U.S. patent application number 12/888141 was filed with the patent office on 2011-03-24 for drain assembly, drain body for use in such an assembly and method for building-in of a drain.
This patent application is currently assigned to N. V. STEYLAERTS. Invention is credited to Patrick Leo Adriaan Maria STEYLAERTS, Peter Roger Josephina STEYLAERTS.
Application Number | 20110067175 12/888141 |
Document ID | / |
Family ID | 42110123 |
Filed Date | 2011-03-24 |
United States Patent
Application |
20110067175 |
Kind Code |
A1 |
STEYLAERTS; Peter Roger Josephina ;
et al. |
March 24, 2011 |
DRAIN ASSEMBLY, DRAIN BODY FOR USE IN SUCH AN ASSEMBLY AND METHOD
FOR BUILDING-IN OF A DRAIN
Abstract
Methods and devices for drain assemblies including those for
building into a floor. Such drain assemblies including a drain body
which can be built into the floor and which has at the top an inlet
zone with a periphery, a peripheral flange with an upper surface,
extending substantially in a horizontal plane from this periphery,
a water-sealing layer arranged adheringly on the upper surface of
the peripheral flange, a sealing mat with the form of a frame with
an inner periphery fitting around the periphery, wherein a portion
of the sealing mat overlaps at least the outer periphery of the
water-sealing layer, and wherein the sealing mat and the
water-sealing layer are adapted to be water-sealing and to adhere
well to tile adhesive.
Inventors: |
STEYLAERTS; Peter Roger
Josephina; (Hulshout, BE) ; STEYLAERTS; Patrick Leo
Adriaan Maria; (Itegem, BE) |
Assignee: |
N. V. STEYLAERTS
Berlaar
BE
|
Family ID: |
42110123 |
Appl. No.: |
12/888141 |
Filed: |
September 22, 2010 |
Current U.S.
Class: |
4/679 |
Current CPC
Class: |
E03F 5/0408 20130101;
E03F 2005/0413 20130101; E03F 5/0409 20130101 |
Class at
Publication: |
4/679 |
International
Class: |
E03C 1/12 20060101
E03C001/12 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 22, 2009 |
BE |
2009/0583 |
Claims
1. A drain assembly for building into a floor, comprising: a drain
body which can be built into the floor and which has at an inlet
zone at a top, said inlet zone having a periphery; a peripheral
flange having an upper surface, said upper surface extending
substantially in a horizontal plane from said periphery; a
water-sealing layer arranged adheringly on said upper surface of
the peripheral flange, said water-sealing layer having an outer
periphery; a sealing mat having a shape of a frame, said frame
having an inner periphery fitting around said periphery of said
inlet zone, wherein a portion of the sealing mat overlaps at least
said outer periphery of said water-sealing layer; and wherein said
sealing mat and said water-sealing layer are adapted to be
water-sealing and to adhere well to tile adhesive.
2. The drain assembly as claimed in claim 1, wherein the sealing
mat and the water-sealing layer each comprise polyethylene.
3. The drain assembly as claimed in claim 1, wherein the sealing
mat and the water-sealing layer are each provided on both sides
with a fleece webbing for a good anchoring in the tile
adhesive.
4. The drain assembly as claimed in claim 1, wherein the sealing
mat and the water-sealing layer are KERDI mats cut to size.
5. The drain assembly as claimed in claim 1, wherein the
water-sealing layer is arranged on the upper surface of the
peripheral flange using a securing substance selected from a group
consisting of: i) an acrylate adhesive with high adhesive strength;
and ii) a two-sided adhesive transfer tape arranged on the upper
surface of the peripheral flange.
6. The drain assembly as claimed in claim 1, wherein the
water-sealing layer is arranged on the upper surface of the
peripheral flange using a layer of adhesive with a thickness of
between 0.05 mm and 0.50 mm.
7. The drain assembly as claimed in claim 1, wherein the peripheral
flange has an outer periphery; and wherein the sealing mat is
dimensioned to extend from the periphery of the inlet zone to a
position beyond said outer periphery of said peripheral flange.
8. The drain assembly as claimed in claim 1, wherein the peripheral
flange is provided with an upright edge, adjacent to the outer
periphery of the peripheral flange.
9. The drain assembly as claimed in claim 1, wherein the drain body
is a moulded plastic article or is manufactured from metal.
10. The drain assembly as claimed in claim 1, wherein the drain
body is provided on its underside with a number of protrusions for
stabilizing the drain body during placing thereof in a floor
material such as mortar.
11. The drain assembly as claimed in claim 1, wherein the sealing
layer completely covers the upper surface of the peripheral
flange.
12. The drain assembly as claimed in claim 1, said sealing layer
having a peripheral zone, wherein the sealing mat is dimensioned to
overlap with said peripheral zone, said peripheral zone having a
width of at least 2 cm, preferably at least 3 cm and more
preferably at least 5 cm.
13. A drain body for building into a floor, comprising: a drain
body which can be built into the floor and which has an inlet zone
at a top, the inlet zone having a periphery; a peripheral flange
having an upper surface, said upper surface extending substantially
in a horizontal plane from said periphery; a water-sealing layer
arranged adheringly on the upper surface of the peripheral flange;
and wherein the water-sealing layer is adapted to be water-sealing
and to adhere well to tile adhesive.
14. The drain body as claimed in claim 13, wherein the
water-sealing layer is provided on both sides with a fleece webbing
for a good anchoring in the tile adhesive.
15. The drain body as claimed in claim 13, wherein the
water-sealing layer is a KERDI mat cut to size.
16. A drain assembly for building into a floor, comprising: a drain
body which can be built into the floor and which has an inlet zone
at a top, the inlet zone having a periphery; a peripheral flange
having an upper surface, said upper surface extending substantially
in a horizontal plane from said periphery; a water-sealing layer
arranged adheringly on said upper surface of the peripheral flange,
said water-sealing layer having an outer periphery; said
water-sealing layer comprising polyethylene and being provided with
a fleece webbing for a good anchoring in the tile adhesive; and a
sealing mat having a shape of a frame, said frame having inner
periphery fitting around said periphery of said inlet zone, wherein
a portion of the sealing mat overlaps at least said outer periphery
of said water-sealing layer; said sealing mat comprising
polyethylene and being provided with a fleece webbing for a good
anchoring in the tile adhesive.
17. The drain assembly as claimed in claim 16, wherein the sealing
mat and the water-sealing layer are KERDI mats cut to size.
18. The drain assembly as claimed in claim 16, said sealing layer
having a peripheral zone, wherein the sealing mat is dimensioned to
overlap with said peripheral zone, said peripheral zone having a
width of at least 2 cm, preferably at least 3 cm and more
preferably at least 5 cm.
19. A method for placing the drain assembly of claim 1, wherein the
water-sealing layer has been connected adheringly to the upper
surface of the peripheral flange prior to building into the floor;
and wherein the sealing mat has been cut to size with the form of a
frame with an inner periphery fitting around the periphery, this
prior to building into the floor, wherein the sealing mat is
dimensioned such that a portion of the sealing mat overlaps at
least the outer periphery the water-sealing layer; the method
comprising the steps of: arranging the drain body in a floor
material such that the underside of the peripheral flange is
arranged in the floor material; and placing the sealing mat around
the periphery and connecting the sealing mat adheringly to the
sealing layer by means of tile adhesive, wherein a portion of the
sealing mat overlaps at least the outer periphery of the
water-sealing layer.
20. The method as claimed in claim 19, wherein the sealing mat and
the water-sealing layer are cut to size from KERDI mats.
Description
BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention relates to a drain assembly,
particularly for a walk-in shower, which drain assembly is intended
for building into a tile floor. The invention further relates to a
drain body for use in such an assembly and to a method for
building-in of a drain.
[0003] 2. Description of the Related Art
[0004] A known problem of the existing drains for tile floors is
associated with making the connections between the drain and the
tiles watertight. The development of drains typically takes place
from the viewpoint of the plumber. Insufficient attention is paid
here to the convenience of placing for a tiler.
SUMMARY OF THE INVENTION
[0005] The present invention has for its object to provide a drain
assembly which can be placed easily and properly by a tiler and
with which leakage and/or moisture problems can particularly be
avoided.
[0006] The invention relates for this purpose to a drain assembly
which is distinguished in that it comprises the following
components: [0007] a drain body which can be built into the floor
and which has at the top an inlet zone with a periphery; [0008] a
peripheral flange with an upper surface, extending substantially in
a horizontal plane from this periphery; [0009] a water-sealing
layer arranged adheringly on the upper surface of the peripheral
flange; [0010] a sealing mat intended for placing around the
periphery, wherein a portion of the sealing mat overlaps at least
the outer periphery of the water-sealing layer.
[0011] A minimal overlap zone will typically be necessary along the
whole outer periphery of the water-sealing layer in order to
guarantee an adequate water sealing. Such a drain assembly will
ensure that penetration of water due to capillary action in the
tile floor is largely prevented. The water-sealing layer will more
particularly provide for a good water sealing close to the drain,
this without the tiler having to be particularly experienced. This
water-sealing layer is after all pre-adhered watertightly to the
peripheral flange, and the sufficient overlap between this layer
and the water-sealing mat will in this way bring about an efficient
sealing.
[0012] According to a preferred embodiment, the water-sealing layer
extends along the periphery so as to form a peripheral zone with a
minimal width. The whole peripheral flange is more preferably
covered with the water-sealing layer.
[0013] According to an advantageous embodiment, the sealing mat is
dimensioned to extend from the periphery of the inlet zone to a
position beyond the outer periphery of the peripheral flange. In
this way it will be immediately apparent to a tiler how this
sealing mat must be placed. A smaller overlap part will however
generally be technically sufficient to realize an adequate sealing.
In the case that a KERDI material (see below) is used for the
sealing layer and mat, use will typically be made of for instance a
minimal overlap of 5 cm.
[0014] According to a preferred embodiment of the invention, the
peripheral flange is provided close to the outer periphery thereof
with an upright edge, this such that water seeping in along the
sealing layer is held back by this upright edge. This will further
improve the watertightness and reduce the overlap necessary in
determined embodiments.
[0015] According to an advantageous embodiment, the water-sealing
layer and/or the sealing mat comprises polyethylene. The sealing
mat and/or the water-sealing layer are typically adapted to be
water-sealing and to adhere well to tile adhesive, and comprise for
instance polyethylene, wherein a fleece webbing is provided on both
sides for a good anchoring in tile adhesive. According to a
possible embodiment, the water-sealing layer and/or the sealing mat
are manufactured from a KERDI material manufactured by the Schluter
company.
[0016] According to a preferred embodiment, the drain body is a
moulded plastic article.
[0017] According to a possible embodiment, the water-sealing layer
consists of a KERDI mat material which is arranged on the drain
body by means of an adhesive. This adhesive must particularly
realize a watertight adhesion of the KERDI mat material to the
peripheral flange.
[0018] According to a further developed embodiment, the drain body
can be provided on its underside with a number of protrusions for
stabilizing the drain body during placing thereof in a floor
material such as mortar. The inlet zone can further be provided on
the inner side with one or more support edges for supporting a
grate assembly along which the water flows from the floor to the
inlet zone.
[0019] According to a possible embodiment, the drain body is
substantially elongate with a substantially rectangular inlet zone,
although other designs are also possible. The inlet zone can
further be provided with one or more buffer zones for controlling
the flow rate to the outlet. A modified design can be chosen for
these buffer zones depending on the form of the drain body. In the
case of a rectangular inlet zone the sealing mat for instance takes
form of a frame with an inner periphery fitting around the
periphery.
[0020] The invention further relates to a drain body, particularly
for use in a drain assembly according to any of the above described
embodiments, with features as described above, which can be
combined at random.
[0021] Finally, the invention relates to a method for placing a
drain, comprising of: [0022] selecting a drain body having an inlet
zone with a periphery and a peripheral flange with an upper surface
extending substantially in a horizontal plane from this periphery;
[0023] connecting a water-sealing layer adheringly to the upper
surface of the peripheral flange; [0024] arranging the drain body
in a floor material such that the underside of the peripheral
flange is arranged in the floor material; [0025] placing the
sealing mat around the periphery, wherein a portion of the sealing
mat overlaps at least an outer peripheral zone of the water-sealing
layer.
[0026] The present invention will be further elucidated on the
basis of a number of non-limitative exemplary embodiments, with
reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a schematic perspective view of a first embodiment
of a drain assembly according to the invention.
[0028] FIG. 2 is a schematic perspective view of the drain body of
FIG. 1 as seen from below.
[0029] FIG. 3 is a schematic perspective view of the drain body
illustrated in FIG. 1 as seen from above.
[0030] FIG. 4 is an exploded schematic perspective view of a grate
assembly for use with the drain assembly of FIG. 1.
[0031] FIG. 5 shows a cross-section along line A-A in FIG. 3,
wherein two connecting laid tiles are also shown.
[0032] FIGS. 6A-D illustrate schematically an embodiment of the
method according to the invention.
[0033] FIG. 7 is a schematic perspective view similar to the view
of FIG. 3 of a second variant of a drain assembly according to the
invention.
[0034] FIG. 8 shows a partially schematic cross-section similar to
the cross-section of FIG. 5 of a third variant of a drain assembly
according to the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0035] A first embodiment of a drain assembly according to the
invention will be illustrated hereinbelow with reference to FIGS.
1-5. The drain assembly comprises a drain body 1 with an upper side
3 and an underside 2. Drain body 1 is provided on its upper side 3
with an inlet zone 4 with a periphery 5. This periphery 5
transposes into a substantially horizontally extending peripheral
flange 6. Underside 3 of drain body 1 is preferably intended to be
arranged directly into a floor material such as mortar. The
underside of peripheral flange 6 is thus placed directly against
the floor material here, as will be further illustrated with
reference to FIGS. 6A-D.
[0036] The drain body is preferably manufactured from a plastic
which adheres to the typical floor materials such as mortar, and
preferably from a mouldable plastic. It is however also possible to
manufacture the drain body from metal. An example of a suitable
material is a mouldable plastic on the basis of polyester resins
and aluminium trihydrates. Such a plastic is already used nowadays
for the moulding of other bathroom components, such as shower
trays.
[0037] Arranged on the upper surface of peripheral flange 6 is a
water-sealing layer 7 which can be connected adheringly to a
sealing mat 8 using for instance a tile adhesive. Water-sealing
layer 7 preferably extends over substantially the whole upper
surface of peripheral flange 6. This water-sealing layer can for
instance be a KERDI mat cut to size which is connected with a
suitable adhesive to peripheral flange 6 of the drain body. Such
KERDI mats are sold by the manufacturer Schluter and are
manufactured from a soft polyethylene material, wherein a special
fleece webbing is arranged on both sides of the mat for a good
anchoring with tile adhesive and other trowel-applied covering
materials or plaster layers.
[0038] The water-sealing layer must preferably be arranged on the
upper surface of the peripheral flange in adhering manner such that
water is prevented from being able to permeate under the
water-sealing layer. According to a possible embodiment, the
sealing layer is arranged by arranging a KERDI mat material on the
peripheral flange using a suitable adhesive. This adhesive must
therefore preferably ensure a good watertight adhesion of the
water-sealing layer to the drain body. An example of a suitable
adhesive is an acrylate adhesive with a high adhesive strength. It
is for instance possible here to envisage two-sided adhesive
transfer tapes (for instance Transfertape 3M Scotch 969/950). A
layer of adhesive of between 0.05 and 0.5 mm is typically provided,
and for instance a layer of adhesive of about 0.13 mm.
[0039] The first embodiment of the drain assembly further comprises
a sealing mat 8 intended for placing on the upper surface of
peripheral flange 6 around periphery 5. In the shown embodiment the
inlet zone 4 of the drain body is substantially rectangular and
sealing mat 8 takes the form of a frame with a recess 9, the
dimensions of which substantially correspond to those of inlet zone
4. When placed on peripheral flange 6, sealing mat 8 will in this
way extend from periphery 5 beyond outer periphery 10 of peripheral
flange 6. This sealing mat will typically be sold together with the
other parts of the drain assembly and arranged by a tiler around
periphery 5 before arranging of the tiles, as will be further
illustrated with reference to FIG. 5 and FIGS. 6A-D. In this way
the sealing mat can form a kind of bridge to other parts of sealing
mats used under the tiles.
[0040] According to an advantageous embodiment, peripheral flange 6
is provided close to its outer periphery 10 with an upright edge
11. This edge 11 will particularly ensure that, should water
nevertheless seep under or over sealing layer 3, this water will in
any case be held back by this edge.
[0041] In order to guarantee a good water sealing, it is typically
appropriate in the case KERDI materials are used to make use of a
minimal overlap of 5 cm between adjacent mats. Similarly, a
sufficient overlap is required between the sealing layer and the
sealing mat. When the drain body is provided with an upright edge
11, it is possible to in most cases to opt for a smaller
overlap.
[0042] As illustrated in FIG. 2, the underside of the drain body
can be formed so as to enhance a stable placing thereof in a floor
material. Underside 2 of the drain body is provided centrally with
a recessed portion 12 in which a siphon (not shown) can be provided
which carries the water to outlet 14. In the shown embodiment the
underside is further provided with a number of protrusions 13
intended for a more stable placing of the drain body. The skilled
person will appreciate that more or fewer protrusions can be
provided depending on the design of the drain body. The skilled
person will further appreciate that the invention not only relates
to substantially rectangular drain bodies as shown in FIGS. 1-5,
but also to square drain bodies, round drain bodies, etc.
[0043] Inlet zone 4 can be provided on its inner side with a
plurality of support edges 15, 16 for supporting a grate assembly.
A possible embodiment of a grate assembly is shown in FIG. 4. The
grate assembly is formed here from substantially two parts 40, 41,
being a substantially rectangular frame 40 and a U-profile 41
fitting therein. The water can flow to the inlet zone between walls
43 of the U-profile and the inner walls of frame 40. In order to
arrange the grate assembly in inlet zone 4 a number of supports 44
are typically provided which are intended to support on a support
edge 15, 16 of the drain body. These supports 44 are for instance
formed in order to receive and position frame 40 and U-profile 41.
Additional support blocks 45 can further be added. Such additional
support blocks allow the height of the grate assembly to be
adjusted to the thickness of tiles 50. This can be seen in detail
in FIG. 5.
[0044] FIG. 5 further illustrates how the drain assembly of FIG. 1
is built into a tile floor, wherein tiles 50 extend to a position
against frame 42 of grate assembly 40. Sealing mat 8 is here
arranged over flange 6 to which a sealing layer 3 has been adhered
beforehand (i.e. prior to being built into the floor). In this way
a watertight connection can be guaranteed without a tiler having to
perform complicated operations.
[0045] FIGS. 6A-D illustrate an embodiment of the method according
to the invention. In a first step (FIG. 6A) the drain body is
positioned on the floor. An auxiliary part 60 (for instance of
expanded polystyrene) is typically arranged here in the inlet zone.
After the drain assembly has been built in, this auxiliary part
will be removed and grate assembly 40, 41, 44 will be placed. In a
second step (FIG. 6B) a floor material such as concrete is arranged
around the drain body. Sealing mat 8 is then arranged over the
drain body, after which the rest of the floor and/or wall(s) can be
finished in the usual manner using additional sealing mats (FIG.
6D). The tiles can now be placed, these tiles extending as shown in
FIG. 5 to a position beyond the outer periphery of inlet zone 4 of
the drain assembly.
[0046] FIGS. 7 and 8 illustrate a second and third embodiment of
the drain assembly according to the invention. The difference with
the first embodiment lies in the provision of a second upright edge
117 close to the periphery 105 of inlet zone 104, wherein a sealing
layer 103 extends from this second upright edge 117 in the
direction of the outer periphery of peripheral flange 106. In the
variant of FIG. 7 the upright edge 111 is located along the outer
periphery of flange 106, while in the variant of FIG. 8 it is
displaced further inward. Sealing layer 103 and sealing mat 108
further do not overlap fully but only over an outer peripheral zone
of sealing layer 103, this applying to both the second and third
variant.
[0047] The skilled person will appreciate that many modifications
to the above described exemplary embodiments are possible without
departing from the scope of the invention, this scope being defined
solely by the following claims.
* * * * *