U.S. patent application number 11/732733 was filed with the patent office on 2008-10-09 for plumbing control unit drainage device.
Invention is credited to Donald D. Logsdon.
Application Number | 20080245091 11/732733 |
Document ID | / |
Family ID | 39825764 |
Filed Date | 2008-10-09 |
United States Patent
Application |
20080245091 |
Kind Code |
A1 |
Logsdon; Donald D. |
October 9, 2008 |
Plumbing control unit drainage device
Abstract
The present invention is a drain system for use with a manifold
plumbing control unit (MPCU) including a drain pan having a sloping
bottom surface with a peripheral wall forming a reservoir. The
peripheral wall may include upwardly extending sidewalls, and
upwardly extending endwalls secured to the edges of the sloped
bottom surface. One or more attachment brackets may extend from the
wall to facilitate attachment to one or more wall studs under the
MPCU. The drain pan has a unique drain hole assembly in the bottom
surface for attachment of a drainage line, that prevents the line
from protruding upward to prevent blockage of the drain. A separate
access opening is provided in the bottom surface to allow for
passage of a water supply line to the MPCU. In alternative
embodiments, splash shields may be provided to surround the MPCU to
help contain and drain off any spraying or leaking liquid into the
drain pan. Methods of installation are also provided.
Inventors: |
Logsdon; Donald D.; (Zephyr
Cove, NV) |
Correspondence
Address: |
MARK D MILLER;KIMBLE, MACMICHAEL & UPTON
5260 NORTH PALM AVENUE, SUITE 221
FRESNO
CA
93704
US
|
Family ID: |
39825764 |
Appl. No.: |
11/732733 |
Filed: |
April 4, 2007 |
Current U.S.
Class: |
62/285 ;
137/15.18 |
Current CPC
Class: |
Y10T 137/0491 20150401;
E03C 1/12 20130101 |
Class at
Publication: |
62/285 ;
137/15.18 |
International
Class: |
F25D 21/14 20060101
F25D021/14 |
Claims
1. A drain system for a manifold plumbing control unit comprising:
a drain pan having a sloped bottom surface; a pair of elongate
upwardly extending sidewalls attached to said pan and running along
two opposite sides of said drain pan; a pair of upwardly extending
endwalls attached to said pan and to each end of the elongate
sidewalls connecting the sidewalls to each other; a drain hole at a
lowest point of the bottom surface; a downwardly extending wall
attached underneath said bottom surface around said drain hole for
receiving a drain line, the interior of said wall having a
perimeter that is larger than that of said drain hole; an access
hole assembly in the bottom surface including an access hole for
passage of a water supply line to the manifold plumbing control
unit, and an upwardly extending wall surrounding said access
hole.
2. The drain system of claim 1 wherein said drain hole is round,
said downwardly extending wall is cylindrical, and the
circumference of the interior of said cylindrical wall is larger
than the circumference of said drain hole.
3. The drain system of claim 1 wherein a lip is formed inside said
downwardly extending wall between said drain hole and said
wall.
4. The drain system of claim 1 wherein the sloped bottom surface
has a plurality of low points and a drain hole assembly at each
such point.
5. The drain system of claim 1 wherein said upwardly extending
access hole wall is cylindrical, and a rubberized covering is
provided over said cylindrical wall for sealing engagement with an
access line passing through said wall.
6. A drain system for a manifold plumbing control unit comprising:
a drain pan having a sloped bottom surface and a lowermost location
on said surface; at least one upwardly extending wall attached to
and extending around outside edges of said drain pan; a round drain
hole at said lowermost location on said bottom surface; a
cylindrical wall extending downwardly from said drain hole for
engagement with a drainage line, the circumference of the interior
of said wall being larger than the outer circumference of said
drain hole forming an annular lip that is flush with said bottom
surface; an access hole assembly in the bottom surface including an
access hole for passage of a fluid supply line to the manifold
plumbing control unit, and an upwardly extending cylindrical wall
surrounding said access hole.
7. The drain system of claim 6 wherein the sloped bottom surface
has a plurality of low points and a drain hole assembly at each
such point.
8. The drain system of claim 6 wherein a rubberized covering is
provided over said upwardly extending cylindrical wall for sealing
engagement with an access line passing through said wall.
9. The drain system of claim 6 wherein the width of the reservoir
body is approximately the same as the distance between parallel
stud boards of a building wall such that the reservoir body fits
snugly therebetween.
10. The drain system of claim 6 wherein at least one bracket
extends out from the drain pan for attachment to at least one stud
board of a building.
11. The drain system of claim 6 further comprising at least one
splash shield having a lower flange that extends into said drain
pan.
12. The drain system of claim 6 wherein a plurality of splash
shields are provided in overlapping side relationship to each
other, each shield also having a lower flange that extends into
said drain pan.
13. The drain system of claim 6 further comprising a back splash
shield and at least one side splash shield, each such shield having
a lower flange that extends into said drain pan, wherein said back
and at least one side shield are formed into an integrated
unit.
14. The drain system of claim 11 wherein at least one opening is
provided in at least one of said splash shields for passage of at
least one fluid line from said manifold plumbing control unit.
15. The drain system of claim 14 wherein at least one rubberized
boot is provided to cover each of at least one of said fluid lines
extending through at least one of said openings.
16. The drain system of claim 15 wherein a plug is provided to seal
any opening that does not have a fluid line passing through it.
17. A drain system for a plumbing manifold control unit comprising:
a drainage means having a sloped bottom surface; a fluid retaining
means extending around outside edges of said drain means; an
opening at a lowest point on the bottom surface; an engagement
means extending downwardly from said opening for receiving a
drainage line, the perimeter of the interior of said engagement
means being larger than the perimeter of said opening forming a lip
that is flush with said bottom surface; a passage means in said
bottom surface for receiving a water supply line; and an upwardly
extending fluid retaining means surrounding said passage.
18. A method for installing a drain system for a plumbing manifold
control unit comprising the steps of: installing a drain pan
between a pair of stud boards of a building, said drain pan having
an upwardly extending peripheral wall, a sloped bottom surface, a
lowermost location on said surface, a round drain hole at said
lowermost location on said bottom surface, a cylindrical wall
extending downwardly from said drain hole, the circumference of the
interior of said downwardly extending wall being larger than the
outer circumference of said drain hole forming a lip that is flush
with said bottom surface, and an access hole in the bottom surface
surrounded by an upwardly extending cylindrical wall; inserting a
drain pipe into said downwardly extending wall such that it abuts
against said lip; and passing a fluid supply line through said
access hole.
19. The method of claim 18 further comprising the steps of:
extending said drain pipe to an exterior location of said building;
and sealingly installing a boot between said supply line and said
upwardly extending cylindrical wall.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a drainage device for
installation within the frame of a residential or commercial
dwelling underneath a plumbing control unit to prevent leakage from
the unit seeping into the wall of said structure, creating
structural and other safety problems, including the possibility of
mold.
[0003] 2. Description of the Prior Art
[0004] The use of drip or drain pans for the collection of moisture
under any device which contains and circulates fluid is common.
Many times such devices are a precautionary or safety measure to
prevent fluids, such as oil, from entering the workplace and
causing a safety or environmental hazard. An example of such a
drainage tray is described in Pat. No. 4,941,901. This patent
discloses a drain pan device specifically for collecting the
condensate from wall mounted air conditioning units. Unlike the
present invention the apparatus of this patent is not designed to
be installed in an enclosed area, such as within a wall.
[0005] A relatively new device currently installed in many building
structures is a manifold plumbing control unit (hereinafter a
"MPCU"). The MPCU is a water distribution unit which supplies water
to individual plumbing fixtures through dedicated ports and
distribution lines. Such a device has separate hot and cold water
inlets and ports to manage the entire plumbing system. These
systems are being widely used in hot and cold potable water
distribution systems in single and multifamily dwellings, as well
as multiple unit structures.
[0006] Typically, the MPCU is installed within a wall of a dwelling
or commercial structure between a pair of studs. The MPCU is
secured in place by attachment to the pair of studs. Once
installed, the structure can be built in the normal fashion around
the MPCU (i.e., insulation can be placed in the wall and the wall
covered in the normal fashion). An access panel is usually created
in the wall so that the MPCU unit can be easily accessed for
repairs or adjustments. Holes are drilled in the stud boards
through which tubing leading to or from the MPCU is run, each such
tube eventually extending to a desired water outlet, fixture, or
faucet.
[0007] The tubing running from the MPCU is usually flexible
Vanex.RTM. PEX tubing, or similar piping, which runs the entire
length from the MPCU to the fixture as a single piece without the
need of any fittings to further prevent the chance of leaking. If
leaking occurs, it usually occurs at a connection point. Leaks can
occur from improper installation of the connection, thereby
creating an improper seal. When using the MPCU, the only connection
points are at the MPCU unit and at the actual fixture to which
water is being provided. As the MPCU has a multitude of fixture
points based on the number of water lines installed, there is a
great potential for one or more of the connections to leak based on
improper installation of the fitting or the PEX tubing to the
MPCU.
[0008] If, for any reason, the MPCU leaks, the moisture from such a
leak is likely to soak into the wall in which the MPCU is
installed. This may become problematic as the water may not be
detected from some time, as it will be covered from view. If such a
leak proceeds to go undetected, extensive water damage could occur.
This damage could include the rotting of the wall structure, the
floor structure under the wall structure, and damage to the
surrounding area. The moisture from such a leak also creates a risk
of the development of mold which can be toxic, and harmful to the
inhabitants of the building.
[0009] Even in a situation where the leak is minor, it may go
undetected for quite some time causing more substantial damage than
a major leak that is immediately noticed. This is especially true
for MPCU systems as the unit is designed to be placed in an
integrated position within a wall of a structure to economize
space. It is designed to be hidden, which decreases the visibility
and access to the unit thereby making it less probable that the
owner would notice a leak. An additional problem may occur from the
water in the MPCU being under pressure in that a leak may manifest
itself in the form of squirting water. In such a case the leak can
spray water in many directions, causing damage to any of the
adjacent wall surfaces.
[0010] It is therefore desirable to provide a convenient, universal
drain system which can be hidden from view and provided under
and/or around a MPCU in the wall of a building structure. It is
also desirable to have a drain system which automatically drains
leaking water from an MPCU unit to prevent structural damage and
mold. Finally, it is desirable to have a drain system capable of
containing a large leak that may spray water in many
directions.
SUMMARY OF THE INVENTION
[0011] The present invention addresses the above problems by
providing a plumbing manifold control unit drain system including a
reservoir body formed by a sloping bottom surface surrounded by a
peripheral wall. In one embodiment, a pair of elongate sidewalls
run generally parallel to each other on opposite sides of the
bottom surface, and a pair of endwalls connect to the ends of the
sidewalls. The sidewalls and endwalls all are secured to or
integrated with each other and the edges of the sloped bottom
surface. The integrated reservoir body is sealed at all the edges
of the sidewalls, endwalls and bottom surface to prevent water from
leaking from the reservoir. In other embodiments the drain
apparatus has one or more vertically mounted attachment brackets
extending from each endwall and/or one or more horizontally mounted
attachment brackets extending from the ends of one of the elongate
sidewalls for attachment to one or more wall studs under or around
the MPCU.
[0012] The reservoir body has a drain hole assembly in the bottom
surface for attachment of a drainage line (e.g., 1/2'' PVC schedule
40 pipe). A stop structure extends into the orifice of the drain
hole to prevent the over insertion of a drain supply line. A
separate access hole is provided in the bottom surface of the pan
allowing for passage of a separate water supply line to the
MPCU.
[0013] The present invention includes various methods and apparatus
for an integrated manifold water distribution system which is to be
installed under a MPCU to prevent leaking and damage to the
building structure in which it is placed. A preferred embodiment
the drain includes a generally rectangular reservoir pan with at
least one drainage port on the bottom surface of the pan. The
drainage port is designed with one or more stops to ensure that
drainage tubing attached to the port does not extend upward past
the bottom surface of the pan where it might otherwise create a lip
that could prevent water from draining out of the reservoir. In
some embodiments, the stop is in the form of a ridge; in other
embodiments one or more prongs may be used. In one embodiment, the
reservoir is an integrated rectangular unit having two shorter
endplates that are installed in close proximity to the wall studs,
and longer sideplates that run between the studs in the same
direction as the wall surface. In further embodiments, the drain
pan may have other styles and/or shapes. For example, the drain pan
assembly can be rectangular, oval or kidney shaped in design. In
alternative embodiments, the drain pan may extend around the supply
line, rather than have the access opening run through the drain
pan. In such an embodiment, a supply line access hole assembly is
not required in the drain pan.
[0014] The bottom surface of the reservoir body is sloped in nature
to allow any liquid drain to the lowest point of the bottom
surface. At the lowest point of the bottom surface of the reservoir
body is a drain hole assembly. The drain hole assembly consists of
a circular orifice at a point on the bottom surface where liquid
contained in the reservoir will drain through the drain hole
orifice. The orifice connects to a short integral cylindrical tube
that extends below the reservoir. A drainage pipe is then inserted
into this tube to receive liquids draining through the orifice. The
orifice and cylinder can be provided in various sizes and/or
shapes, but preferably is of a size to accommodate standard piping
or tubing to fit into the cylinder. An adhesive or sealant may be
provided between the drainage pipe and the cylindrical tube to
prevent leaking.
[0015] In one embodiment, the diameter of the orifice of the drain
hole assembly is smaller than that of the cylinder, and of the
drain tube inserted in the cylinder. This creates a generally
horizontal lip or edge of material of the bottom surface which acts
as a stop to block the drainage tubing from extending above the
upper edge of the orifice into the reservoir where it would
otherwise act as a dam to the flow of liquid out of the reservoir.
While the diameter of the orifice is smaller than that of the
cylinder, the orifice is still of a large enough size to allow for
proper draining. No part of the drain structure in this embodiment
extends up into the floor of the reservoir.
[0016] In an alternative embodiment, one or more prongs are
provided along and flush with the plane of the bottom surface of
the reservoir, extending in a generally horizontal direction
towards the center of the orifice of the drain hole assembly. Each
prong partially blocks the orifice and serves as a stop to prevent
the drain tube or pipe from extending above the upper edge of the
orifice into the reservoir where it would otherwise act as a dam to
the flow of liquid out of the reservoir. Accordingly, the prongs
ensure proper drainage of the reservoir. The prongs should be of
sufficient size to prevent the drain tubing or pipe from extending
above the horizontal plane created by the prongs, but the prongs
should not be of such a size to prevent drainage through the
orifice.
[0017] In a further alternative embodiment, the drain tubing is
secured by sliding the drain tubing around the outside of the lower
cylinder. If fully engaged, the drain tube will come in contact
with the bottom surface of the pan on the outside of the cylinder,
and cannot extend into the reservoir to create drainage problems.
Sealant or adhesive may be applied between the tube and the
cylinder to further prevent leaking.
[0018] It is to be appreciated that different embodiments of the
drain hole assembly may use different combinations of prong(s), lip
and/or cylinder.
[0019] It should be noted that sloped design of the bottom surface
of the drainage assembly need not be symmetrical. The bottom
surface can be concavely curved with the drain hole at the lowest.
point of the curvature. If curved, the curvature need not be
symmetrical. In a preferred embodiment, the drain hole assembly can
be offset to either side of the reservoir and the curvature can be
designed to make the area where the drain hole assembly is located
at the lowest point of the bottom surface. In further embodiments,
the device may have one or more drain hole assemblies to further
assist in draining. If there are more than one drain holes, the
bottom surface can be curved in such a manner has to have more than
one low point, with a drain hole placed at each low point for
proper draining.
[0020] In the preferred embodiments, in addition to a drain hole
assembly, the reservoir assembly also contains a supply line access
hole assembly. The access hole assembly allows for the passage of a
water supply line up to the MPCU. In these embodiments, the access
hole is placed so as to correspond to an input location on the
MPCU, ordinarily relatively close to the center of the drainage
reservoir, although different positions may also be provided
depending on the requirements of the MPCU. The access hole is of a
large enough diameter to allow the water supply line to pass
through it. To prevent leakage through the access hole, a
cylindrical segment extends upward into the reservoir body,
preventing water or other liquid from draining out through the
access hole. The access hole is not designed to act as a drain. The
cylindrical segment extends a significant distance upward to block
water in case the reservoir fills with liquid.
[0021] To further prevent leakage out of the supply line access
hole, in some embodiments a rubberized boot can be placed over the
top of the access hole creating a seal between the supply line and
the cylindrical segment. The boot creates a seal by elastically
constricting around the supply line and the cylindrical segment of
the access hole to create a secure fit.
[0022] The height of the walls of the reservoir can vary, but
should be of a substantial height to allow for the containment of a
significant quantity of liquid as it drains from the drain hole
assembly. While the reservoir assembly is designed to hold a
certain amount of liquid in the event of a serious leak, liquid
should normally drain out immediately. Accumulated water is not
desirable due to contamination by bacteria and mold, and as a water
source for insects and vermin that may inhabitate the structure.
Accordingly, once any leaks are detected, they should be fixed as
soon as possible to prevent further damage.
[0023] The reservoir can be secured to the wall in various ways. In
some embodiments, the reservoir can be wedged between two stud
beams by making the reservoir tray the same size as the distance
between the two beams. As stud beams are normally placed at
standard distances from each other, the reservoir body can be
provided in standard sizes which apply to the standard distances.
In some embodiments, one or more holes can be made in each of the
endwalls through which a fastening device can be secured to retain
the reservoir in place against the studs. In other embodiments, one
or more brackets may be provided at the ends of the reservoir that
come in close proximity to the wall studs, extending laterally for
the attachment of the reservoir to the studs. In some embodiments,
a pair of brackets is provided along the plane of one of the longer
sidewalls of the reservoir. These brackets may create a flush
surface with the sides of the stud facing outward form the wall. In
some embodiments, one or more brackets are provided that extend
vertically either in an upward or downward direction from the
reservoir, to create a bracketing surface for the connection of the
reservoir to the studs. The brackets can be an integrated part of
the sideplate or endwalls, or alternatively can be separate
components which are connected by fasteners to both the reservoir
and stud boards. In some embodiments, weakened areas may be
provided where the brackets attach to the sideplate or endwalls,
allowing the brackets to be easily broken off for removal, if
desired. The brackets may extend a distance from the drain
reservoir to allow for proper attachment to the stud boards.
[0024] The brackets may be provided with one or more openings to
allow for fasteners such as nails, screws, bolts, or other
fasteners commonly known in the art to connect the brackets to the
wall. The openings in the bracket for fasteners are placed away
from the reservoir body to allow for the user to be able to insert
and secure the fasteners without interference from the reservoir
body. In some embodiments, clips are used to connect the reservoir
to the stud boards. In some embodiments, bolts may be fastened to
the wall, and the reservoir provided with brackets made to slip
over or otherwise engage the bolts for proper attachment.
[0025] It is to be appreciated that different permutations and
combinations of the various brackets and attachment means of these
embodiments may be utilized in the same structure.
[0026] In some embodiments, an integrated spray skirt assembly is
provided around the MPCU to prevent squirting leaks from causing
water to come in contact with the wall surface or any other portion
of the building structure. In some embodiments, the spray skirt is
provided in the form of one or more sheets of material adjacent to
the sides and top of the MPCU. These sheets include a backplate
which is a generally flat piece of material that is water
resistant, such as stainless steel or plastic. The backplate
creates a generally vertical surface that runs parallel to the wall
of the structure or other surface on the opposite side of the
access opening to the MPCU. The bottom edge of backplate is shaped
as to extend into the reservoir assembly overlapping the back wall
of the drain pan so as to allow liquid that comes in contact with
the backplate to run down the plate and into the reservoir.
[0027] In some embodiments, two sideplates may also be provided.
The sideplates prevent liquid from exiting from the sides of the
present invention, or coming into contact with the stud boards or
other parts of the building structure. The bottom edges of the
sideplates are designed to overlappingly extend into the reservoir
assembly. The edges of the sideplates overlappingly connect to the
back plate on one edge, and the front panel on the other edge. The
sideplates overlap in such manner as to prevent moisture from
escaping. It is to be appreciated that any overlapping relationship
between the backplate, sideplates and reservoir may be employed
such that the water squirting or otherwise escaping from the MPCU
is directed into the reservoir and prevented from coming into
contact with the building structure.
[0028] In most embodiments, the sideplates are provided with access
holes which correspond to the water supply lines which exit the
MPCU then pass through the sideplates. Ordinarily, holes are
drilled through the stud board, and the supply lines travel through
the sideplate and stud boards and into the next segment of the wall
frame and eventually to various fixtures. The holes in the
sideplate generally correspond to the elevation of the exit ports
of the MPCU. After the supply lines are installed though the
sideplates, rubberized caps (small boots) are placed over the lines
to cover the holes in the sideplates, creating a water tight seal
to prevent leaking through the holes in the sideplate. If any of
the holes in the sideplate are not used (i.e. the sideplates have
more holes than waterlines from the MPCU), they can be plugged with
rubberized caps to create proper seals.
[0029] In some embodiments, a front plate may also be provided to
protect the area of the wall in which access to the MPCU is
obtained. The front plate may have an access panel which can be
removed or opened for maintenance on the MPCU. Alternatively, the
entire front plate can be removed for maintenance. The access panel
can be attached in any manner commonly know in the art.
[0030] In some embodiments, a top plate may be provided above the
MPCU with edges that overlap the frontplate, back plate and
sideplates. The top plate prevents liquid from exiting over the top
of the spray skirt. Openings and boots may also be provided on the
top plate to allow passage of any pipes on tubes leading to or from
the MPCU, and for sealing of any such openings.
[0031] It is appreciated that the components of the components of
the splash skirt assembly can be fastened in place by connecting to
the walls by ay means customarily used in the art. The edges of all
the components overlap in such a manner as to direct water down the
splash skirt assembly to collect in the reservoir.
[0032] It is contemplated that any combinations of the frontplate,
backplate, and sideplates can be constructed as integrated pieces
to simplify the structure and assembly of the device. For example,
the backplate and sideplates can be constructed from one piece
allowing for the user to just install one item, rather than three.
It is further contemplated that portions of the spray skirt
assembly can be installed. For example, the spray skirt assembly
can be installed without the top plate, or alternatively, the
sideplates might not be installed and instead the stud boards can
act to prevent moisture from escaping. Rubberized boots can even be
placed directly over the holes in the stud board. Further, it is
contemplated that any or all of the portions of the spray skirt
assembly can be integrated with the reservoir assembly.
[0033] Due to possible leakage of the unit, rubberized boots can be
placed over the supply lines where the lines travel through the
sidewalls, creating a barrier to prevent any leakage out from
within the area between the wall studs. In some embodiments, these
boots are made from an EPDM plastic material that has elastic
(elastomeric) properties and/or thermoplastic rubber (TPR). The
material from which the boots are made should allow the
configuration to stretch enough to create a seal around the tubing
and/or drain housing without overextending the flexibility of the
material which could lead to cracks.
[0034] It is therefore an object of the present invention to
provide a drain pan for installation inside a wall of a building
below a MPCU to collect and direct any leaking water away from the
MPCU to prevent damage to the wall.
[0035] It is also an object of the present invention to provide an
apparatus for collecting water or other liquid leaking from an MPCU
or other liquid containing object in the wall of a building
structure.
[0036] It is a further object of the present invention to provide a
unique drain pan for use with an MPCU having a unique structure
that prevents accommodation of water leaking from the MPCU, and
allows for passage of water supply line(s) to the MPCU.
[0037] It is a further object of the present invention to provide
leakage protection from an MPCU in lateral directions such as
sidewall and topwall protection, if desired.
[0038] It is a further object of the present invention to provide a
self draining reservoir assembly.
[0039] It is a further object of the present invention which can be
installed and secured to the wall in various ways depending on the
wall structure.
[0040] It is a further object of the present invention to provide a
reservoir assembly that can be installed in various building
structure types with varying wall thicknesses and distance between
stud boards.
[0041] It is a further object of the present invention to provide
methods for installation of drain pans and related structures for
use with an MPCU that collect and direct any leaking water away
from the MPCU to prevent damage to the wall.
[0042] Additional objects of the present invention shall be
apparent from the detailed description and claims herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] FIG. 1 is a top perspective view of an embodiment of the
drain pan of the present invention.
[0044] FIG. 2 is bottom perspective view of an embodiment of the
drain pan of the present invention.
[0045] FIG. 3 is a side elevational view of one embodiment of the
drain pan of the present invention.
[0046] FIG. 4 is a bottom plan view of one embodiment of the drain
pan of the present invention.
[0047] FIG. 5 is a top plan view of one embodiment of the drain pan
of the present invention.
[0048] FIG. 6 is a sectional side view of the embodiment of the
drain pan of the present invention along line A-A of FIG. 5.
[0049] FIG. 7 is an end view of one embodiment of the drain pan of
the present invention.
[0050] FIG. 8 is an opposite end view of one embodiment of the
drain pan of the present invention.
[0051] FIG. 9 is a perspective view of an embodiment of an interior
shield of the present invention.
[0052] FIG. 10 is a perspective view of an embodiment of an
interior shield and drain pan of the present invention showing a
typical wall installation prior to installation of an MPCU.
[0053] FIG. 11 is a side view of the installation illustrated in
FIG. 10.
[0054] FIG. 12 is a front view of the installation illustrated in
FIG. 10.
[0055] FIG. 13 is a top view of the pan installation illustrated in
FIG. 10.
[0056] FIG. 14. is a perspective view of an embodiment of an
interior shield and drain pan of the present invention showing a
typical wall installation following installation of an MPCU.
[0057] FIG. 15 is a front view of the installation illustrated in
FIG. 14.
[0058] FIG. 16 is a side view of the installation illustrated in
FIG. 14.
[0059] FIG. 17 is a top view of the pan installation illustrated in
FIG. 14.
[0060] FIG. 18A is a perspective view of an embodiment of a tube
shield of the present invention.
[0061] FIG. 18B is a side view of the tube shield of FIG. 18A.
[0062] FIG. 19A is a perspective top view of an embodiment of a
tube shield of the present invention installed on a tube.
[0063] FIG. 19B is a lower perspective view of the tube shield of
FIG. 19A.
[0064] FIG. 20A is a bottom perspective view of an embodiment of a
boot shield of the present invention.
[0065] FIG. 20B is a top perspective view of the boot shield of
FIG. 20A.
[0066] FIG. 20C is a side view of another embodiment of a boot
shield of the present invention.
[0067] FIG. 20D is a top perspective view of the boot shield of
FIG. 20C.
[0068] FIG. 21 is a top perspective view of an embodiment of the
drain pan of the present invention.
[0069] FIG. 22 is bottom perspective view of an embodiment of the
drain pan of the present invention.
[0070] FIG. 23 is a front plans view of one embodiment of the drain
pan of the present invention.
[0071] FIG. 24 is a side elevational view of one embodiment of the
drain pan of the present invention.
[0072] FIG. 25 is a bottom plan view of one embodiment of the drain
pan of the present invention.
[0073] FIG. 26 is a top plan view of one embodiment of the drain
pan of the present invention.
[0074] FIG. 27 is a sectional side view of the embodiment of the
drain pan of the present invention along line A-A of FIG. 26.
DETAILED DESCRIPTION
[0075] Referring to the drawings wherein like reference characters
designate like or corresponding parts throughout the several views,
and referring particularly to the embodiment of FIGS. 1-8, it is
seen that the invention includes a reservoir body 50, capable of
receiving and holding a quantity of fluid that may leak from the
fluid manifold control unit. The reservoir is preferably elongate
in shape, in order to allow it to fit within the wall of a
structure, under the fluid manifold unit. In the illustrated
exemplary embodiment, the reservoir has four sidewalls which
connect in the general form of a rectangle. An elongate back wall
52 and an elongate front wall 53 with bracket extensions 64 &
65, run the length of the reservoir. The position of body 50 is
interchangeable as the front wall 53 with brackets 64, 65 may be
made to face either direction by rotating the reservoir 50 body 180
degrees. The front and back walls are interconnected by two
endwalls 54, which are shorter in length than the front and back
walls. All walls should be of a tall enough height to allow for the
reservoir to collect a substantial amount of fluid without
overflowing. The sides of the body 50 are preferably flat in order
to allow for installation in the wall of a building unit.
[0076] In several embodiments, the reservoir body 50 has a sloped
bottom surface 56 which connects to the bottom of each of the
front, back and end walls to form a basin. A drain opening 70 is
located at the lowest point of the bottom surface 56. There are no
ridges or other obstructions around opening 70 that might otherwise
prevent fluids from exiting from the drain unit 50 (see cross
sectional view of FIG. 6). In other embodiments, the bottom surface
may be arcuate, concave, or curved with drain 70 at the bottom or
apex of the curve. At or near the center of the bottom surface 56
is a supply line access assembly which allows for a supply line 91
to run through the reservoir body 50 to the fluid manifold control
unit or MPCU 125 (see FIGS. 21-27). The supply line access assembly
includes a separate opening 80 in the bottom surface 56 of the
reservoir body with walls 81 which extend upward from the bottom
surface of the reservoir body to prevent liquid from leaking out
through access hole 80. Wall 82 is preferably cylindrical, but may
be of any shape that corresponds to the shape of the supply line
used. The access hole 80 should be large enough that commonly found
water supply lines 91 can easily fit through the access hole 80, as
shown in FIG. 27. The access hole need not have a snug fit with the
water supply line to the manifold as a rubber cap or boot 95 may be
used to seal the line 91 to wall(s) 81 (See FIGS. 20-21.) The
height of wall(s) 81 may be of any suitable height, but preferably
as tall as the walls 52-54 of the reservoir.
[0077] In some embodiments, the reservoir body 50 is provided with
one or more connecting brackets to allow the reservoir body to be
connected to the stud boards 82 of a wall in a manner that is
convenient to the user. The illustrated embodiments show a pair of
vertically mounted brackets 60, 61, and a pair of horizontally
mounted brackets 64, 65. Such brackets may be provided with one or
more securing holes 67 though which fasteners commonly know in the
art, such as nails or screws in order to attach the brackets to the
stud boards 82. In some embodiments, a weakened area 62 may be
provided between side brackets 64, 65 and body 50 to allow brackets
64 and/or 65 to be easily broken off for removal, if desired, as
shown in FIGS. 21-23. Due to the design of the brackets of the
reservoir body, it is not necessary to provide or use a horizontal
and vertical bracket on each side; only one bracket on each side
may be used if the reservoir body is securedly attached. When
provided, vertical brackets 60 and/or 61 attach to the interior
surface of the stud boards 82, and the horizontal brackets 64
and/or 65 secure to the outside face of the wall stud boards. The
horizontal and vertical brackets as discussed may extend from the
reservoir body in any manner in which the bracket can be easily
secured. For example, the vertical brackets may extend either in an
upward or downward direction from the reservoir body 50.
[0078] In alternative embodiments, the brackets may not be provided
with holes 67. Instead, the brackets may have integrated mounting
prongs or clips to secure the unit 50 to one or more stud boards;
or nails or screws may be forced directly through the brackets
themselves at whatever locations are most desirable. In further
embodiments, the brackets may have clamps which extend from the
brackets and wrap around the stud boards for a secure connection.
It is understood that any combinations of the above brackets and/or
attachment mechanisms may be employed to attach the reservoir body
50 to the studs 82. It is to be appreciated that other embodiments
of the invention may not have brackets at all, and attach directly
to the stud boards directly from (through) one or both of the end
walls 54. The end walls can be secured to the stud boards 82 by any
means know in the art including the use of fasteners, nails,
screws, adhesive, or simply wedging the reservoir in place.
[0079] FIGS. 2 and 22 illustrate side perspective views of
embodiments of the present invention showing the underside of a
reservoir body. In these views, the lower portion of the drain
assembly is shown. A circular opening 70 is provided in the bottom
surface 56 of the reservoir body 50. The circular opening is
connected to a wall 72 which extends downwardly from the bottom
surface of the reservoir body. Wall 72 is preferably cylindrical,
but may be of any shape that corresponds to the shape of the drain
pipe or hose 84 used. Drain pipe or hose 84 is inserted inside wall
72 to create a seal, ensuring that water or other liquid in the
reservoir body 50 exits through pipe 84 and does not leak into the
wall structure, as shown in FIG. 22. It is preferred that body 72
have a cylindrical form that is of an appropriate size as to allow
a drainage tube of a standard size to be sealingly inserted
therein. The drain hole opening 70 is more narrow than the inside
edge(s) of wall 72, creating a lip 71 where wall 72 attaches to
body 50. This lip prevents pipe or hose 84 from extending through
opening 70 into the floor 56 of reservoir body 50, so as not to
impede the exit of fluids through opening 70. Alternatively, drain
pipe 84 may be inserted over the outside of wall 72. Sealant or
adhesive may be placed between pipe 84 and wall 72.
[0080] In some embodiments, one or more prongs and/or a grate
structure (not shown) may also be provided in opening 70, extending
towards the center and/or encompassing opening 70 to prevent the
drain pipe 84 from being inserted beyond the bottom surface of the
reservoir, which could prevent water from properly draining.
[0081] FIGS. 2 and 22 further illustrate an embodiment of the
curvature or slope of the bottom surface 56 of the reservoir. While
the angle and shape of the bottom surface may vary, the curvature
of the surface needs not be extensively angled, just enough to
allow the liquid in the reservoir to run towards the drain hole 70
located at or near the lowest point of the bottom surface. It
should also be noted that the drain hole 70 may be located at any
location on surface 56 (e.g. in a corner), so long as it is at the
lowest point in order to act as a drain.
[0082] FIGS. 3 and 23 illustrate side elevational views of
embodiments of the present invention.
[0083] The proportions and relative size of the invention may vary
based on the size and type of wall assembly in which the reservoir
is to be installed. FIGS. 4 and 25 show bottom plan views of
embodiments of the present invention. As shown, the curvature of
the bottom surface of the invention is not centered in these
embodiments.
[0084] FIGS. 5 and 26 are top plan views of embodiments of the
present invention. FIGS. 6 and 27 are cross-sectional views along
the line A-A of the prior figures. In FIGS. 6 and 27, exemplary
heights of walls 54 and 81 are shown. The distances shown in these
figures are illustrative only, and the actual proportion of each
individual size and shape be varied greatly.
[0085] FIGS. 7, 8 and 24 are side elevational views of embodiments
of endwalls 54 of the reservoir body 50. In the illustrated
exemplary embodiments, vertical brackets 60, 61 extend upwardly
from the end walls 54, and contain optional securing holes 67 for
attachment of the invention to the stud boards 82 of a constructed
wall.
[0086] FIG. 9 illustrates an embodiment of an interior shield 101
of the present invention. This shield is designed to be inserted
between wall studs 82 where the MPCU 125 is installed, as shown in
FIGS. 10-12 and 14-16. Shield 101 includes a back surface 103 and
may also include left and/or right side surfaces 104, 105. Walls
104, 105 may be provided without any openings, allowing openings to
be cut or drilled later, or they may include one or more openings
107 along the sides for receiving tubes 110 extending out from the
MPCU 125. To the extent that extra openings 107 are provided, these
may be plugged if not used. Shield 101 may also include a lip or
flange 102 at the bottom for directing any leaking moisture into
drain unit 50.
[0087] As illustrated in FIG. 10, an exemplary reservoir body 50 is
sized so as to extend roughly the distance between two stud boards
82 forming the wall structure. A drain pipe 84 connects to the
drain hole 70 and runs downwardly therefrom, to a point where
excess liquid can properly drain without causing damage to the
structure. A supply line 91 runs through the access hole 80 to the
MPCU 125. This allows for liquids to be supplied to the bottom of
the MPCU even with the reservoir body in place. A cap or boot 95 is
provided between supply line 91 and upper wall 81 to provide a seal
to prevent moisture from draining out through opening 80.
[0088] In the preferred embodiments, side walls 104, 105 are
generally parallel to the inner surface of the stud boards 82, and
generally perpendicular to back shield 101. The a lip or flange 102
at the base of back shield 101 and side walls 104, 105 extends
inwardly and overlaps the reservoir body 50, thereby allowing
proper draining from the back and side walls into body 50.
[0089] Referring to FIGS. 14-16, it is seen that the illustrated
exemplary embodiment of the back shield 101 extends vertically a
distance greater than that of the MPCU 125. This prevents any leak
from an outlet or inlet of the MPCU from spraying water on the
adjacent wall which is now covered by the backplate 101. The
illustrated back shield 101 has integrated side walls 104, 105; in
other embodiments, the sideplates can be separate pieces. The back
shield 101 and side walls 104, 105 may connect to an optional front
plate and optional top plate (not shown) to form an integrated
splash shield to prevent the wall structure from getting sprayed
with moisture.
[0090] Referring to FIGS. 10 and 14-16, it is seen that the
illustrated embodiments show one or more openings 107 in the side
walls that correspond to the supply lines that exit the MPCU. The
supply lies 110 extend through the openings 107 in the side walls
and then through openings 109 in the stud boards 82. Rubberized
caps 115 may be placed over the openings 107 in the side walls to
create seals so leaking water will not run through the openings.
Detail of the attachment of caps to supply lines 110 is shown in
FIGS. 18 and 19. The bottom edge 102 of the back shield 101 and
side plates 104, 105 are flared inward and fit along the inside
wall of the reservoir body 50, so that water running down the walls
will empty into the reservoir and be properly drained.
[0091] The reservoir body embodiments 50 of the present invention
should be installed between a pair of stud boards 82 in the wall of
a building before connection of the water supply line 91 to the
MPCU. Body 50 may be attached to the stud boards using any of
several different or combined attachment means, such as the use of
screws or nails forced through holes in brackets 64 and/or 65, or
forced directly through such brackets if no holes are provided, or
forced directly through end walls 54 into stud boards 82.
Alternatively or in addition, adhesive may be attached between end
walls 54 and stud boards 82, or body 50 may simply be wedged
between stud boards 82 using friction. Thereafter, supply line 91
is inserted through access hole 80 and through optional boot 95,
and connected to the MPCU 125. Boot 95 is then pulled over upper
wall 81 to provide a seal to prevent moisture from draining out
through opening 80.
[0092] Drain pipe 84 is connected to drain hole 70 by being
inserted inside downwardly extending wall 72, with lip 71
preventing pipe 84 from extending above the bottom surface of the
reservoir floor 56 which might otherwise prevent proper drainage
through hole 70. The frictional connection between pipe 84 and wall
72 may be sufficient to prevent leakage between these two
structures, or sealant may be applied between pipe 84 and wall 72
to secure the seal, ensuring that water or other liquid in the
reservoir body 50 exits through pipe 84 and does not leak into the
wall structure. Pipe 84 is extended downwardly and away from body
50, leading to an exit point where excess liquid can properly drain
without causing damage to the structure, such as through a wall to
the exterior of the structure.
[0093] When either back, side and/or front skirts are used, these
are generally installed by similar attachment means to the stud
boards 82 prior to installation of reservoir body 50. However,
these structures may also be installed after body 50 has been
installed. The bottom edges 102, 104 and 105 of these skirts should
be placed so as to overlap the inside walls of reservoir body 50.
It is to be appreciated that side boots 115 should be provided over
supply lines 110 as they are inserted through openings 107 in the
side skirts, and then plugs are inserted into unused openings 107
to prevent side wall leakage.
[0094] It is to be appreciated that different versions of the
invention may be made from different combinations of the various
features described above. It is to be understood that other
variations and modifications of the present invention may be made
without departing from the scope thereof. It is also to be
understood that the present invention is not to be limited by the
specific embodiments disclosed herein, but only in accordance with
the appended claims when read in light of the foregoing
specification.
* * * * *