U.S. patent application number 12/868080 was filed with the patent office on 2011-03-03 for drain assembly.
Invention is credited to James Daniel Niedens.
Application Number | 20110047695 12/868080 |
Document ID | / |
Family ID | 43622652 |
Filed Date | 2011-03-03 |
United States Patent
Application |
20110047695 |
Kind Code |
A1 |
Niedens; James Daniel |
March 3, 2011 |
DRAIN ASSEMBLY
Abstract
A drain assembly includes a main body including a substantially
horizontal first wall extending in a longitudinal direction of the
main body, a drainage channel depending from the first wall and
extending in said longitudinal direction, a substantially vertical
second wall depending from the first wall and extending in the
longitudinal direction, and a first longitudinal end, the first
wall, the drainage channel, and the second wall together forming a
first attachment channel configured for receiving and attaching to
a first attachment feature of an end device at the first
longitudinal end.
Inventors: |
Niedens; James Daniel; (Fort
Wayne, IN) |
Family ID: |
43622652 |
Appl. No.: |
12/868080 |
Filed: |
August 25, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61237059 |
Aug 26, 2009 |
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Current U.S.
Class: |
4/679 |
Current CPC
Class: |
E03F 2005/0415 20130101;
E03F 5/04 20130101; E03F 5/0408 20130101 |
Class at
Publication: |
4/679 |
International
Class: |
E03C 1/12 20060101
E03C001/12 |
Claims
1. A drain assembly, comprising: a main body including a
substantially horizontal first wall extending in a longitudinal
direction of said main body, a drainage channel depending from said
first wall and extending in said longitudinal direction, a
substantially vertical second wall depending from said first wall
and extending in said longitudinal direction, and a first
longitudinal end, said first wall, said drainage channel, and said
second wall together forming a first attachment channel configured
for receiving and attaching to a first attachment feature of an end
device at said first longitudinal end.
2. The drain assembly of claim 1, wherein said main body includes a
substantially vertical third wall depending from said first wall,
extending in said longitudinal direction, and being spaced apart
from said second wall and said drainage channel, said drainage
channel being between said second and third walls, said first wall,
said drainage channel, and said third wall together forming a
second attachment channel configured for receiving and attaching to
a second attachment feature of said end device at said first
longitudinal end.
3. The drain assembly of claim 2, wherein said main body includes a
second longitudinal end opposing said first longitudinal end, and a
substantially vertical drainage device positioned between said
first and second longitudinal ends and intercepting said drainage
channel, said first and second attachment channels extending at
least substantially a first length running from said drainage
device to said first longitudinal end and a second length running
opposingly from said drainage device to said second longitudinal
end, said end device being selectively attachable to one of said
first longitudinal end and said second longitudinal end by way of
said first and second attachment features and said first and second
attachment channels.
4. The drain assembly of claim 3, wherein said first and second
attachment features of said end device are selectively positionable
between a first position and a second position along respectively
said first and second attachment channels, said first and second
attachment features occupying said second position when said first
length is selectively shortened by way of field cutting and thereby
when said first longitudinal end is moved from said first position
to said second position which is closer to said drainage device
than said first position.
5. The drain assembly of claim 4, wherein said first and second
attachment features are connected respectively to said first and
second attachment channels using an adhesive, each of said first
and second attachment features including two substantially vertical
fourth walls and a substantially horizontal fifth wall attached to
said fourth walls therebetween, said fourth walls being positioned
adjacent respectively said second wall, said third wall, and said
drainage channel, said fifth wall being positioned adjacent said
first wall.
6. The drain assembly of claim 5, wherein said end device is
selectively one of a floor endcap, a wall endcap, a linear junction
member configured for coupling said main body in a substantially
straight line with another said main body which is substantially
similar to said main body, and a corner member configured for
coupling said main body substantially perpendicularly with said
other main body, said first and second attachment features of each
of said floor endcap, said wall endcap, said linear junction
member, and said corner member being substantially identical and
thereby being selectively attached to said main body.
7. The drain assembly of claim 6, wherein said floor endcap
includes a substantially vertical sixth wall and a substantially
horizontal seventh wall attached to said sixth wall, said first and
second attachment features projecting from said sixth wall, said
sixth wall being positioned adjacent said first longitudinal
end.
8. The drain assembly of claim 6, wherein said wall endcap includes
a substantially vertical eighth wall, said first and second
attachment features projecting from said eighth wall, said eighth
wall being positioned adjacent said first longitudinal end.
9. The drain assembly of claim 6, further including said other main
body, said linear junction member including a substantially
horizontal span connecting said first and second attachment
features together, said linear junction member spanning a joint
formed by said main body and said other main body abutting one
another in an end-to-end manner, said span underlapping said
drainage channel of each of said main body and said other main
body.
10. The drain assembly of claim 6, further including said other
main body, said corner member including a substantially horizontal
ninth wall, two corner drainage channels angled perpendicularly
relative to one another and depending from said ninth wall, a
substantially vertical tenth wall depending from said ninth wall,
and a substantially vertical eleventh wall depending from said
ninth wall and angled perpendicularly relative to said tenth wall,
said first and second attachment features projecting from said
tenth wall, said eleventh wall including third and fourth
attachment features projecting therefrom and which are
substantially identical to said first and second attachment
features, said corner drainage channels being aligned respectively
with said drainage channel of said main body and said drainage
channel of said other main body, said first, second, third, and
fourth attachment features being received by and connected
respectively to said first and second attachment channels of said
main body and said other main body.
11. A method of using a drain assembly, comprising: providing a
drain assembly including a main body which includes a substantially
horizontal first wall extending in a longitudinal direction of said
main body, a drainage channel depending from said first wall and
extending in said longitudinal direction, a substantially vertical
second wall depending from said first wall and extending in said
longitudinal direction, and a first longitudinal end, said first
wall, said drainage channel, and said second wall together forming
a first attachment channel; receiving, by said first attachment
channel, a first attachment feature of an end device at said first
longitudinal end; and attaching said first attachment channel to
said first attachment feature at said first longitudinal end.
12. The method of claim 11, wherein said main body includes a
substantially vertical third wall depending from said first wall,
extending in said longitudinal direction, and being spaced apart
from said second wall and said drainage channel, said drainage
channel being between said second and third walls, said first wall,
said drainage channel, and said third wall together forming a
second attachment channel, the method further including receiving,
by said second attachment channel, a second attachment feature of
said end device at said first longitudinal end, and attaching said
second attachment channel to said second attachment feature at said
first longitudinal end.
13. The method of claim 12, wherein said main body includes a
second longitudinal end opposing said first longitudinal end, and a
substantially vertical drainage device positioned between said
first and second longitudinal ends and intercepting said drainage
channel, said first and second attachment channels extending at
least substantially a first length running from said drainage
device to said first longitudinal end and a second length running
opposingly from said drainage device to said second longitudinal
end, the method further including attaching selectively said end
device to one of said first longitudinal end and said second
longitudinal end by way of said first and second attachment
features and said first and second attachment channels.
14. The method of claim 13, further including positioning
selectively said first and second attachment features of said end
device between a first position and a second position along
respectively said first and second attachment channels, said first
and second attachment features occupying said second position when
said first length is selectively shortened by way of field cutting
and thereby when said first longitudinal end is moved from said
first position to said second position which is closer to said
drainage device than said first position.
15. The method of claim 14, wherein said first and second
attachment features are connected respectively to said first and
second attachment channels using an adhesive, each of said first
and second attachment features including two substantially vertical
fourth walls and a substantially horizontal fifth wall attached to
said fourth walls therebetween, said fourth walls being positioned
adjacent respectively said second wall, said third wall, and said
drainage channel, said fifth wall being positioned adjacent said
first wall.
16. The method of claim 15, wherein said end device is selectively
one of a floor endcap, a wall endcap, a linear junction member
coupling said main body in a substantially straight line with
another said main body which is substantially similar to said main
body, and a corner member coupling said main body substantially
perpendicularly with said other main body, said first and second
attachment features of each of said floor endcap, said wall endcap,
said linear junction member, and said corner member being
substantially identical, and thereby being selectively attached to
said main body.
17. The method of claim 16, wherein said floor endcap includes a
substantially vertical sixth wall and a substantially horizontal
seventh wall attached to said sixth wall, said first and second
attachment features projecting from said sixth wall, said sixth
wall being positioned adjacent said first longitudinal end.
18. The method of claim 16, wherein said wall endcap includes a
substantially vertical eighth wall, said first and second
attachment features projecting from said eighth wall, said eighth
wall being positioned adjacent said first longitudinal end.
19. The method of claim 16, wherein said linear junction member
includes a substantially horizontal span connecting said first and
second attachment features together, said linear junction member
spanning a joint formed by said main body and said other main body
abutting one another in an end-to-end manner, said span
underlapping said drainage channel of each of said main body and
said other main body.
20. The method of claim 16, wherein said corner member includes a
substantially horizontal ninth wall, two corner drainage channels
angled perpendicularly relative to one another and depending from
said ninth wall, a substantially vertical tenth wall depending from
said ninth wall, and a substantially vertical eleventh wall
depending from said ninth wall and angled perpendicularly relative
to said tenth wall, said first and second attachment features
projecting from said tenth wall, said eleventh wall including third
and fourth attachment features projecting therefrom and which are
substantially identical to said first and second attachment
features, said corner drainage channels being aligned respectively
with said drainage channel of said main body and said drainage
channel of said other main body, said first, second, third, and
fourth attachment features being received by and attached
respectively to said first and second attachment channels of said
main body and said other main body.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a non-provisional application based upon U.S.
provisional patent application Ser. No. 61/237,059, entitled "DRAIN
ASSEMBLY", filed Aug. 26, 2009, which is incorporated herein by
reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to drain assemblies, and, more
particularly, to linear drain assemblies.
[0004] 2. Description of the Related Art
[0005] Water drains can be used in many different applications. One
such application is a shower drain. A linear shower drain assembly
is known which includes a linear drain body including a horizontal
wall or flange from which a linear trough depends, the flange
surrounding the trough. The trough is pitched such that water
entering the trough drains from the longitudinal ends of the trough
downwardly towards a vertical, generally cylindrical outlet which
intercepts the trough and is wider in diameter than a width of the
trough. An integral waterproofing membrane is factory-attached to
the drain body around the whole perimeter of the trough. A
stainless steel strainer (a drain cover) covers the trough and is
coupled to the drain body during installation of the drain
assembly.
[0006] What is needed in the art is a drain assembly which is field
adjustable in length and can thus be selectively attached to at
least one of a plurality of end devices at a plurality of positions
along a length of at least one main body of the drain assembly.
SUMMARY OF THE INVENTION
[0007] The present invention provides a drain assembly which is
field adjustable in length and can thus be selectively attached to
at least one of a plurality of end devices at a plurality of
positions along a length of at least one main body of the drain
assembly.
[0008] The invention in one form is directed to a drain assembly
including a main body including a substantially horizontal first
wall extending in a longitudinal direction of the main body, a
drainage channel depending from the first wall and extending in
said longitudinal direction, a substantially vertical second wall
depending from the first wall and extending in the longitudinal
direction, and a first longitudinal end, the first wall, the
drainage channel, and the second wall together forming a first
attachment channel configured for receiving and attaching to a
first attachment feature of an end device at the first longitudinal
end.
[0009] The invention in another form is directed to a method of
using a drain assembly, the method including: providing a drain
assembly including a main body which includes a substantially
horizontal first wall extending in a longitudinal direction of the
main body, a drainage channel depending from the first wall and
extending in the longitudinal direction, a substantially vertical
second wall depending from the first wall and extending in the
longitudinal direction, and a first longitudinal end, the first
wall, the drainage channel, and the second wall together forming a
first attachment channel; receiving, by the first attachment
channel, a first attachment feature of an end device at the first
longitudinal end; and attaching the first attachment channel to the
first attachment feature at the first longitudinal end.
[0010] An advantage of the present invention is that it is
adjustable in length and can run continuously from wall-to-wall in
a shower. The drain assembly is adjustable in length in that (a)
the main body can be field cut (which can be readily accomplished
considering that the drain assembly is made of PVC, or any other
suitable material) to the desired length to reduce the length of
the drain assembly, or (b) a plurality of main bodies can be
coupled to one another in an end-to-end fashion, perpendicularly to
one another, and/or at any predetermined angular relationship
relative to one another (using junction members, corner members,
and/or, more generally, coupling members) and thereby increase the
overall length of the drain assembly (depending upon the
environment in which the drain assembly is installed, a main body,
then, can be field cut and also coupled with another main
body).
[0011] Another advantage of the present invention is that it
provides that the shower floor may be pitched in only one or two
directions; therefore, any size format tile on the shower floor is
possible. Stated differently, a large drain tile can be used with
the drain assembly of the present invention. For instance, 12
inch.times.12 inch or 16 inch.times.16 inch drain tiles can be used
with the drain assembly of the present invention. By removing extra
pitches/planes adjacent the drain assembly, a mosaic tile does not
have to be used. By way of comparison, the largest mosaic tile is
typically 3 inch.times.3 inch.
[0012] Yet another advantage of the present invention is that it is
designed to work with most of the primarily used, existing shower
floor systems already on the market. This allows the installers of
drains the ability to use their current system and techniques.
[0013] Yet another advantage of the present invention is that it
does not have a decorative drain cover (which can be in the form of
a decorative grill). Without a decorative cover, the drain tile of
the shower floor can come right next to the water channel of the
main body of the drain assembly. Further, the bathroom industry
overall is concerned with color coordination between such parts and
items like faucets, shower door hardware, etc. The absence of a
decorative drain cover allows the distributor the flexibility of
not having to stock multiple pieces and finishes, which is often
the source of warranty issues related to shower drains. Further,
the absence of a decorative drain cover made of metal allows the
drain assembly to be field cut as necessary by an installer of the
drain assembly.
[0014] Yet another advantage of the present invention is that it
does not necessarily provide that the waterproofing membrane is
already integrated with the drain assembly prior to installation.
Thus, the drain assembly can be field cut as necessary.
[0015] Yet another advantage is of the present invention is that it
provides that a drain screen can optionally by slid from the
underside into a substantially vertical drainage device of the main
body of the drain assembly, the drainage device being configured
for connecting to, for example, house plumbing.
[0016] Yet another advantage of the present invention is that it
allows for wheel-chair accessibility into a shower.
[0017] Yet another advantage of the present invention is that the
drain assembly does not include any steel or metallic parts.
[0018] Yet another advantage of the present invention is that the
drainage channel of the main body of the drain assembly can be
transversely cut therethrough when adjusting the length of the main
body, the end device then being able to be secured to the new
longitudinal end of the main body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The above-mentioned and other features and advantages of
this invention, and the manner of attaining them, will become more
apparent and the invention will be better understood by reference
to the following description of embodiments of the invention taken
in conjunction with the accompanying drawings, wherein:
[0020] FIG. 1 is a sectional view of a shower floor system
including a drain assembly according to the present invention, the
cross-section of the main body being taken along line 1-1 of FIG.
5;
[0021] FIG. 2 is a schematic view of a drain assembly according to
the present invention;
[0022] FIG. 3 is a perspective view of a drain assembly according
to another embodiment of the present invention, the main body of
the drain assembly being shown in FIG. 1;
[0023] FIG. 4 is a perspective view of the drain assembly of FIG.
3;
[0024] FIG. 5 is a bottom view of the main body of the drain
assembly of FIG. 3, the floor endcaps of FIG. 3 being broken
away;
[0025] FIG. 6 is a perspective, cross-sectional view of the main
body of the drain assembly of FIG. 5, the cross-section being taken
longitudinally through the top dead center of the main body along
line 6-6 of FIG. 5, a drain screen also being shown but not in
cross-section;
[0026] FIG. 7 is a perspective view of the floor endcap of FIG. 3,
the floor endcap being shown in relation to a subfloor;
[0027] FIG. 8 is a perspective view of a wall endcap according to
the present invention, the wall endcap being shown in relation to a
backerboard;
[0028] FIG. 9 is a perspective view of the wall endcap of FIG. 8
attached to the main body of FIG. 5, with portions of the main body
being broken away;
[0029] FIG. 10 is a bottom view of the drain assembly of FIG.
9;
[0030] FIG. 11 is a bottom view of the drain assembly of FIG. 10,
with a portion of the main body of FIG. 10 being broken away;
[0031] FIG. 12 is a perspective view of a linear junction member
according to the present invention;
[0032] FIG. 13 is a perspective view of the drain assembly
according to another embodiment of the present invention, the drain
assembly including the linear junction member of FIG. 12;
[0033] FIG. 14 is a perspective view of a corner member according
to the present invention;
[0034] FIG. 15 is a perspective view of the drain assembly
according to another embodiment of the present invention, the drain
assembly including the corner member of FIG. 14; and
[0035] FIG. 16 is a perspective view of the drain assembly of FIG.
15.
[0036] Corresponding reference characters indicate corresponding
parts throughout the several views. The exemplifications set out
herein illustrate embodiments of the invention, and such
exemplifications are not to be construed as limiting the scope of
the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
[0037] Referring now to the drawings, and more particularly to FIG.
1, there is shown a shower floor system 20 which generally includes
floor joists 22, a subfloor 24 (such as a three-quarter inch
plywood subfloor), a drain assembly 26 according to the present
invention, an underlayment 25 (which can be, for example, concrete
and serve to provide a slope, such as a two degree slope, of the
surrounding floor to drain assembly 26), a drain pipe 27 (such as a
two inch polyvinyl chloride drain pipe) which forms part of the
environment to which drain assembly 26 connects and can be, for
example, a part of house plumbing, a waterproofing membrane 28
(which can be painted on as a coating or can be a glued-on fabric
member, the glue being bought with the membrane fabric), and
ceramic floor tiles 30 mounted on top of the waterproofing membrane
28. As a fabric, waterproofing membrane 28 can have a seam (not
shown) running in longitudinal direction 52 and positioned over
subfloor 24. The structural features in FIG. 1 are not necessarily
proportioned to correct size. Drain assembly 26 can be a drain for
a shower, a pool, a sink, or the like. With regard to a swimming
pool, drain assembly 26 could be applied to the perimeter of the
swimming pool (this is provided merely by way of example and not be
way of limitation). The drain assembly 26 discussed herein is in
reference to a shower drain; this application of the drain assembly
of the present invention, however, is provided by way of example
and not by way of limitation. Drain assembly 26 is a slot/trough
drain which can be installed into a tiled shower floor.
[0038] FIG. 2 shows that drain assembly 26 includes at least one
main body 32 and at least one end device 34. Main body 32 can also
be referred to as a drain body. Main bodies 32 and end devices 34
of drain assembly 26 can be made of polyvinyl chloride, of another
polymer, or of any suitable material. In a shower application, for
example, main body 32 provides drainage for water accumulating or
falling on the shower floor (such as on tiles 30). As also shown in
FIG. 2, drain assembly 26 can include at least two main bodies 32
joined together by an end device 34, each terminating end of drain
assembly 26 also having attached thereto an end device 34.
Depending upon the application, drain assembly 26 can optionally
include three or more main bodies 32 coupled to one another in a
straight line and/or at right angles using end devices 34C or 34D;
such a coupling of three main bodies 32 could form a generally
U-shaped drain assembly 26, by way of example. Further, each main
body 32 can include two end devices 34 attached to the longitudinal
ends 36 of the respective main body 32, as shown in FIG. 2. End
device 34, as discussed below, refers generically to a floor endcap
34A, a wall endcap 34B, a linear junction member 34C, or a corner
member 34D.
[0039] Main body 32, as shown in FIGS. 3-6, is a linear structure
and includes a first longitudinal end 36 and a second longitudinal
end 38 opposing first longitudinal end 36. Main body 32 includes a
substantially horizontal first wall 40, a drainage channel 42, a
substantially vertical second wall 44, a substantially vertical
third wall 46, a substantially vertical drainage device 48, and
substantially vertical support walls 50. Main body 32 can be a
monolithic structure such that the main body 32 is a single piece
made of the same material (i.e., polyvinyl chloride). Main body 32
is not formed monolithically with, or formed attached to, any of
end devices 34; rather, end devices 34 (whichever ones are needed
according to the application) are attached during installation of
drain assembly 26 in a shower, for example, as disclosed herein.
Main body 32 can be formed by injection molding (floor end device
34A, wall end device 34B, linear junction member 34C, and corner
member 34D each can be formed as monolithic pieces and formed by
injection molding as well). Main body 32 can have a full length for
the transverse edge of first longitudinal end 36 to the transverse
edge of second longitudinal end 38 of sixty inches (five feet) from
the manufacturer.
[0040] First wall 40 extends in a longitudinal direction 52 of main
body, longitudinal direction 52 being shown by double arrow 52. As
shown in the drawings, first wall 40 can alternatively be viewed as
two distinct walls which are spaced apart by drainage channel 42;
however, for simplicity, first wall 40 is discussed herein as a
wall in the singular, but it is understood that first wall 40
includes first and second sections (which are shown but not
separately labeled in the drawings) which are coplanar relative to
one another and spaced apart from one another by drainage channel
42. First wall 40 is flat. First wall 40 includes a plurality of
fastener holes 54 which are spaced apart along both longitudinal
sides of first wall 40; fasteners (not shown), such as screws,
project respectively through fastener holes 54 and are used to
mechanically fasten main body 32 to subfloor 24. First wall 40
further includes two adhesive channels 56 (which are shallow
grooves formed into first wall 40) which extend in longitudinal
direction 52 and parallel to one another (adhesive channels 56 can
run from the transverse edge of first longitudinal end 36 to the
transverse edge of second longitudinal end 38), which are spaced
apart by drainage channel 42, and which are formed respectively on
the two sections of first wall 40. Adhesive channels 56 are shallow
and can be used to receive an adhesive to adhere waterproofing
membranes 28 to first wall 40.
[0041] Drainage channel 42 depends from first wall 40 and extends
in longitudinal direction 52. In depending from first wall 40,
drainage channel 42 extends below the bottom surface of first wall
40. As shown in FIGS. 1 and 3, drainage channel 42 is open facing
upwards and includes a generally U-shaped cross-section having two
substantially vertical walls 58 and a substantially horizontal
bottom wall 60 connecting and extending between the two vertical
walls 58. Drainage channel 42 can also be referred to as a slot or
trough. Drainage channel 42 is linear and runs at least
substantially from first longitudinal end 36 to second longitudinal
end 38, drainage channel 42 being intercepted by vertical drainage
device 48; more specifically, drainage channel 42 runs from the
transverse edge of first longitudinal end 36 to the transverse edge
of second longitudinal end 38, but for the break provided by
vertical drainage device 48. Drainage channel 42 is sloped; more
specifically, drainage channel 42 is sloped (angled/pitched)
downwardly running from first longitudinal end 36 to vertical
drainage device 48, and similarly drainage channel 42 is sloped
downwardly running from second longitudinal end 38 to vertical
drainage device 48 (drainage channel 42 runs the full length of
main body 32 except for being intercepted by vertical drainage
device 48). Drainage channel 42 is thus in fluid communication with
vertical drainage device 48. The slope of drainage channel 42
causes water, for example, entering drainage channel 42 to flow,
under the force of gravity, to vertical drainage device 48. As
such, drainage channel 42 thus provides a fluid flow path which
causes water which enters drainage channel 42 to flow downwardly in
drainage channel 42 to vertical drainage device 48; upon falling
into vertical drainage device 48, the water flows through drainage
device 48 and into the plumbing network of the environment into
which drain assembly 26 is installed (such as house plumbing, of
which drain pipe 27 is a part). FIG. 6 shows the sloped
configuration of drainage channel 42. It is understood that the
interior of the U-shaped channel can be formed such that the
corners where the vertical walls 58 meet horizontal wall 60 are
curved, rather than forming sharp right-angle corners. Tile 30 can
be laid adjacent drainage channel 42, as indicated in FIG. 1.
[0042] Second wall 44 depends from first wall 40 and extends in
longitudinal direction 52. In depending from first wall 40, second
wall 44 extends below the bottom surface of first wall 40. Second
wall 44 is attached to the bottom surface of first wall 40 and is
perpendicular to first wall 40. Second wall 44 is linear and runs
from the transverse edge of first longitudinal end 36 to the
transverse edge of second longitudinal end 38; a portion of second
wall 44 can merge with and form a part of drainage device 48.
Second wall 44 is spaced apart from and runs parallel to drainage
channel 42.
[0043] Third wall 46 is substantially identical to, and
substantially mirrors, second wall 44. Third wall 46 depends from
first wall 40, extends in longitudinal direction 52, and is spaced
apart from and parallel to second wall 44 and drainage channel 42,
drainage channel 42 being between second and third walls 44, 46. In
depending from first wall 40, third wall 46 extends below the
bottom surface of first wall 40. Third wall 46 is attached to the
bottom surface of first wall 40 and is perpendicular to first wall
40. Third wall 46 is linear and runs from the transverse edge of
first longitudinal end 36 to the transverse edge of second
longitudinal end 38; a portion of third wall 46 can merge with and
form a part of vertical drainage device 48.
[0044] First wall 40, drainage channel 42, and second wall 44
together form a first attachment channel 62. First attachment
channel 62 is configured for receiving and attaching to a first
attachment feature 66 of end device 34 at first longitudinal end 36
(more specifically, at the transverse edge of first longitudinal
end 36). First attachment channel 62 is also configured for
receiving and attaching to an attachment feature 66 (first and
second attachment features 66 of each of end devices 34A, 34B, 34C,
34D are substantially identical) of end device 34 at second
longitudinal end 38 (more specifically, at the transverse edge of
second longitudinal end 38). First attachment channel 62 has a
generally U-shaped cross-section. While drainage channel 42 is an
upwardly facing U-shaped channel (the open portion of the U faces
upwardly), first attachment channel 62 is a downwardly facing
U-shaped channel (the open portion of the U faces downwardly).
First attachment channel 62 is formed by the bottom surface of
first wall 40, an outwardly facing surface of one vertical wall 58
of drainage channel 42, and an inwardly facing surface of second
wall 44. First attachment channel 62 can also be referred to as a
slot or trough. First attachment channel 62 is linear and runs at
least substantially from the transverse edge 37 of first
longitudinal end 36 to the transverse edge 37 of second
longitudinal end 38; first attachment channel 62 can run from the
transverse edge of first longitudinal end 36 to the transverse edge
of second longitudinal end 38 except for being interrupted by
vertical drainage device 48, as shown in FIGS. 3-6. Thus, first
attachment channel 62 extends at least substantially a first length
68 running from vertical drainage device 48 to first longitudinal
end 36 and a second length 70 running opposingly from vertical
drainage device 48 to second longitudinal end 38. Similarly, first
attachment channel 62 can be interrupted periodically by support
walls 50, as shown in FIGS. 4-6. Even with these interruptions by
vertical drainage device 48 and support walls 50, it is understood
that first attachment channel 62 runs at least substantially from
the transverse edge of first longitudinal end 36 to the transverse
edge of second longitudinal end 38.
[0045] First wall 40, drainage channel 42, and third wall 46
together form a second attachment channel 64. Second attachment
channel 64 is configured for receiving and attaching to a second
attachment feature 66 of end device 34 at first longitudinal end 36
(more specifically, at the transverse edge of first longitudinal
end 36). Second attachment channel 64 is also configured for
receiving and attaching to an attachment feature 66 (first and
second attachment features 66 of each of end devices 34A, 34B, 34C,
34D are substantially identical) of end device 34 at second
longitudinal end 38 (more specifically, at the transverse edge of
second longitudinal end 38). Second attachment channel 64 has a
generally U-shaped cross-section. While drainage channel 42 is an
upwardly facing U-shaped channel (the open portion of the U faces
upwardly), second attachment channel 66 is a downwardly facing
U-shaped channel (the open portion of the U faces downwardly).
Second attachment channel 66 is formed by the bottom surface of
first wall 40, an outwardly facing surface of one vertical wall 58
of drainage channel 42, and an inwardly facing surface of third
wall 46. Second attachment channel 64 can also be referred to as a
slot or trough. Second attachment channel 64 is linear and runs at
least substantially from the transverse edge of first longitudinal
end 36 to the transverse edge of second longitudinal end 38; second
attachment channel 64 can run from the transverse edge 37 of first
longitudinal end 36 to the transverse edge 37 of second
longitudinal end 38 except for being interrupted by vertical
drainage device 48, as shown in FIGS. 3-6. Thus, second attachment
channel 64 extends at least substantially first length 68 running
from vertical drainage device 48 to first longitudinal end 36 and
second length 70 running opposingly from vertical drainage device
48 to second longitudinal end 38. Similarly, second attachment
channel 64 can be interrupted periodically by support walls 50, as
shown in FIGS. 4-6. Even with these interruptions by vertical
drainage device 48 and support walls 50, it is understood that
second attachment channel 64 runs at least substantially from the
transverse edge of first longitudinal end 36 to the transverse edge
of second longitudinal end 38. Second attachment channel 64 is
substantially identical to, and substantially minors, first
attachment channel 62. Second attachment channel 64 is spaced apart
from and parallel to first attachment channel 62. Each end device
34 is selectively attachable to one of first longitudinal end 36
and second longitudinal end 36 by way of first and second
attachment features 64, 66 and first and second attachment channels
64, 66. First and second attachment channels 64, 66, each of which
can be referred to as slots, are thus formed on the underside of
main body 32.
[0046] Vertical drainage device 48 is positioned between first and
second longitudinal ends 36, 38 and intercepts drainage channel 42.
Vertical drainage device 48 is in fluid communication with drainage
channel 42; more specifically, vertical drainage device 48 is in
fluid communication with both wings of drainage channel 42 (each
wing running from a respective longitudinal end 36, 38 to vertical
drainage device 48). FIGS. 4 and 5 show that vertical drainage
device 48 can have a generally circular cross-section (a
cylindrical piece) with a stepped diameter, vertical drainage
device 48 being attached to drain pipe 27 of the surrounding
environment (i.e., house plumbing). The stepped diameter of
vertical drainage device 48 forms a shoulder 72 which provides a
stop for stopping house drain pipe 27 and thus ensuring proper
fitting of house drain pipe 27. Vertical drainage device 48 can be
glued to the house drain 27 using, for example, a standard
polyvinyl chloride rubber cement. Vertical drainage device 48
serves as a liquid outlet for main body 32 and thus for drain
assembly 26.
[0047] FIG. 6 shows a drain screen 74 which can be included as part
of the drain assembly 26 according to the present invention. FIG. 6
shows main body 32 with a cross-sectional slice taken through the
top dead center of main body 32. FIG. 6 shows drain screen 74
installed into vertical drainage device 48 of main body 32, drain
screen 74 not being shown in section. Drain screen 74 abuts
shoulder 72 (which provides the stepped diameter of the vertical
drainage device 48) of the vertical drainage device 48. The drain
screen 74 is an optional structural feature of drain assembly 26 of
the present invention; as such, drain screen 74 does not have to be
used as a part of drain assembly 26. Vertical drainage device 48
can be formed longer when drain screen 74 is used, as opposed to
when drain screen 74 is not used. Drain screen 74 (which can be
variously referred to as a grate, a strainer, or a drain guard)
serves as a screen to prevent objects of a predetermined size from
draining into the drain pipe 27 of the surrounding environment.
Drain screen 74 is not a decorative cover, such a decorative cover
being omitted from the present invention; on the other hand, drain
screen 74 can include decorative aspects. Drain screen 74 can be
made of the same material (or another material) as the remaining
portions of drain assembly; drain screen 74 can be made of
polyvinyl chloride. Drain screen 74 can be formed as a separate
piece relative to main body 32; in other words, drain screen 74 may
not be formed integral or molded with main body 32 but may be an
add-on piece relative to main body 32. Alternatively, drain screen
74 can be formed integral with (i.e., molded with) main body 32. As
a separate piece, however, drain screen 74 can be slid into
vertical drainage device 48--by way of the bottom opening of
vertical drainage device 48--until drain screen abuts shoulder 72
of vertical drainage device 48. Drain screen 74 is thus sandwiched
on one side by shoulder 72 of vertical drainage device 48 and on
the other side by the drain pipe 27 of the environment; drain
screen 74 is thereby held in place.
[0048] Main body 32 includes a plurality of substantially vertical
support walls 50. Support walls 50 depend from first wall 40 and
thus are attached to and extend below the bottom surface of first
wall 40. Support walls 50 are parallel relative to one another and
are perpendicular to second wall 44, third wall 46, and drainage
channel 42. Each support wall 50 runs from the inwardly facing
surface of second wall 44 to the outwardly facing surface of one
vertical wall 58 of drainage channel 42 and then from the outwardly
facing surface of the other vertical wall 58 of drainage channel 42
to the inwardly facing surface of third wall 46. Support walls 50
do not traverse through drainage channel 42, as this would form a
blockage within drainage channel 42. Each support wall 50 is the
same height as second and third walls 44, 46. Support walls 50
provide structural support and reinforcement to second wall 44,
third wall 46, and drainage channel 42.
[0049] As shown in FIGS. 2-4, 9-11, 13, and 15-16, end devices 34A,
34B, 34C, 34D attach individually to first and second longitudinal
ends 36, 38 of main body 32 during installation of drain assembly
26 in the surrounding environment, such as a shower. Stated another
way, any of end devices 34A, 34B, 34C, 34D can be selectively
attached to first longitudinal end 36 or second longitudinal end
38, depending upon the needs of the installer during installation
of drain assembly 26. For example, main body 32 can have end device
34A attached to first longitudinal end 36 and end device 34B
attached to second longitudinal end 38. On the other hand, end
device 34B can be attached to first longitudinal end 36, and end
device 34A can be attached to second longitudinal end 38. Or, end
device 34C can be attached to first longitudinal end 36, and end
device 34D can be attached to second longitudinal end 38. End
devices 34A, 34B, 34C, 34D, first and second longitudinal ends 36,
38 (along with first and second attachment channels 62, 64) can be
selectively attached to one another in any combination, depending
upon the needs of the installer. End devices 34C and 34D are not
connectors for strainers; rather end devices 34C and 34D serve as
connectors for main bodies 32.
[0050] End device 34 is selectively one of a floor endcap 34A, a
wall endcap 34B, a linear junction member 34C, and a corner member
34D. Each end device 34 has two attachment features 66, which can
be referred to as first and second attachment features 66. First
and second attachment features 66 themselves are substantially
identical to one another. Further, first and second attachment
features 6 of each of floor endcap 34A, wall endcap 34B, linear
junction member 34C, and corner member 34D are substantially
identical to one another and are thereby selectively attached to
main body. In other words, any of end devices 34A, 34B, 34C, 34D
can be attached to main body 32 using first and second attachment
features 66. First attachment feature 66 can attach to first
attachment channel 62 or second attachment channel 64, depending
upon whether the respective end device 34 is attached to first or
second longitudinal end 36, 38. Similarly, second attachment
feature 66 can attach to first attachment channel 62 or second
attachment channel 64, depending upon whether the respective end
device 34 is attached to first or second longitudinal end 36, 38.
Thus, first and second attachment features 66 are connected
respectively to first and second attachment channels 62, 64.
Further, first and second attachment features 66 are connected
respectively to first and second attachment channels 62, 64 using
an adhesive therebetween; thus, end devices 34A, 34B, 34C, 34D can
be directly glued to first and second attachment channels 62, 64. A
primer can first be applied to end device 34, particularly to
attachment features 66 and the areas of end device 34 surrounding
attachment features 66 which are likely to come into contact with
main body 32 when end device 34 is connected to main body 32; the
primer can also be applied to the respective longitudinal end 36,
38 of main body 32 in the areas which are expected to come into
contact with end device 34. After priming main body 32 and end
device 34 as described, a glue can be applied to the same areas of
main body 32 and end device 34. Then, end device 34 can be attached
and thus adhered to main body 32. The primer used can be a standard
PVC/ABS primer to clean main body 32 and end device 34; for
example, the primer can be Weld-On.RTM. P-68 Primer by IPS Corp.,
the primer softening and preparing a polyvinyl chloride (PVC)
fitting surface, for example. The adhesive used can be a standard
all-purpose clear PVC cement to welt main body 32 and end device 34
together (the adhesive can also be described as a standard PVC
rubber cement); for example, the adhesive can be a heavy duty clear
PVC cement by Oatey. The adhering action provided by this adhesive
can provide a chemical weld such that the respective parts of main
body 32 and end device 34 heat up and melt the two plastic pieces
together permanently (i.e., main body 32 and end device 34 being
made of polyvinyl chloride in one embodiment of the invention).
Alternatively or in addition thereto, first and second attachment
features 66 can form an interference fit with first and second
attachment channels. The installer of drain assembly 26 can apply
the primer and adhesive to attachment features 66, to attachment
channels 62, 64, and to the entire respective longitudinal end 36,
38 (including the respective transverse edge 37 of longitudinal end
36, 38, transverse edge 37 formed by first wall 40, drainage
channel 42, second wall 44, and third wall 46) during installation
and then attach the respective end device 34 to the respective
longitudinal end 36, 38.
[0051] Each of first and second attachment features 66 are
generally U-shaped and are matingly received in first and second
attachment channels 62, 64, the U-shape being upside down like
first and second attachment channels 62, 64. Each of first and
second attachment features 66 includes two substantially vertical
fourth walls 76 and a substantially horizontal fifth wall 78
attached to fourth walls 76 therebetween. Fourth walls 76 are
positioned adjacent respectively second wall 44, third wall 46, and
drainage channel 42, fifth wall 78 being positioned adjacent first
wall 40. More specifically, when end device 34 is placed on first
longitudinal end 36 in first and second attachment channels 62, 64,
one fourth wall 76 of first attachment feature 66 is adjacent the
inwardly facing surface of second wall 44, the other fourth wall 76
of first attachment feature 66 is adjacent the outwardly facing
surface of one vertical wall 58 of drainage channel 42, fifth wall
78 of first attachment feature 66 is adjacent the bottom surface of
first wall 40, one fourth wall 76 of second attachment feature 66
is adjacent the inwardly facing surface of third wall 46, the other
fourth wall 76 of second attachment feature 66 is adjacent the
outwardly facing surface of one vertical wall 58 of drainage
channel 42, and fifth wall 78 of second attachment feature 66 is
adjacent the bottom surface of first wall 40. The adhesive between
these walls of the attachment features 66 and these walls of main
body 32 secures these walls together. A similar attachment (albeit
turned around in orientation) of first and second attachment
features 66 can occur on second longitudinal end 38.
[0052] As shown in FIGS. 3-4 and 7, floor endcap 34A includes a
substantially vertical sixth wall 80 and a substantially horizontal
seventh wall 82 attached to sixth wall 80. First and second
attachment features 66 project from sixth wall 80. Sixth wall 80 is
positioned adjacent first longitudinal end 36 (or, optionally,
second longitudinal end 38). Seventh wall 82 can be attached to
subfloor 24, as indicated in FIG. 7 (alternatively or in addition
thereto, seventh wall 82 can be supported by underlayment 25, such
as concrete). Seventh wall 82 can be positioned flush and level
with first floor 40 of main body 32. Seventh wall 82 includes a
plurality of fastener holes 54 for receiving fasteners (such as
screws, which are not shown) to connect floor endcap 34A to
subfloor 24. Floor endcap 34A provides a seal between main body 32
(or at least an extension of main body 32) and the associated
surrounding structure (i.e., the subfloor, the shower base floor
(such as the underlayment 25)). Sixth and/or seventh walls 80, 82
can be formed thicker or thinner as desired; a thicker sixth and/or
seventh wall 80, 82 can provide greater rigidity. Because drainage
channel 42 proceeds all the way to transverse edge 37 of
longitudinal ends 36, 38, wall 60 of drainage channel 42 is always
lower than the top surface of first wall 40 and is thus open
extending longitudinally on longitudinal ends 36, 38; vertical
sixth wall 80 of floor endcap 34A closes this opening and thus
encloses drainage channel 42 along its vertical boundaries and thus
further prevents water from falling off the longitudinal ends 36,
38 of main body 32. Main body 32 can thus also be cut
advantageously transversely through drainage channel 42 along
virtually any point along drainage channel 42, sixth wall 84 then
enclosing the longitudinal ends of drainage channel 42.
[0053] As shown in FIGS. 8, 9-11, and 13, wall endcap 34B includes
a substantially vertical eighth wall 84. First and second
attachment features 66 project from said eighth wall 84. Eighth
wall 84 is positioned adjacent first longitudinal end 36 (or,
optionally, second longitudinal end 38). Eighth wall 84 can be
attached to house framing structure (such as a stud) and/or to
additional blocking (i.e., additional two inch.times.four inch
wood) attached to the house framing structure (not shown) in a
cutout 104 formed in backerboard 86 (such as drywall used on a
shower wall to which shower wall tiles can be directly or
indirectly affixed). Eighth wall 84 and first wall 40 abut one
another perpendicularly. Wall endcap 34B provides a seal between
main body 32 (or at least an extension of main body 32) and the
associated surrounding structure (i.e., the backerboard 86). Eighth
wall 84 can be formed thicker or thinner than as shown in FIG. 8,
depending upon the application. For instance, eighth wall 84 can be
formed to be as thick as the thickness of backerboard 86 (eighth
wall 84 is shown as being thinner than backboard 86 in FIG. 8).
Thus, the thickness of eighth wall 84 can coincide with the
backerboard 86 of the environment. A thicker eighth wall 84 can
provide greater rigidity and can facilitate installation. When wall
endcaps 34B, for instance, are used on the longitudinal ends 36, 38
of a drain assembly 26, drain assembly 26 can run from wall-to-wall
in the shower; as such, the shower floor need pitch in at most only
two directions (pitching only towards the longitudinal sides of
main body 32). Eighth wall 84 of wall endcap 34B includes fastener
holes 54 for receiving fasteners (not shown), such as screws, to
attach wall endcap 34B to the building studs and/or blocking that
is added to the house framing during installation of drain assembly
26. Vertical eighth wall 84 wall 80 of wall endcap 34B closes the
opening at the longitudinal ends 36, 38 of drainage channel 42 and
thus encloses drainage channel 42 along its vertical boundaries and
thus further prevents water from falling off the longitudinal ends
36, 38 of main body 32. Main body 32 can thus also be cut
advantageously transversely through drainage channel 42 along
virtually any point along drainage channel 42, eighth wall 84 then
enclosing the longitudinal ends of drainage channel 42.
[0054] As shown in FIGS. 12 and 13, linear junction member 34C is
configured for coupling, and does couple, one main body 32 in a
substantially straight line with another main body 32 (as shown in
FIG. 13), both main bodies 32 being substantially similar to one
another (as described above). By stating that both main bodies 32
are substantially similar to one another, this means that the main
bodies 32 have the same design, but it is understood that one can
be shorter than the other; this can occur, for example, during
installation when one main body 32 needs to be shortened for the
application by field cutting off a portion of that main body 32.
Field cutting refers to cutting of the main body 32 by an installer
who is installing drain assembly 26 in, for example, a shower, as
opposed to any cutting that may occur at the manufacturer's
facility. Main body 32 can be field cut using a square cut miter
box to ensure a smooth square cut. Linear junction member 34C
includes a substantially horizontal span 88 connecting first and
second attachment features 66 together. Linear junction member 34C
spans a joint 90 formed by the two main bodies 32 which abut one
another in an end-to-end manner. Span 88 underlaps drainage channel
42 of each of these main bodies 32. First and second attachment
features 66 of linear junction member 34C can be adhered to first
and second attachment channels 62, 64 of each of the two main
bodies 32 with the adhesive therebetween; alternatively or in
addition thereto, first and second attachment features 66 can form
an interference fit with first and second attachment channels 62,
64 of each of the two main bodies 32. Thus, drain assembly 26 can
optionally be lengthened by coupling two main bodies 32 together in
end-to-end fashion using linear junction member 34C. In so coupling
two main bodies 32 together, the adjacent drainage channels 42 of
the two main bodies 32 are aligned with one another and slope
downwardly running away from joint 90; as such, separate vertical
drainage devices 48 of the respective two main bodies 32 can be
used to remove the water from the shower. Linear junction member
34C thus attaches to the respective undersides of the two main
bodies 32 and further spans the two main bodies 32. Linear junction
member 34C thus can be used to attach two five feet main bodies 32
together to form a linear drain assembly 26 which is ten feet long,
this drain assembly 26 having a continuous drainage channel 42 the
entire length of drain assembly (but for the holes formed by the
respective drainage devices 48 in the two main bodies 32). Main
body 32 can thus also be cut advantageously transversely through
drainage channel 42 along virtually any point along drainage
channel 42.
[0055] As shown in FIGS. 14-16, corner member 34D is configured for
coupling, and does couple, one main body 32 substantially
perpendicularly with another main body 32, both main bodies 32
being substantially similar to one another (as described above).
Corner member 34D includes a substantially horizontal ninth wall
92, two corner drainage channels 94 angled perpendicularly relative
to one another and depending from said ninth horizontal wall 92, a
substantially vertical tenth wall 94 depending from said ninth wall
92, and a substantially vertical eleventh wall 98 depending from
said ninth wall 92 and angled perpendicularly relative to said
tenth wall 96. Ninth wall 92 is functionally equivalent to first
wall 40. Ninth wall 92 defines a plurality of fastener holes 54 so
that fasteners, such as screws (not shown), can fasten corner
member 34D to subfloor 24. Ninth wall 92 also includes adhesive
channels 56 on both sides of corner drainage channels 94 and thus
angled perpendicularly relative to one another. Corner drainage
channels 94 are functionally equivalent to drainage channel 42 of
main body 32. Corner drainage channels 94 angle downwardly running
from the place where corner drainage channels 94 connect with one
another. Thus, at least a portion of corner drainage channels 94
are positioned below ninth wall 92. Because corner drainage
channels 94 are angled this way, water in one corner drainage
channel 94 runs away from water in the other corner drainage
channel 94 (at a right angle). Corner drainage channels 94 are
aligned respectively with drainage channels 42 of the two main
bodies 32 which are coupled together by way of corner member 34D;
stated another way, corner drainage channels 94 merge with and form
corresponding slopes with drainage channels 42 of the two main
bodies 32 which are coupled together using corner member 34D such
that water flows, under the force of gravity, away from corner
member 34D to the main bodies 32. Drain assembly 26 thus provides
that water flows from corner member 34D to respective vertical
drainage devices 48 of the two main bodies 32. Thus, corner member
34D provides for drainage of water from a shower floor, in a shower
application for example. First and second attachment features 66
project from tenth wall 96. Eleventh wall 98 includes third and
fourth attachment features 66 which project therefrom and which are
substantially identical to first and second attachment features 66.
First, second, third, and fourth attachment features 66 are
received by and connected respectively to first and second
attachment channels 62, 64 of the two main bodies 32 on the
underside of the main bodies 32. Tenth and eleventh walls 96, 98
abut against second and third walls 44, 46 of the two main bodies
32. First, second, third, and fourth attachment features 66 can
thus be adhered to first and second attachment channels 62, 64 of
the two main bodies 32 using the adhesive described above;
alternatively or in addition thereto, first, second, third, and
fourth attachment features 66 can form an interference fit with
first and second attachment channels 62, 64 of the two main bodies
32. Thus, two main bodies 32 can be coupled together at a right
angle to one another using corner member 34D. Corner member 34D can
be placed anywhere where drain assembly 26 needs to be extended at
a right angle (i.e., in the corner of a shower). Corner member 34D
thus provides for a smooth transition between drainage channel 42
and corner drainage channel 94 or provides a vertical wall 96, 98
for enclosing the respective drainage channel 42. Main body 32 can
thus also be cut advantageously transversely through drainage
channel 42 along virtually any point along drainage channel 42.
[0056] First and second attachment features 66 of any of the end
devices 34 (as well as third and fourth attachment features 66 of
corner member 34D) are selectively positionable between a first
position 100 and a second position 102 along respectively first and
second attachment channels 62, 64 of a respective main body 32.
First position 100 corresponds to end device 34 being attached to
first longitudinal end 36 when that portion of main body 32
extending between vertical drain device 48 and the longitudinal end
36, 38 to which end device 34 is to be attached has not yet been
field cut. In other words, first longitudinal end 36 extends the
same distance from vertical drainage device 48 as main body 32 was
provided by the manufacturer of main body 32. Second position 102
corresponds to end device 34 being attached to first longitudinal
end 36 when that portion of main body 32 extending between vertical
drain device 48 and the longitudinal end 36, 38 to which end device
is to be attached has been field cut. In other words, because of
the field cutting of main body 32, the distance between vertical
drainage device 48 and first longitudinal end 36 has shortened and,
thus, first longitudinal end 36 has effectively moved from its
original position (that is, first position 100) as provided by the
manufacturer to an alternate position (that is, second position
102) as determined by the installer. Thus, first and second
attachment features 66 (or third and fourth attachment features of
corner member 34D) occupy second position 102 when first length 68
is selectively shortened by way of field cutting and thereby when
first longitudinal end 36 is moved from first position 100 to
second position 102, second position 102 being closer to vertical
drainage device 48 than first position 100. Because first and
second attachment channels 62, 64 run all the way from first
longitudinal end 36 (as provided by the manufacturer) to vertical
drainage device 48, second position 102 can be located anywhere
between the first position 102 and adjacent vertical drainage
device 48 (allowing enough space for first and second attachment
features 66 to fully join with first and second attachment channels
62, 64), except where a support wall 50 may interfere with
connecting first and second attachment features 66 with first and
second attachment channels 62, 64; in such an instance, the cut
along main body 32 has to be made in such a place that first and
second attachment features 66 can fully join with first and second
attachment channels 62, 64, without interference by a support wall
50. It is understood that such attachment of end devices 34 and
shortening of main body 32 can occur also on second longitudinal
end 38 of main body 32. It is further understood that, for example,
a main body 32 can be shortened on one longitudinal end 36, 38 by
field cutting and, on the other longitudinal end 36, 38, attached
to a linear junction member 34C or a corner member 34D so as to
lengthen the drain assembly 26 in that direction by coupling the
main body 32 to another main body 32, which itself can be shortened
and/or again coupled to another main body 32, as the application
dictates.
[0057] In use, as the installation requires, end device 34A, 34B,
34C, 34D is selectively attached to main body 32 before main body
32 is placed in position relative to subfloor 24. Subfloor 24 can
be plywood or concrete. End device 34 is glued to main body 32
using attachment features 66 and attachment channels 62, 64 in that
attachment features 66 are positioned in corresponding attachment
channels 62, 64 on the longitudinal end 36, 38 of main body 32. If
end device 34C or 34D is used, the second main body 32 can be
attached to the first main body 32 before or after the first main
body 32 is in position relative to subfloor 24 as the application
permits. In placing main bodies 32 in position on subfloor 24,
vertical drainage device 48 is attached to the house drain pipe 27
and glued thereto. If drain screen 74 is used, drain screen 74 is
securely sandwiched between shoulder 72 and house drain pipe 27.
Fasteners (not shown), such as screws, can be placed in any
fastening holes 54 of main bodies 32 and/or end devices 34 and
fastened to subfloor 24. Shims can be used to level drain assembly
26. An adhesive can be applied to adhesive channels 56. End devices
34 can be secured to surrounding environmental structure as
described above. Waterproofing membranes 28 can then be glued to
the top surface of main bodies 32 using the glue the installer
places in adhesive channels 56 (optionally, waterproofing membrane
28 can be a coating which is painted on). Underlayment 25 can be
used to form the appropriate slope towards drain assembly 26;
underlayment 25 can be concrete or another material. Ceramic tile
30 (such as relatively large ceramic tile 30) can be secured to the
waterproofing membrane. While FIG. 1 shows the end of tile 30
nearest drainage channel being curved, it is understood that this
portion of tile 30 can be formed by one or more angled straight
edges (for instance, a vertical straight edge proceeding from the
bottom edge of tile 30 being connected to an angled straight edge
which connects to the top edge of tile 30). End devices 34 can be
applied to any longitudinal end 36, 38 in any combination of end
devices 34, as the installation requires. If the installation
requires shortening one or more main bodies 32, the installer can
field cut one or more longitudinal ends 36, 38 of a respective main
body 32 in a direction perpendicular to longitudinal direction 52
and in a location such that support walls 50 or vertical drainage
device 48 do not inhibit securely attaching attachment features 66
to attachment channels 62, 64. Main body 32, having longitudinally
extending attachment channels 62, 64, can be field cut along
virtually the entirety of first length 68 and/or second length 70
of main body 32. A square cut miter saw can be used to field cut
main body 32.
[0058] One specific installation process can be described relative
to installing drain assembly 26 into a concrete subfloor 24, drain
assembly 26 including one main body 32 and wall endcaps 34B
attached to each longitudinal end 36, 38. Concrete subfloor 24 can
be prepared (broken so as to form appropriate holes therein) to
receive drain assembly relative to house drain pipe 27. The PVC
riser formed by house drain pipe 27 can be cut flush with the rough
floor covering. The location for drain assembly 26 can be measured
off of each wall/curb relative to house drain pipe 27. One or more
respective longitudinal ends 36, 38 of main body 32 can be field
cut by the installer so that main body 32 is cut to size (using a
square cut miter box) according to the measurements taken; main
body 32 should be cut a distance (possibly one-half inch, depending
upon the thickness of eighth wall 84) less than the original
measurement, this distance accounting for the thickness of the
backerboard 86. The gap between the respective longitudinal end 36,
38 and the house framing structure allows for the installation of
wall endcap 34B. Wall endcap 34B can be attached to the respective
longitudinal end 36, 38 (without yet applying any primer or glue)
to verify a tight fit of wall endcap 34B to longitudinal end 36,
38. Primer can be applied liberally to appropriate places of wall
endcap 34B and main body 32, as described above. Then, adhesive can
be applied liberally to appropriate places of wall endcap 34B and
main body 32, as described above. Upon adhering wall endcaps 34B to
main body 32, drain assembly 26 is ready to be installed. Upon
placing drain assembly 26 on drain pipe 27, drain assembly 26 can
be leveled using shims; drain assembly 26 must be installed level
for proper performance. Drain assembly 26 can be installed by
gluing drain assembly 26 (specifically, drainage device 48)
directly to drain pipe 27 and, optionally, screwing down to the
floor main body 32 using fastener holes 54 at a pre-drilled
location (such fasteners are not always needed, such as if concrete
is used under longitudinal sides of first wall 40 and the concrete
levels drain assembly 26). The shower wall backerboard 86 can now
be prepared. The backerboard 86 (which can also be considered to be
drywall) is to be placed over the wall studs. Prior to doing so,
the backerboard 86 needs to be cut so as to form a cutout 104 at
the base of the backerboard 86, this cutout 104 shaped to receive
eighth wall 84 of wall endcap 34B with little space between
backerboard 86 and eighth wall 84; thus, the backerboard 86 of
choice can be cut so as to leave a cutout 104 (which can also be
referred to as a notch) the size of wall endcap 34B. Wall endcap 34
can be secured to additional blocking (additional 2 inch.times.4
inch pieces attached to house framing structure) using fasteners
through fastener holes 54 (formed in eighth wall 84 by the
manufacturer of wall endcap 34B) of wall endcap 34B, but the use of
such fasteners is not always absolutely necessary. The backerboard
86 can now be installed per the manufacturer's recommendation. The
cutout 104 formed in the backerboard 86, in conjunction with the
size of eighth wall 84 (which can be formed wider than a transverse
extent of main body 32), keeps water from coming in contact with
the backerboard 86 and wicking up into the backerboard 86; thus,
wall endcap 34 isolates backerboard 86 so that water from drainage
channel 42 does not come into contact with the backerboard 86. It
is noted that eighth wall 84 forms the vertical enclosing endwall
for drainage channel 42; in other words, without eighth wall 84
being attached to longitudinal end 36, 38, then drainage channel 42
would have no way of stopping water from falling off the
longitudinal end 36, 38 of main body in drainage channel 42 other
than the sloped walls 60 of drainage channel 42 (unless additional
efforts were taken to provide some sort of vertical wall for
drainage channel 42). The shower base mud (concrete material) of
choice can be used to create a flat sloped floor with at least two
percent grade to allow for water to flow to main body 32. This mud
can be leveled off and allowed to cure so as to form the
underlayment 25. One-inch painters tape can be used to cover and
thereby protect drainage channel 42 and drainage opening 48 while
applying this mud and also while installing the waterproofing
system. Once this sloped floor is dried, the sloped floor is ready
for waterproofing. Fiberglass mesh tape can be used to cover over
the top of eighth wall 84 (the portion sitting within the cutout
104 of the backerboard 86) and the transition to the backerboard
86. Spackling can be used to fill in joints between eighth wall 84
and backerboard 86 (eighth wall 84 can be formed as thick as the
thickness of backerboard 86 so that eighth wall 84 in a sense forms
a part of the backerboard 86); alternatively or in addition to the
spackling, the waterproofing material used to coat the shower floor
can also be used to cover over the fiberglass mesh. This way of
installing wall endcap 34B can be done on both longitudinal ends
36, 38 (the other end can be another shower wall or a curb).
Further, the shower base and the transition between the drain
assembly 26 and the shower base can be waterproofed using the
waterproofing system of choice. Such a waterproofing system can be
a coating 28 which is painted onto the dried underlayment 25 (the
concrete that was poured); such a coating 28 can be Laticrete Hydro
Ban. When the waterproofing coating 28 dries, the shower base is
ready to be tiled; the painters tape is removed to expose drainage
channel 42. The tile 30 of choice is set directly over drain
assembly 26 leaving only the width of drainage channel 42 exposed.
The shower base can be completed using, for example (not by way of
limitation), a 13 inch.times.20 inch tile in a running bond
pattern. Thus, waterproofing membrane 28 (i.e., in the form of
coating 28) and tiles 30 are laid across the longitudinal extent of
main body 32 except for drainage channel 42.
[0059] According to an alternative embodiment of the present
invention, waterproofing membranes 28 (formed as a fabric or mesh)
can be formed integral with main body 32. As such, one
waterproofing membrane 28 can be attached by the manufacturer to
the top surface of first wall 40 of main body 32 respectively along
each longitudinal side of main body 32. This factory attachment can
be accomplished using an adhesive to glue each waterproofing
membrane 28 to the top surface of first wall 40 of main body 32.
Alternatively, this factory attachment can be accomplished by
embedding and thereby overmolding each waterproofing membrane 28 in
first wall 40 of main body 32. Even with integrating waterproofing
membranes 28, main body 32 and thus also waterproofing membranes 28
can be field cut to size.
[0060] The present invention further provides a method of using a
drain assembly 26. The method includes: providing a drain assembly
26 including a main body 32 which includes a substantially
horizontal first wall 40 extending in a longitudinal direction 52
of main body 32, a drainage channel 42 depending from first wall 40
and extending in longitudinal direction 52, a substantially
vertical second wall 44 depending from first wall 40 and extending
in longitudinal direction 52, and a first longitudinal end 36,
first wall 40, drainage channel 42, and second wall 44 together
forming a first attachment channel 62; receiving, by first
attachment channel 62, a first attachment feature 66 of an end
device 34 at first longitudinal end 36; and attaching first
attachment channel 62 to first attachment feature 66 at first
longitudinal end 36. Main body 32 includes a substantially vertical
third wall 46 depending from first wall 40, extending in
longitudinal direction 52, and being spaced apart from second wall
44 and drainage channel 42, drainage channel 42 being between
second and third walls 44, 46, first wall 40, drainage channel 42,
and third wall 46 together forming a second attachment channel 64,
the method further including receiving, by second attachment
channel 64, a second attachment feature 66 of end device 34 at
first longitudinal end 36, and attaching second attachment channel
64 to second attachment feature 66 at first longitudinal end 36.
Main body 32 includes a second longitudinal end 38 opposing first
longitudinal end 36, and a substantially vertical drainage device
48 positioned between first and second longitudinal ends 36, 38 and
intercepting drainage channel 48, first and second attachment
channels 62, 64 extending at least substantially a first length 68
running from drainage device 42 to first longitudinal end 36 and a
second length 70 running opposingly from drainage device 42 to
second longitudinal end 38, the method further including attaching
selectively end device 34 to one of first longitudinal end 36 and
second longitudinal end 38 by way of first and second attachment
features 66 and first and second attachment channels 62, 64. The
method can further include positioning selectively first and second
attachment features 66 of end device 34 between a first position
100 and a second position 102 along respectively first and second
attachment channels 62, 64, first and second attachment features 66
occupying second position 102 when first length 68 is selectively
shortened by way of field cutting and thereby when first
longitudinal end 36 is moved from first position 100 to second
position 102 which is closer to drainage device 48 than first
position 100. First and second attachment features 66 are connected
respectively to first and second attachment channels 62, 64 using
an adhesive, each of first and second attachment features 66
including two substantially vertical fourth walls 76 and a
substantially horizontal fifth wall 78 attached to fourth walls 76
therebetween, fourth walls 76 being positioned adjacent
respectively second wall 44, third wall 46, and drainage channel
42, fifth wall 78 being positioned adjacent first wall 40. End
device 34 is selectively a floor endcap 34A, a wall endcap 34B, a
linear junction member 34C coupling main body 32 in a substantially
straight line with another main body 32 which is substantially
similar to one another, or a corner member 34D coupling main body
32 substantially perpendicularly with the other main body 32, first
and second attachment features 66 of each of floor endcap 34A, wall
endcap 34B, linear junction member 34C, and corner member 34D being
substantially identical, and thereby being selectively attached to
main body 32. When end device 34 is floor endcap 34A, floor endcap
34A includes a substantially vertical sixth wall 80 and a
substantially horizontal seventh wall 82 attached to sixth wall 80,
first and second attachment features 66 projecting from sixth wall
80, sixth wall 80 being positioned adjacent first longitudinal end
36. When end device 34 is wall endcap 34B, wall endcap 34B includes
a substantially vertical eighth wall 84, first and second
attachment features 66 projecting from eighth wall 84, eighth wall
84 being positioned adjacent first longitudinal end 36. When end
device 34 is linear junction member 34C, linear junction member 34C
includes a substantially horizontal span 88 connecting first and
second attachment features 66 together, linear junction member 34C
spanning a joint 90 formed by main body 32 and the other main body
32 abutting one another in an end-to-end manner, span 88
underlapping drainage channel 42 of each of main body 32 and the
other main body 32. When end device 34 is corner member 34D, corner
member 34D includes a substantially horizontal ninth wall 92, two
corner drainage channels 94 angled perpendicularly relative to one
another and depending from ninth wall 92, a substantially vertical
tenth wall 96 depending from ninth wall 92, and a substantially
vertical eleventh wall 98 depending from ninth wall 92 and angled
perpendicularly relative to tenth wall 96, first and second
attachment features 66 projecting from tenth wall 96, eleventh wall
98 including third and fourth attachment features 66 projecting
therefrom and which are substantially identical to first and second
attachment features 66, corner drainage channels 94 being aligned
respectively with drainage channel 42 of main body 32 and the other
main body 32, first, second, third, and fourth attachment features
66 being received by and attached respectively to first and second
attachment channels 62, 64 of main body 32 and the other main body
32.
[0061] While this invention has been described with respect to at
least one embodiment, the present invention can be further modified
within the spirit and scope of this disclosure. This application is
therefore intended to cover any variations, uses, or adaptations of
the invention using its general principles. Further, this
application is intended to cover such departures from the present
disclosure as come within known or customary practice in the art to
which this invention pertains and which fall within the limits of
the appended claims.
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