radially spaced about the center of the
upper flange. In some embodiments, the attachment points include
flange recesses formed within a surface of the upper flange. The
flange recesses may extend partially through the upper flange. In
some embodiments, the flange recesses extend fully through the
upper flange. Some embodiments have an upper flange with
cylindrically formed flange recesses capable of receiving a
cylindrically shaped pin. Some drain installation kits have guide
bars with a protrusion that can be inserted into a flange recess on
the upper flange. Some guide bars have a guide bar recess capable
of receiving a member. In some embodiments, the guide bar recess
may extend partially and/or fully through the guide bar. In some
embodiments, the multiple attachment points on the upper flange may
include protrusions that can extend into a guide bar recess in the
guide bar. Some guide bars are dimensioned so that they do not
obstruct the movement of an adjustable drain plate housing when
they are attached to the upper flange. In some drain installation
kits, the first ends of the guide bars are substantially fixed with
respect to the drain base when attached to the upper flange. In
some embodiments, the guide bars are positioned so as to create a
substantially planar drain surface. The support structure of some
guide bar embodiments can be trusses. Some drain installation kits
have guide bars which are positioned so as to urge water away from
a central area. In some embodiments, the width of a guide bar's
bottom edge is greater than that of its top edge.
[0049] Thus, embodiments of a drain installation kit are disclosed.
One skilled in the art will appreciate that the drain installation
kit can be practiced with embodiments other than those disclosed.
The disclosed embodiments are presented for purposes of
illustration only and not limitation.
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