U.S. patent application number 12/046352 was filed with the patent office on 2008-11-13 for floor drain.
Invention is credited to Lawrence G. Meyers.
Application Number | 20080277324 12/046352 |
Document ID | / |
Family ID | 39760011 |
Filed Date | 2008-11-13 |
United States Patent
Application |
20080277324 |
Kind Code |
A1 |
Meyers; Lawrence G. |
November 13, 2008 |
FLOOR DRAIN
Abstract
A floor drain system includes a generally rectangular drain
grate having a plurality of drain apertures, and a drain body,
having a circular lower portion defining an outlet and configured
to mate with an underdrain structure, and an upper portion defining
an inlet configured to receive the drain grate in a frictional fit.
The drain body includes an integral grout rim surrounding the
inlet, having a knife-tapered top edge, configured to reduce the
visibility of the grout rim between the surrounding material and
the grate.
Inventors: |
Meyers; Lawrence G.;
(Layton, UT) |
Correspondence
Address: |
DAVID R. MCKINNEY, P.C.
P.O. BOX 1460
SANDY
UT
84091
US
|
Family ID: |
39760011 |
Appl. No.: |
12/046352 |
Filed: |
March 11, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11716851 |
Mar 12, 2007 |
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12046352 |
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60781512 |
Mar 10, 2006 |
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Current U.S.
Class: |
210/164 |
Current CPC
Class: |
E03F 5/0408 20130101;
E03F 5/06 20130101; E03F 2005/0413 20130101; E03F 2005/0414
20130101 |
Class at
Publication: |
210/164 |
International
Class: |
E03F 5/14 20060101
E03F005/14 |
Claims
1. A floor drain system, comprising: a generally rectangular drain
grate having a plurality of drain apertures; and a drain body,
having a circular lower portion defining an outlet and configured
to mate with an underdrain structure, and an upper portion defining
an inlet, configured to receive the drain grate in a frictional
fit, the drain body including an integral grout rim surrounding the
inlet, having a knife-tapered top edge, configured to reduce the
visibility of the grout rim between the surrounding material and
the grate.
2. A floor drain system in accordance with claim 1, wherein the
lower portion includes helical threads configured to threadedly
interconnect with the underdrain structure, whereby a height of the
inlet can be adjusted by rotating the drain body about a vertical
axis.
3. A floor drain system in accordance with claim 1, wherein the
drain grate is selected from the group consisting of a solid metal
grate, and a metal-clad polymer grate.
4. A floor drain system in accordance with claim 1, wherein the
drain body comprises a thin-set tray, configured to overlie a
circular drain structure therebeneath, and including undercut grout
locking features disposed on an outer perimeter of the upper
portion, configured to mechanically interlock the drain body with
surrounding grout material.
5. A floor drain system in accordance with claim 1, wherein the
drain body includes undercut grout locking features disposed on an
outer perimeter of the upper portion, configured to mechanically
interlock the drain body with surrounding grout material.
6. A floor drain system in accordance with claim 5, wherein the
undercut grout locking features are selected from the group
consisting of a horizontal undercut edge, and tapered
buttresses.
7. A floor drain system in accordance with claim 1, wherein the
knife-tapered top edge of the grout rim has a top edge with a
minimum thickness of from about from about 0.01'' to about
0.005''.
8. A floor drain system in accordance with claim 1, further
comprising a plug, configured to removably fit into the inlet to
support the drain body and the grout rim during installation of the
floor drain.
9. A floor drain system in accordance with claim 1, further
comprising a handle, configured to rotationally interlock with a
selected aperture of the drain grate, to allow removal of the grate
from the drain body.
10. A floor drain system in accordance with claim 1, further
comprising a recess in an inner portion of the inlet, for receiving
a hair trap.
11. A floor drain, comprising: a height-adjustable drain body,
having a circular lower portion defining an outlet, the lower
portion being configured to interconnect to an underdrain
structure, and a generally rectangular upper portion defining an
inlet, the upper portion including an integral grout rim
surrounding the inlet and having a knife-tapered top edge; and a
generally rectangular drain grate, supported by the drain body,
having a plurality of drain openings, configured to insert into the
inlet with an interference fit, whereby the drain grate is
removably secured to the drain body.
12. A floor drain in accordance with claim 11, wherein the drain
grate is selected from the group consisting of a solid metal grate,
and a metal-clad polymer grate.
13. A floor drain in accordance with claim 11, wherein the grout
rim includes a knife-tapered top edge with a thickness of from
about from about 0.01'' to about 0.005'' and an outer face having a
taper of about 30.degree..
14. A floor drain in accordance with claim 11, further comprising a
plug, configured to removably fit into the inlet to support the
drain body and the grout rim during installation of the floor
drain.
15. A floor drain assembly, comprising: a drain body, having a
generally rectangular upper portion defining an inlet aperture, and
a circular lower portion defining an outlet in fluid communication
with the inlet aperture, the lower portion having helical threads
configured to threadedly interconnect with an underdrain, whereby a
height of the inlet can be adjusted by rotating the drain body
about a central axis, and the upper portion including an integral
grout rim surrounding the inlet and having a knife-tapered top
edge; a generally rectangular drain grate, having a plurality of
drain openings, surrounded by the grout rim and supported by the
drain body; and an underdrain attached to the outlet of the drain
body.
17. A floor drain in accordance with claim 15, wherein the drain
body includes undercut grout locking features disposed on an outer
perimeter of the upper portion, configured to mechanically
interlock the drain body with surrounding grout material.
18. A floor drain in accordance with claim 15, wherein the
knife-tapered top edge of the grout rim has a top edge with a
minimum thickness of from about from about 0.01'' to about
0.005''.
19. A floor drain in accordance with claim 15, wherein the drain
grate is selected from the group consisting of a solid metal grate,
and a metal-clad polymer grate.
20. A floor drain in accordance with claim 15, further comprising a
T-handle grate removal tool, configured to insert through a
selected opening in the drain grate, to facilitate removal of the
drain grate from the drain body.
Description
PRIORITY CLAIM
[0001] The present application claims priority from United States
non-provisional patent application Ser. No. 11/716,851, filed Mar.
12, 2007, which claims priority from United States provisional
patent application Ser. No. 60/781,512, filed on Mar. 10, 2006,
both entitled FLOOR DRAIN.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates generally to floor drains for
tiled showers and the like. More particularly, the present
invention relates to a rectangular floor drain with a flush-fit
drain grate and a knife edge rim.
[0004] 2. Related Art
[0005] Floor drains for showers and the like are most commonly
circular in shape. Floor drain styles generally fall into two broad
categories. The first category is drains that have grates
fabricated from thin metals. These can be referred to as
"top-mounted" strainers. The thin top-mounted strainers allow these
to be set over top of the surrounding finished floor material.
Finished flooring materials are grouted or caulked directly to and
flush with the body of the drain, which also supports the perimeter
of the thin strainer from below. These strainers self-finish, and
do not require a surrounding grout rim.
[0006] Another common category of drains incorporates grates that
are "flush-mounted". These drains may have grates that are
substantially thicker than top-mounted strainers. This drain style
incorporates a grout rim that surrounds the grate and has an upper
surface that is generally coplanar with the top surface of the
grate. Flush-mounted drains are typically engineered with a
controlled amount of clearance between the grate and the grout rim
to allow for removal of the grate. This design also incorporates
structure supporting the grate from below. The outer perimeter of
the grout rim is bonded to the surrounding finished floor material
with tile grout or caulking at installation.
[0007] Commonly constructed from stamped stainless steel or brass
sheet material, top-mounted grates often incorporate snap features
that allow them to be held in place without the use of screws.
These may appear to be easy to remove without tools, but are often
quite difficult to remove. Commonly available tools, i.e. a screw
driver, do not adequately function as a removal tool. Due to their
thin cross-sectional thickness, top-mounted drain grates are often
not capable of supporting a substantial amount of weight, and are
often observed having been deformed as a result. This style is not
a good candidate for a square configuration because exposed corners
are likely to become a hazard to bare feet. Should the grate become
deformed, this problem becomes worse.
[0008] Floor drains with flush-mounted grates are commonly
available with grout rim features that are formed from the same
metal as the grate, or by a portion of the drain body that is
allowed to be exposed. Both of these approaches have inherent
design problems. Those designs that allow the drain body to be
exposed are limited to having an aesthetically incompatible visual
element surrounding the grate. The nature of grout rims is that
they are a portion of the drain structure that are designed to be
bonded into the finished floor installation, and cannot be
removed.
[0009] There is a growing trend within the plumbing fixtures market
to offer consumers a wider selection of metal finish styles and
colors. The market is becoming much more design-conscious. Plumbing
fixtures are now available in often more delicate patina finishes.
Whereas the choices used to be limited to brass and chrome, now
colors and finishes such as aged pewter, brushed nickel, oil rubbed
bronze, gun metal black, antique copper and others have become
popular and widely available.
[0010] This greater variety of colors and finishes raises
maintenance concerns. Because of the harsh nature of chemicals that
are used to remove water deposits, mold and other common
conditions, delicate patina surfaces cannot be exposed to such
substances without becoming visually altered. This is especially
the case for shower floor drains which are in contact with such
chemicals for a much longer duration than fixtures mounted to
vertical surfaces, for example. Additionally, because of their
delicate surface finish, such drains cannot incorporate a matching
grout rim that has any kind of delicate surface patina without a
substantial risk of damage from maintenance procedures and
chemicals. The likelihood that these would exhibit any durability
is questionable. Additionally, screws that are frequently used to
secure the grate are difficult and time consuming to remove.
Moreover, sharp burrs can easily form on brass and stainless screw
heads from repeated use, and screws can be dropped and become lost
down the drain if care is not taken.
SUMMARY
[0011] It has been recognized that it would be advantageous to
develop a floor drain having a grate that is simpler to remove and
maintain.
[0012] It has also been recognized that it would be advantageous to
have a floor drain which is easy to set and does not include an
unsightly grout rim.
[0013] It has also been recognized that it would be advantageous to
have a floor drain with a drain grate that is easily removable and
can be constructed of a greater variety of materials for allowing a
wider range of decorative appearance.
[0014] In accordance with one embodiment thereof, the present
invention provides a floor drain, including a drain body, a
generally rectangular drain grate supported by the drain body and
having a plurality of drain openings, and a grout rim supported by
the drain body and surrounding the drain grate. The drain body
includes a generally rectangular upper portion defining an inlet
aperture, and a circular lower portion defining an outlet in fluid
communication with the inlet aperture, the lower portion being
configured to interconnect to an underdrain structure. The grout
rim has an outside surface having interlocking structure configured
to interlock with surrounding materials, and a sharply tapered top
edge, configured to reduce the visibility of the grout rim between
the surrounding material and the grate.
[0015] In accordance with another aspect thereof, the invention
provides a floor drain, including a drain body, a generally
rectangular drain grate supported by the drain body, and a grout
rim supported by the drain body and surrounding the drain grate.
The drain body includes a generally rectangular upper portion
defining an inlet aperture, and a circular lower portion defining
an outlet in fluid communication with the inlet aperture, the lower
portion being configured to interconnect to an underdrain
structure. The drain grate includes a plurality of drain openings
and a plurality of downwardly oriented mounting posts configured to
insert into receiving holes in the drain body with an interference
fit, whereby the drain grate is removably secured to the drain
body.
[0016] In accordance with yet another aspect thereof, the invention
provides a floor drain assembly, including a drain body having an
outlet, a generally rectangular drain grate supported by the drain
body and having a plurality of drain openings, a grout rim
supported by the drain body and surrounding the drain grate, and an
underdrain inlet attached to the outlet of the drain body. The
drain body includes a generally rectangular upper portion defining
an inlet aperture, and a circular lower portion defining an outlet
in fluid communication with the inlet aperture, the lower portion
having helical threads configured to threadedly interconnect with
corresponding helical threads of an underdrain structure, whereby a
height of the inlet can be adjusted by rotating the drain body
about a central axis.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Additional features and advantages of the invention will be
apparent from the detailed description which follows, taken in
conjunction with the accompanying drawings, which together
illustrate, by way of example, features of the invention, and
wherein:
[0018] FIG. 1 is a perspective view of one embodiment of a floor
drain in accordance with the present invention;
[0019] FIG. 2 is a top view of the floor drain of FIG. 1, showing
the drain grate;
[0020] FIG. 3 is a side view of the floor drain of FIG. 1;
[0021] FIG. 4 is a bottom view of the floor drain of FIG. 1;
[0022] FIG. 5 is an exploded perspective view of the floor drain of
FIG. 1, showing the drain grate, grout rim, and drain body;
[0023] FIG. 6 is a partial cross-sectional perspective view of the
assembled floor drain;
[0024] FIG. 7 is a side, cross-sectional view of a complete
installation of the floor drain of FIG. 1 in a shower floor
assembly, and a drain grate removal tool;
[0025] FIG. 8 is a partial perspective view of an alternative
embodiment of a drain body of a floor drain assembly in accordance
with the present disclosure;
[0026] FIGS. 9A and 9B are perspective views of an alternative
embodiment of a drain grate removal tool;
[0027] FIG. 10 is a perspective view of a floor drain assembly
without a drain grate, showing one embodiment of a cover cap
configured for use during installation of a floor drain
assembly;
[0028] FIG. 11 is a perspective view of another embodiment of a
drain body in accordance with the present disclosure;
[0029] FIG. 12 is a cross-sectional perspective view of the drain
body of FIG. 11;
[0030] FIG. 13 is a perspective view of an embodiment of a
metal-clad polymer drain grate and grate removal tool;
[0031] FIG. 14 is a perspective view of a thin-set tray that
incorporates many features of the floor drain with knife edge in
applications where a friction-fit grate is desired without using
the drain body having the knife edge.
DETAILED DESCRIPTION
[0032] Reference will now be made to exemplary embodiments
illustrated in the drawings, and specific language will be used
herein to describe the same. It will nevertheless be understood
that no limitation of the scope of the invention is thereby
intended. Alterations and further modifications of the inventive
features illustrated herein, and additional applications of the
principles of the inventions as illustrated herein, which would
occur to one skilled in the relevant art and having possession of
this disclosure, are to be considered within the scope of the
invention.
[0033] To address some of the problems with existing floor drain
structures, the inventor has developed an easily removable drain
grate that can include a desired delicate finish, surrounded by a
minimal grout rim that is nearly invisible to the eye. When
cleaning or maintenance is to be performed the grate can be quickly
and easily removed to a place where care can be taken to clean it
while preserving its designer finish. The design does not use
screws to secure the grate, which avoids the difficulty and time
required to remove them, and which can drop and become lost down
the drain if care is not taken. The design also avoids sharp burrs
that can easily form on brass and stainless steel screw heads from
repeated use.
[0034] One embodiment of a floor drain device in accordance with
the present invention is shown in FIGS. 1-6. The drain device 10
comprises three main parts: a drain body 12, a grout rim 14, and a
grate 16. The drain body includes an upwardly open square top
portion 18, with a downwardly extending circular threaded stem 20,
and a tapered transition section 22 therebetween. The drain body as
shown is a single integral piece of material, though it will be
apparent that the body could also be assembled from multiple
pieces. A variety of materials can be used for the drain body,
including polymer materials such as ABS, PVC, etc. Other materials
can also be used. The drain body can be injection molded, or
produced by other methods. While the top portion of the drain body
as shown in the figures is square in shape, other shapes can also
be used in accordance with the invention, such as rectangular,
round, hexagonal, etc.
[0035] The grout rim 14 is supported on a shoulder 24 of the top
portion 18 of the drain body 12. The shoulder can be designed to
provide three positive points of contact with the grout rim along
each side of the drain body. This helps to ensure that the grout
rim is level and rests firmly against the shoulder, to compensate
for possible irregularities in the line and level of the grout rim
that are a result of the casting and trimming process. As shown in
FIG. 5, the grout rim can include a wedge-shaped locking tab 26,
which interlocks with interlocking notches 28 disposed in the outer
rim 30 of the top portion of the drain body. This interlocking
configuration allows the grout rim to snap fit onto the top portion
of the drain body with a tight, secure fit. The grout rim 14 can be
of metal or other suitably strong material, and can be a single
integral piece (e.g. a single metal casting), or can be an assembly
of multiple pieces. The single piece configuration is believed to
have greater strength and to simplify assembly.
[0036] The top edge 32 of the grout rim 14 is tapered to a very
narrow edge, almost a knife edge, so that when the floor drain is
installed with grout packed therearound, the grout rim becomes
barely visible. The thickness of the top edge can vary. In one
embodiment, the inventor has used a grout rim having a top edge
having a thickness of from about 0.01 to 0.04 inches. The thickness
of the top edge can also be in the range of about 0.01 to 0.03
inches. Additionally, the top edge can be configured with a radius.
In one embodiment, the inventor has provided a radius equal to
about half the thickness of the grout rim at top (e.g. about 0.005
inches) on the outside of the top edge (i.e. the side facing away
from the inlet). Providing a radius only on the outside edge of the
grout rim helps transition from the surrounding grout to the rim,
and also maintains a square surface on the inside to match with the
drain grate. To facilitate removal of the grout rim from a mold,
the sides of the grout rim (both inside and outside) can be tapered
at a slight angle of, e.g. 1 to 3 degrees. The outside edge of the
drain grate (45 in FIG. 5) can be provided with a corresponding
taper to enhance the fit between the grate and the inside face of
the grout rim. The grout rim can be of a neutral color, so that it
blends into its surroundings and becomes practically
unnoticeable.
[0037] A cross-sectional view of the floor drain installed in a
shower or the like is provided in FIG. 7. The outer faces of the
grout rim are configured to provide a positive lock with the grout
or other material that is packed around the drain, so that the rim
is prevented from moving up or down with respect to the surrounding
structure. Particularly, the grout rim includes an outside shoulder
34 and an inwardly tapered upper face 36 that interlock with the
surrounding material to hold the rim in place and prevent upward
movement of the rim relative to the surrounding grout. The grout
rim also includes a lower tapered face 38 that helps prevent
downward movement of the rim. These features interlock with the
material surrounding the drain to hold it in its proper elevational
position.
[0038] The grout rim 14 has a height that makes it taller than the
outer rim 30 of the drain body 12, so that the top edge 32 of the
grout rim extends above the top portion 18 of the drain body when
the grout rim is installed on the shoulder 24. This upper portion
of the grout rim is configured to surround the drain grate 16. The
drain grate comprises a substantially planar piece of material with
a plurality of drainage holes 40 formed in it. The drain grate can
be of metal, such as brass, bronze, zinc, stainless steel,
aluminum, or other suitable material. The grate can also be surface
treated such as with a coating, plating, or chemical finish to
provide a desired color, shine or patina. For example, the inventor
has used a nickel plated zinc drain grate. Other platings can also
be used, such as chrome and copper. The drain grate is supported by
the top edge 42 of the upper portion of the drain body.
[0039] Unlike most floor drain devices, the drain grate 16 of this
floor drain 10 is not attached with screws or other fasteners, but
is removably inserted onto the drain body 12 with an interference
fit. Alignment of the grate with the drain body is assisted by the
grout rim 14, which surrounds the grate. Additionally, the drain
grate includes a plurality of mounting posts 44, in this case one
mounting post at each of the four corners, which extend downwardly
from the plane of the grate and are configured to insert into
corresponding grate mounting holes 46 in the drain body. The grate
mounting holes can have a slightly tapering diameter that gradually
diminishes in size, so that when the mounting posts are inserted
into the mounting holes, they will naturally reach a position at
which friction between the posts and the sides of the holes holds
the grate structure to the drain body with an interference fit. The
mounting posts can also have a mating angle to their outer surfaces
to match the taper of the mounting holes. In addition to attaching
the grate to the draining body, the mounting posts also align the
grate with the draining body and the grout rim, so that the gap
surrounding the grate is substantially uniform on all sides.
[0040] This interference fit configuration makes it easy to remove
the drain grate 16 whenever desired, and avoids the use of small
fasteners that can become lost down the drain when removed. Shown
in FIG. 7 is one embodiment of a grate removal tool 48 that can be
used to remove the grate from the drain assembly. This grate
removal tool comprises a stiff, springy wire having a central
handle portion 49 and two leg portions 50 that descend from the
handle portion, with a hook 52 at the distal end of each leg
portion. To remove the grate, the user holds the grate removal tool
by the handle portion, and pushes the two hooks downwardly into two
of the drainage holes 40 in the grate. When the hooks are pushed
into the holes, the spring nature of the grate removal tool causes
the free ends of the hook to bear against the underside of the
grate. The user can then remove the grate by simply pulling
upwardly on the tool.
[0041] An alternative embodiment of a grate removal tool 148 is
shown in FIGS. 9A and 9B. This grate removal tool comprises a wire
having a central handle portion 149 and two leg portions 150 that
descend from the handle portion, with a hook 152 at the distal end
of each leg portion. As can be seen in the figures, the hooks are
oriented out of the plane of the removal tool. Further, one hook
152a is oriented in one direction, while the other hook 152b is
oriented in roughly the opposite direction. To remove the grate
with this tool, the user holds the grate removal tool by the handle
portion, and inserts the two hooks downwardly into two of the
drainage holes in the grate using a pivoting motion. That is, a
user holds the removal tool at an angle (i.e. not perpendicular)
relative to the drain grate to insert one hook into a first hole,
then rotates the tool to an opposite angle to insert the second
hook into a second hole, essentially weaving the hooks into two of
the grate holes. When the hooks are inserted into the holes, the
free ends of the hook bear against the underside of the grate,
allowing the user to remove the grate by pulling upwardly on the
tool.
[0042] Easy removal of the grate 16 is advantageous for in many
ways. It is helpful for cleaning. For example, harsh abrasive
cleansers that are often used to clean a shower floor or other
surface around a drain can damage the drain grate. If the grate can
be easily removed for cleaning, this can allow a wider variety of
more delicate materials or materials with more delicate surface
finishes to be used for grates. Easy removal of the grate is also
advantageous from a decorative or maintenance standpoint. If one
desires to replace a grate with a different color, material or
style, for example, or a new grate is needed, this is a simple
matter of removing one grate and replacing it with another. Easy
removal of the grate is also advantageous in preparation for
clearing clogs with a pipe snake or other device, and can also help
avoid damage to the material of the grate or its finish from harsh
clog dissolving or drain clearing chemicals.
[0043] Referring back to FIG. 5, the drain body can also include a
group of set screw holes 54 which can be used for inserting a set
screw 56 to assist in leveling the grate. When in place, the tops
of these screws support the bottom of the grate, and by turning the
screw a user can raise or lower the top of the screw to help
maintain the level of the grate. This can be desirable where the
grate is not exactly flat. It is to be understood that the
embodiment shown in FIG. 5 can also be used without the set
screws.
[0044] An alternative embodiment of a drain body 112 is shown in
FIG. 8. In this embodiment the grate mounting holes 146 (into which
the grate mounting posts of the grate insert) each include a relief
slot 148 defined by side walls 154. The relief slot can serve at
least two functions. First, it increases the flexibility of the
grate mounting hole, which can be desirable for the interference
fit of the grate mounting posts. If there are slight variations in
the relative size or shape of the mounting holes and/or the grate
mounting posts (due to manufacturing variations, for example), the
increased flexibility of the mounting holes can allow greater
tolerance for these variations. Additionally, the relief slots can
provide an avenue for promoting removal of debris, such as sand,
grout, etc., that might enter the mounting holes during
construction or at other times. With a blind hole, debris can
become trapped in the hole, and can thus hinder the fit of the
drain grate into mounting holes, and can also cause a change in
elevation or tilt of the drain grate, potentially exposing sharp
edges or causing other undesirable conditions.
[0045] The threaded stem 20 of the drain body 12 is configured to
screw into an underdrain fixture 58, shown in the cross-sectional
view of FIG. 7. This drain structure is typical of showers, but is
only representative of the type of structure with which the
invention is compatible. The outside threads 60 of the stem
intermesh with the inside threads 62 of the underdrain fixture to
allow precise adjustment of the height of the top of the floor
drain. To raise or lower the top of the floor drain, a user simply
rotates the drain structure about its axial centerline 64.
[0046] The underdrain fixture 58 is typically attached to a
waterproof membrane 66, which has a flat bottom surface 68 that is
to be supported on a building subfloor, and a sloped top surface 70
that is configured to promote drainage toward the drain. Finished
floor material 72, such as ceramic tile, porcelain, or the like, is
affixed to the top surface of the mortar bed using thinset mortar
74 or other suitable material. Once the drain is adjusted to the
proper height, the grout is packed in around it to eliminate any
voids. Then, when the floor surface material is in place, grout is
also packed around the grout rim 14 to provide a secure
construction.
[0047] FIG. 10 is a perspective view of an embodiment of a cover
cap or plug 116 configured for use during installation of a floor
drain assembly in accordance with the present disclosure. The cover
cap is configured similar to a drain grate (16 in FIG. 1) and
includes mounting posts 144 that are positioned to fit into the
mounting holes 46 in the drain body 12 with an interference fit, in
a manner similar to the installation of the drain grate (16 in FIG.
5). The cover cap serves several functions. During installation of
the drain assembly and construction of the surrounding floor, the
cap can be temporarily inserted into the drain inlet opening
instead of a drain grate. This protects the drain grate from
possible damage during construction. Additionally, because the top
surface 140 of the cap does not include any openings, the cover cap
prevents sand, grout, or other construction debris from falling
into the drain or becoming lodged in the grate mounting holes or
other portions of the drain during construction.
[0048] Additionally, the cover cap or plug 116 helps maintain the
shape and integrity of the grout rim 14 during construction.
Because the grout rim tapers to a relatively sharp top edge 32, the
grout rim can be quite thin and flexible and susceptible to damage
during construction of the surrounding floor. The cover cap can be
designed to have a very tight fit with the grout rim (e.g. having a
much tighter fit than is intended for the drain grate) so as to
provide positive mechanical support of the grout rim during
construction, to prevent the rim from being bent, damaged, etc. The
cover cap can be made of resilient polymer materials, such as
polypropylene, etc. The top of the cover cap can be smooth, so as
not to interfere with screening of the surrounding floor. To remove
the cover cap, a user can cut it with a blade and remove it in
pieces, or drive a screw into the cap and pull the cap out of the
drain body while gripping the screw. Other removal methods can also
be employed.
[0049] Shown in FIGS. 11 and 12 are perspective and cross-sectional
views of another embodiment of a drain body 200 in accordance with
the present disclosure. This drain body 200 is a one piece unit,
having a generally rectangular upper portion 202 defining an inlet,
and a circular lower portion 204 defining an outlet and being
configured to mate with an underdrain structure (e.g. like that
shown in FIG. 7). As with the embodiments described above, the
lower portion of the drain body includes helical threads 206 for
connection to the underdrain, allowing the height of the drain
inlet to be adjusted by rotating the drain body. The drain body can
be of an injection-molded polymer, allowing it to be strong and
lightweight.
[0050] The inlet portion 202 of the drain body 200 includes a
shoulder 208 on its inner perimeter, for supporting a drain grate.
Surrounding the shoulder is a knife edge grout rim 210 that is
integral with the drain body, rather than being a separate grout
rim piece. The inner surface 212 of the grout rim includes 90
degree filleted corners 214 to contact the corners of the grate.
This configuration helps reduce binding of the grate and also
allows for a greater selection of grate configurations. The drain
body can also include a step or recess 216 in the bowl floor 218,
which can allow for the inclusion of a hair trap device (not
shown).
[0051] As with other embodiments discussed above, the knife edge
grout rim 210 provides a sharp termination (e.g. from about 0.01''
to about 0.005'' width) at the top edge of the drain body 200, to
reduce visibility of the drain body. When a drain grate is inserted
into the inlet portion 202 and supported by the shoulder 208,
friction between the grout rim 210 and the drain grate holds the
grate in place. At the same time, the edges of the drain grate
provide lateral support for the knife edge as its thickness tapers
toward the top. The outer sides 220 of the inlet portion of the
drain body include vertical buttresses 222 for added strength. The
knife edge grout rim has an outer surface 224 that quickly tapers
to the upper edge (e.g. a 30 degree taper) for greater stability
between the vertical buttresses.
[0052] Around the outer sides 220 of the inlet portion 202 of the
drain body 200 are undercut grout locking features 220. One grout
locking feature is a horizontal undercut edge 226, the shape of
which is best viewed in the cross-sectional view of FIG. 12. This
horizontal undercut provides a surface that tapers inwardly as it
goes down, thus providing a taper in an opposite direction from the
taper of the grout rim, to provide additional interlock with the
grout. The grout locking features can also include tapered (i.e.
non-vertical) surfaces associated with the buttresses 222, to cause
the buttresses to interlock with surrounding grout, allowing the
grout to capture the drain body and hold it in position in a sort
of dovetail arrangement. The outer sides 220 of the drain body can
also include vertical darts 228 can also be provided below or along
the horizontal undercut 226 to improve plastic flow to thin wall
sections during the molding process, as well as to add
rigidity.
[0053] A solid metal drain grate (similar to that shown in FIG. 5)
can be used with the drain body depicted in FIGS. 11 and 12. Such a
drain grate can be substantially planar, without mounting posts
like the mounting posts 44 in the drain grate 16 of FIG. 5. The
inventor has also developed a metal-clad polymer drain grate 250,
one embodiment of which is shown in FIG. 13. This drain grate
comprises a polymer body 252 (e.g. injection molded) with a
relatively thin gauge metal skin 254 that covers the top surface
256, the inner surfaces of the drain apertures 258, and the side
edges 260 of the grate.
[0054] The metal skin 254 can be of stainless steel, aluminum, or
other metals that are resistant to degradation in the presence of
water. Advantageously, the thin metal skin can be pressed into the
appropriate shape from sheet products, and then clenched onto the
polymer grate body around the outer edges of the grate and through
the drainage holes. The outer edges 260 of the grate can be rounded
to protect the grate from damage if is it dropped or bumped, and
also to eliminate sharp edges. Likewise, the corners of the metal
cladding can be cut away or relieved to remove sharp edges and to
reduce the likelihood that the cladding could be snagged and pulled
away from the polymer grate body. The height of the shoulder (208
in FIG. 11) and grout rim (210 in FIG. 11) can be selected so that
the elevation of the drain grate surface is slightly above the top
of the grout rim to help protect the grout rim from contact and
damage. The polymer drain grate body can include integral ribs and
other support structure (not shown) on its underside to give it
greater strength. The metal-clad polymer grate design reduces the
cost and weight of the drain grate, while still substantially
retaining the functional and aesthetic characteristics of the solid
metal drain grates described above.
[0055] The drain grate 250 shown in FIG. 13 can be easily removed
using a T-handle grate removal tool 262. This tool includes a
twist-fit shank 264 that can engage into the center drain aperture
266. The user inserts the shank end into the center aperture, and
twists the T-handle 268 to engage a shoulder thereon. Once the
T-handle is engaged, a user can easily remove the drain grate 250
by pulling on the T-handle. The opposite procedure is used to
insert the drain grate.
[0056] The drain body 200 depicted in FIGS. 11 and 12 can be
installed using a plug similar to the plug 116 shown in FIG. 10.
The plug has a generally continuous upper surface (140 in FIG. 10)
and is inserted into the inlet 202 in the same manner as a drain
grate. This plug remains in place during grouting and until the
grout has hardened and is able to stabilize the knife edge rim 210
of the drain body. The plug also serves to maintain a minimal and
uniform clearance around the drain grate by eliminating any
tendency for distortion during grouting.
[0057] Referring to FIG. 10, the plug 116 can include one or more
small tapered screw start holes 146 on its top surface 140. In the
embodiment shown in FIG. 10, the plug includes one screw start hole
146 in each of its four corners, and one in the center. Once the
grout has hardened sufficiently, the plug can be removed by driving
a screw (not shown) into one or more of the screw start holes on
the plug. A common grabber screw can be started into one or more of
the holes just enough to grip the plug so that it can be extracted
by pulling the screw by hand or using the claw of a hammer or some
other tool to remove the plug from the drain body.
[0058] Shown in FIG. 14 is a thin-set tray 300 that can be used to
interconnect a rectangular drain grate with a conventional circular
drain opening. This thin-set tray provides a drain body having many
of the same general parts as the drain body 200 shown in FIG. 11,
but with a thinner profile. The thin-set tray 300 comprises a drain
body having a circular lower outlet portion 302 that is configured
to mate with a circular opening of a drain structure. The upper
portion of the tray includes a rectangular shelf 304 that is
configured to support a rectangular drain grate, like those
discussed above. Surrounding the shelf is an integral grout rim 306
that has an outer tapered surface 308 that tapers to a sharp top
edge 310. The outer perimeter of the thin-set tray includes grout
locking features similar to those associated with the drain body of
FIG. 11. These can include buttresses 314 and darts 316 that have
tapered surfaces to help create a dovetail configuration to
interlock the tray into the surrounding grout.
[0059] The thin-set tray 300 provides an alternative design of a
drain body that incorporates many of the features of the drain body
of FIG. 11, discussed above, for applications where an attractive
rectangular grate is desired like those disclosed herein, but a
drain body having greater thickness like that disclosed herein is
not being used, or a different drain structure is already in place.
For example, such circumstances can arise where a drain fitting is
provided pre-installed into a shower floor assembly, or where a new
layer of tile is to be installed over an existing tile floor. In
such cases the thin-set tray can be installed like a piece of tile
to directly overlie a common round drain inlet, providing the
aesthetic advantages of the floor drain of this disclosure with a
thinner profile drain body. The thin-set tray embodiment can also
be used to provide small adjustments to the angle and position of
the grate.
[0060] This invention provides several advantages. It provides a
drain device that is easier to match with tile because it has
straight sides (i.e. no curved cutting required), and matches more
easily to the generally planar slope segments of a typical shower
floor. Since the drain body and grout rim has square corners, tile
can be cut to fit using saw cuts alone, with no grinding required
(e.g. to form a rounded or curved corner). The knife-edge metal rim
practically disappears, providing a more pleasing appearance than
thick metal or plastic rims of typical round grates. Additionally,
because the grate is not attached with fasteners, it can be easily
removed for protection from harsh cleansers or clog clearing
chemicals. This allows a variety of more delicate materials to be
used for the grate, and also allows easy replacement of the grate
for decorative reasons.
[0061] By way of example, and without limitation, the invention can
be described as a floor drain, including a drain body, a generally
rectangular drain grate supported by the drain body and having a
plurality of drain openings, and a grout rim supported by the drain
body and surrounding the drain grate. The drain body includes a
generally rectangular upper portion defining an inlet aperture, and
a circular lower portion defining an outlet in fluid communication
with the inlet aperture, the lower portion being configured to
interconnect to an underdrain structure. The grout rim has an
outside surface having interlocking structure configured to
interlock with surrounding materials, and a sharply tapered top
edge, configured to reduce the visibility of the grout rim between
the surrounding material and the grate.
[0062] As another example, the invention can be described as a
floor drain, including a drain body, a generally rectangular drain
grate supported by the drain body, and a grout rim supported by the
drain body and surrounding the drain grate. The drain body includes
a generally rectangular upper portion defining an inlet aperture,
and a circular lower portion defining an outlet in fluid
communication with the inlet aperture, the lower portion being
configured to interconnect to an underdrain structure. The drain
grate includes a plurality of drain openings and a plurality of
downwardly oriented mounting posts configured to insert into
receiving holes in the drain body, whereby the drain grate is
removably secured to the drain body.
[0063] As yet another example, the invention can be described as a
floor drain assembly, including a drain body having an outlet, a
generally rectangular drain grate supported by the drain body and
having a plurality of drain openings, a grout rim supported by the
drain body and surrounding the drain grate, and an underdrain inlet
attached to the outlet of the drain body. The drain body includes a
generally rectangular upper portion defining an inlet aperture, and
a circular lower portion defining an outlet in fluid communication
with the inlet aperture, the lower portion having helical threads
configured to threadedly interconnect with corresponding helical
threads of an underdrain structure, whereby a height of the inlet
can be adjusted by rotating the drain body about a central
axis.
[0064] It is to be understood that the above-referenced
arrangements are only illustrative of the application of the
principles of the present invention in one or more particular
applications. Numerous modifications and alternative arrangements
in form, usage and details of implementation can be devised without
the exercise of inventive faculty, and without departing from the
principles, concepts, and scope of the invention as disclosed
herein. Accordingly, it is not intended that the invention be
limited, except as set forth in the claims.
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