U.S. patent application number 12/853639 was filed with the patent office on 2012-02-16 for tileable drain and cover apparatus.
Invention is credited to Joseph R. Cook.
Application Number | 20120036631 12/853639 |
Document ID | / |
Family ID | 45563670 |
Filed Date | 2012-02-16 |
United States Patent
Application |
20120036631 |
Kind Code |
A1 |
Cook; Joseph R. |
February 16, 2012 |
TILEABLE DRAIN AND COVER APPARATUS
Abstract
The present invention is directed to a drain and drain
concealment structure and method of installation and use. The
preferred embodiment of the invention comprises a drain body
adapted to be connected to a conventional prefabricated waterproof
shower or bath pan. The drain body may be connected to the shower
pan by any suitable means, such as but not by way of limitation by
being integrally molded therewith during manufacture of the pan, by
connection post-manufacture or in situ in the field. Other
embodiments do not require use of a prefabricated waterproof shower
or bath pan. The preferred drain body is comprised of a waterproof
structure having a floor section which defines a drain aperture,
and a peripheral sidewall section. Structure for releasably
attaching a drain cover to the drain body is employed. The cover,
which is defined by a peripheral edge, is adapted to lie in
registry with, and thereby cover, a portion of the drain body floor
so as to conceal the drain aperture and as much of the drain body
floor as is practicable. When connected to the drain body, the
peripheral edge of the cover is spaced from the drain body sidewall
so as to define a gap therebetween through which water may pass
while flowing toward the drain aperture. In this way, water is
permitted to exit the shower or bath without the drain aperture
being visible. The drain apparatus of this invention is preferably
utilized as part of a tileable shower or bath arrangement, whereby
flooring material such as tile may be placed onto the shower or
bath pan up to the peripheral sidewall of the drain body, and
additional flooring may be placed upon the drain cover. In this
way, the drain is fully operational yet unnoticeable.
Interchangeable drain covers may be provided to permit alteration
of the decorative appearance of the drain.
Inventors: |
Cook; Joseph R.; (Parkland,
FL) |
Family ID: |
45563670 |
Appl. No.: |
12/853639 |
Filed: |
August 10, 2010 |
Current U.S.
Class: |
4/679 ;
210/164 |
Current CPC
Class: |
E03F 5/0408 20130101;
E03F 5/06 20130101 |
Class at
Publication: |
4/679 ;
210/164 |
International
Class: |
E03C 1/12 20060101
E03C001/12 |
Claims
1. A drain apparatus, comprising; a drain cover for a drain
apparatus, the drain cover defining a peripheral edge and being
adapted to be at least partially covered with one or more wall or
flooring materials; a drain body comprised of a floor section which
defines a drain aperture, a peripheral sidewall section, and
structure for releasably attaching the drain cover to the drain
body; the drain cover adapted to cover a portion of the drain body
floor such that when the drain cover is connected to the drain
body, the peripheral edge of the drain cover is spaced from the
drain body sidewall so as to define a gap therebetween through
which water may pass while flowing toward the drain aperture.
2. The drain apparatus of claim 1, wherein the drain cover is
attached to the drain body by structure which allows a height of an
upper surface of the drain cover to be adjustable so to be
positioned to be coplanar with an upper surface of an adjacent
floor, and further wherein the drain cover is releasably attachable
to the drain body via structure for releasably attaching.
3. The drain apparatus of claim 2, wherein the structure for
releasably attaching the drain cover to the drain body is comprised
of at least one post attached to either the drain body or the drain
cover, and a corresponding at least one socket attached to the
drain cover or the drain body, respectively, wherein when the at
least one post is connected into the at least one socket the drain
cover is releasably held in position relative to the drain
body.
4. The drain apparatus of claim 2, further comprising floor or wall
covering material at least partially covering the drain cover.
5. The drain apparatus of claim 2, further comprising a strainer
attachable to the drain body.
6. The drain apparatus of claim 3, further comprising a strainer
attachable to the drain body.
7. The drain apparatus of claim 4, further comprising a strainer
attachable to the drain body.
8. The drain apparatus of claim 2, wherein the drain cover is made
from any material selected from the group comprising plastic such
as PVC or ABS, polyurethane, polyethylene, metal such as copper,
cast iron, aluminum or steel, building material such as stone,
concrete, marble, cultured marble, mortar and stucco.
9. The drain apparatus of claim 2, wherein the drain cover does not
define any grate free area within itself.
10. The drain apparatus of claim 2 wherein a lower surface of the
attached drain cover and an upper surface of the drain body floor
are spaced so that a sufficient gap is created between them so as
to allow for water to drain therethrough into the drain
aperture.
11. The drain apparatus of claim 2 wherein the drain cover is
adapted to be removable and interchangeable with other tiled,
tileable and/or non tileable drain covers so that the drain
apparatus can have a tiled or non tileable finish.
12. The drain apparatus of claim 2, wherein a non tileable drain
cover is adapted to be interchangeable with the tileable drain
cover in such a fashion as to be vertically adjustable so that an
upper surface of either drain cover can be oriented to be coplanar
with an adjacent surface.
13. The drain apparatus of claim 12, wherein the drain cover is
attachable to the drain apparatus through an attachment structure
which allows the position of an upper surface of the drain cover to
be oriented coplanar with an upper surface of an adjacent
floor.
14. The drain apparatus of claim 13, wherein the attachment
structure comprises at least one post attached to either the drain
body or the drain cover, and a corresponding at least one socket
attached to the drain cover or the drain body, respectively,
wherein the at least one post is adapted to be connected into the
at least one socket to releasably retain the drain cover in
position relative to the drain body, and wherein the position of
the insert relative to the drain body is adjustable by the use of
one or more spacers in association with the one or more of said
posts.
15. The drain apparatus of claim 2 wherein the drain body is
adapted to be integrally associated with a prefabricated shower pan
so that the drain body is sufficiently recessed into or below an
upper surface of the prefabricated shower pan floor adjacent the
drain body so that an upper surface of the drain cover is
substantially coplanar with an adjacent upper surface of the
prefabricated shower pan floor.
16. The drain apparatus of claim 2 wherein the drain body is
adapted for use with a partially prefabricated shower pan so that
the drain body is sufficiently recessed into or below an upper
surface of a floor of the partially prefabricated shower pan
adjacent the drain body so that an upper surface of the drain cover
is substantially coplanar with an adjacent upper surface of the
partially prefabricated shower pan floor.
17. The drain apparatus of claim 2 wherein the drain body is
adapted to be integrally associated with a mortar bed or other hand
made shower pan floor so that the drain body is sufficiently
recessed into or below an upper surface of the mortar bed or other
hand made shower pan floor adjacent the drain body so that an upper
surface of the drain cover is substantially coplanar with an
adjacent upper surface of the mortar bed or other hand made shower
pan floor.
18. The drain apparatus of claim 2 wherein the drain body is
adapted to be integrally associated with a surface or fixture so
that the drain body is sufficiently recessed into or below an upper
surface of the surface or fixture adjacent the drain body so that
an upper surface of the drain cover is substantially coplanar with
an adjacent upper surface of the surface or fixture.
19. The drain apparatus of claim 2, wherein the drain cover defines
grate free area within itself.
20. The drain apparatus of claim 2, wherein the drain cover is
comprised of two more separate pieces.
21. The drain apparatus of claim 20, wherein one or more of the two
or more pieces of drain cover defines one or more grate free areas
therein.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present patent application is related to co-pending and
commonly owned U.S. patent application Ser. No. ______, Attorney
Docket No. 825343-51, entitled "Cover for Concealed Drain," U.S.
patent application Ser. No. ______, Attorney Docket No. 825343-53,
entitled "Kits from which may be Manufactured Drainable Structures
with Concealed Drains," U.S. patent application Ser. No. ______,
Attorney Docket No. 825343-54, entitled "Methods for Installing
Drainable Structures with Concealed Drains," and U.S. patent
application Ser. No. ______, Attorney Docket No. 825343-55,
entitled "Concealed Drainage Apparatus," filed on even date with
the present patent application, the entire teachings of which being
hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to shower pans,
drains, and drain tops, grates or covers used in connection with a
shower, shower pan, bath, sink, floor, and other surface or
fixture, and more particularly to a drain, and to a drain apparatus
attached to or used in conjunction with such drain or other drains,
which permits a drain top, grate, or cover to be securely attached
to and/or over all or a portion of the drain, and such drain top,
grate or cover to (i) be tiled; (ii) be removable; (iii) be
interchangeable with other drain tops, grates or covers; (iv) allow
the drainage of water at or around one or more of the perimeter
edges of the drain top, grate or cover; (v) allow the drainage of
water in a gap between one or more of the perimeter edges of the
tiled or untiled drain top, grate or cover and another grate free
tiled or untiled surface, regardless of the orientation of such
surface (e.g. vertical, horizontal, etc.) surrounding or adjacent
to the drain top, grate or cover; (vi) allow the drainage of water
in a gap which is created when the drain top, grate, or cover is
placed in registry with the drain body, the peripheral edge of the
drain top, grate or cover is spaced from a drain recess peripheral
sidewall (defined by the floor off of which liquid is to be
drained) so as to define a gap therebetween through which water may
pass while flowing toward the drain aperture; (vii) allow such
drain and drain tops, grates or covers to be used and to be adapted
for use in connection with (A) prefabricated shower pans (such as
those described herein), and/or (B) a partially prefabricated
shower pan (such as those described herein), and/or (C) a mortar
bed or other hand made shower pan floor (such as those described
herein), and/or (D) any other tiled or tileable surface or fixture;
and (viii) substantially conceal from view the drain aperture.
[0004] 2. Description of the Prior Art
[0005] The inventor is unaware of any shower, bath, shower pan,
sink, floor, or drain therefore which employs an attachable,
removable, and interchangeable drain top, grate or cover which can
be covered with floor or wall coverings such as tile, stone,
concrete, stucco, or any other floor or wall coverings, etc, and
which permits water to drain (i) at one or more of the grate free
perimeter edges of the tiled or tileable drain top, grate, or
cover, and/or (ii) in a gap between one or more of the grate free
perimeter edges of the tiled or tileable drain top, grate or cover
and another grate free surface with tile, stone, and/or other floor
or wall coverings, and which makes the drain feature essentially
undetectable to ordinary observation. Such an arrangement is highly
desirable from an aesthetic perspective. A similar arrangement in
which the drain top, grate or cover is not removable would also be
desirable.
[0006] Therefore, a need exists for, among other things, drains and
drain tops, grates and covers (i) which are adapted to be covered
with decorative coverings such as floor and wall coverings, (ii)
which are attachable to the floor or other surface at or around the
drain such as a drain of a shower pan, (iii) which drain tops,
grates and covers are optionally removable and interchangeable with
other drain tops, grates and covers, (iv) which permit water to
drain through a gap between one or more of the perimeter sides of
the tiled or tileable drain top, grate or cover and another
adjacent or surrounding tiled or tileable surface, (v) which permit
water or other liquid to drain in a gap created when the drain
cover is placed in registry with the drain body, such that the
peripheral edge of the drain cover is spaced from the drain recess
peripheral sidewall so as to define a gap therebetween through
which water or other liquid may pass while flowing toward the drain
aperture, (vi) which peg nit the drainage of water through a
shower, bath, sink, floor or other drain while giving the
appearance that there is actually no drain, and (vii) which allow
the drains and the drain tops, grates and covers to be used and to
be adapted for use in connection with (A) a prefabricated shower
pan (such as those defined herein), and/or (B) a prefabricated
shower pan (such as those defined herein), and/or (C) a mortar bed
or other hand made shower floor (such as those defined herein),
and/or (D) tiled or tileable surface or fixture (such as those
defined herein).
SUMMARY OF THE INVENTION
[0007] The present invention is directed to shower pans, and drains
and drain tops, grates or covers used in connection with a shower,
shower pan, bath, sink, floor and other surface or fixture, and
which drain tops, grates or covers at least partially cover the
drain apparatus, which drain tops, grates or covers are attachable,
and optionally removable and/or interchangeable with other drain
tops, grates or covers, which drain tops, grates or covers can be
covered with tile, stone, or any other floor or wall covering, and
which permits water to drain (i) at one or more of the grate free
perimeter edges of the tiled or tileable drain top, grate or cover
and/or the grate free perimeter edges of the drain apparatus,
and/or (ii) through a gap between one or more of the perimeter
edges of the tiled or tileable drain top, grate or cover and
another adjacent or surrounding horizontal and/or vertical tiled or
tileable surface, and/or (iii) which permits water or other liquid
to drain in a gap created when the drain cover is placed in
registry with the drain body, such that the peripheral edge of the
drain cover is spaced from the drain recess peripheral sidewall so
as to define a gap therebetween through which water or other liquid
may pass while flowing toward the drain aperture, and (iv) which
permits ample drainage from the shower, shower pan, bath, sink,
floor, fixture or other drain structure while making the drain
apparatus essentially undetectable. A drain body defines a drain
aperture which is adapted to be placed in registry with a shower,
shower pan, bath, sink, floor, fixture or other drain conduit. A
drain top, grate, or cover is associated with the drain body in
such a way that it covers substantially the entirety of the drain
aperture, allows the drainage of water along the perimeter edges or
within the body of the drain top, grate or cover, and/or may be
manufactured so as to be attachable and removable from the drain
body, and/or interchangeable with other drain tops, grates or
covers, and permits the water or other liquid to drain in a grate
free area at one or more of the perimeter edges of the drain top,
grate or cover and or drain apparatus, and/or in a gap between one
or more grate free edges of the tiled drain top, grate or cover and
another adjacent tiled or tileable surface, including but not
limited to an adjacent tiled shower pan surface, shower floor
surface, bath, sink, fixture, floor, or other tiled or tileable
surface, while essentially making the drain apparatus undetectable
from view yet permitting water to flow into and through the drain
aperture. The floor or wall covering may be attached to the drain
top, grate or cover at any time, including, but not limited to, (i)
at or about the time of manufacture of the drain and/or the drain
top, grate or cover, (ii) at or about the time of the manufacture
of the shower pan, shower, floor, sink, bath, fixture or other
tiled or tileable surface or other apparatus into which the drain
has been or will be integrated, (iii) at or about the time the
drain apparatus, or other article or fixture into which the drain
has been or will be integrated, is installed over a drain aperture
in the field, and/or (iv) at any time after the drain and/or a the
shower pan, floor, sink, bath fixture or other surface into which
the drain has been integrated, is installed in the field.
[0008] In one embodiment, a drain body is integrally formed with a
prefabricated shower pan (as defined herein) at the time of
manufacture of the shower pan, such as, but not limited to, the
type of prefabricated shower pan disclosed in U.S. Pat. No.
5,913,777 entitled "Pre-Fabricated Shower Module and Method of
Shower Construction." The drain body defines a drain aperture which
is adapted to be placed in registry with the floor of the
prefabricated shower pan in such a manner that the drain is
sufficiently recessed below the shower pan floor to accommodate a
tileable drain top, grate, or cover. A drain top, grate or cover,
which can be covered with stone, tile, concrete, stucco or other
floor or wall covering, is associated with the drain body and the
prefabricated shower pan surface in such a way that (i) it covers
the drain so that an upper surface of the drain cover is
substantially coplanar with an upper surface of the adjacent floor
of the prefabricated shower pan surface, (ii) both the
prefabricated shower pan and the drain top, grate or cover can be
covered with tile, stone, or other floor or wall covering, so that
the drain will blend into the flooring material used on the
surrounding prefabricated shower pan floor, (iii) the drain top,
grate or cover is attachable to the drain, which drain is
integrated into the prefabricated shower pan, (iv) the drain top,
grate or cover is optionally removable and/or interchangeable with
other drain tops, grates and covers, (v) the drain top, grate or
cover permits water to drain into the drain apparatus along the
outside perimeter of the drain top, grate or cover and/or the drain
apparatus, (vi) the drain top, grate or cover also permits water or
other liquid to drain in a gap created when the drain cover is
placed in registry with the drain body, such that the peripheral
edge of the drain cover is spaced from the drain recess peripheral
sidewall defined by the shower pan so as to define a gap
therebetween through which water or other liquid may pass while
flowing toward the drain aperture, and (vii) the drain top, grate
or cover permits water to drain into a gap between one or more of
the perimeter tiled or tileable edges of the drain top, grate or
cover and one or more of the adjacent tiled or tileable perimeter
edges of the drain recess in the prefabricated shower pan, (viii)
the drain is sufficiently recessed into or below an upper surface
of the prefabricated shower pan floor so that an upper surface of
the tiled or tileable drain top, grate, or cover when attached in
registry with the drain is substantially coplanar with the adjacent
upper surface of the tiled or tileable prefabricated shower pan
floor, and the lower surface of the attached drain top, grate or
cover and the upper surface of the drain body floor are spaced so
that a sufficient gap is created so as to allow for water to drain
therethrough into the drain aperture, (ix) the drain top, grate or
cover substantially covers the entirety of the drain aperture and
the drain apparatus from view while permitting water to flow into
and through the drain apparatus and aperture, (x) optionally, a
removable strainer can be placed between the drain top, grate or
cover and the drain aperture. The drain top grate or cover can be
made of any appropriate material including but not limited to
plastic such as PVC or ABS, polyurethane, polyethylene, metal such
as copper, cast iron, aluminum, steel, or building materials such
as stone, concrete, marble, cultured marble, mortar, stucco or any
other material.
[0009] In another embodiment, a drain body is integrally formed
with a partially prefabricated shower pan of the type which does
not have an integrated drain, such that the drain is attached to
the partially prefabricated shower pan sometime after manufacture,
and in many cases in the field at or about the time of installation
of the partially prefabricated shower pan. The drain body defines a
drain aperture which is adapted to be placed in registry with the
floor of a partially prefabricated shower pan in such a manner that
the drain body is sufficiently recessed into or below the partially
prefabricated shower pan floor to accommodate a drain top, grate or
cover. A drain top, grate or cover, which can be covered with
stone, tile, concrete, stucco or other floor or wall covering, is
associated with the drain body in such a way that (i) it covers all
or a portion of the drain so that an upper surface of the drain
cover is substantially coplanar with an upper surface of the floor
of the partially prefabricated shower pan surface, (ii) both the
partially prefabricated shower pan and the drain top, grate or
cover can be covered with tile, stone, or other floor or wall
covering, so that it will blend into the flooring material used on
the surrounding partially prefabricated shower pan floor, (iii) the
drain top, grate or cover is attachable to the drain or the
partially prefabricated shower pan, (iv) the drain top, grate or
cover is optionally removable and/or interchangeable with other
drain tops, grates and covers, (v) the drain top, grate or cover
permits water to drain into the drain apparatus along the outside
perimeter of the drain top, grate or cover and/or the drain
apparatus, (vi) the drain top, grate or cover also permits water or
other liquid to drain in a gap created when the drain cover is
placed in registry with the drain body, such that the peripheral
edge of the drain cover is spaced from the drain recess peripheral
sidewall so as to define a gap therebetween through which water or
other liquid may pass while flowing toward the drain aperture, and
(vii) the drain top, grate or cover permits water to drain into a
gap between one or more of the perimeter tiled or tileable edges of
the drain top, grate or cover and one or more of the adjacent tiled
or tileable perimeter edges of the drain recess in the partially
prefabricated shower pan, (viii) the drain is sufficiently recessed
into or below an upper surface of the partially prefabricated
shower pan floor so that an upper surface of the tiled or tileable
drain top, grate, or cover when attached in substantial registry
with the drain is substantially coplanar with the adjacent upper
surface of the tiled or tileable partially prefabricated shower pan
floor, and the lower surface of the attached drain top, grate or
cover and the upper surface of the drain body floor are spaced so
that a sufficient gap is created so as to allow for water to drain
therethrough into the drain aperture, (ix) the drain top, grate or
cover covers substantially the entirety of the drain aperture and
the drain apparatus from view while permitting water to flow into
and through the drain apparatus and aperture, and (x) optionally, a
removable strainer can be placed between the drain top, grate or
cover and the drain aperture. The cover can be made of any
appropriate material including but not limited to plastic such as
PVC or ABS, polyurethane, polyethylene, metal such as copper, cast
iron, aluminum, steel, or building materials such as stone,
concrete, marble, cultured marble, mortar, stucco or any other
material.
[0010] In another embodiment, a drain body is integrally formed
with a mortar bed or other hand-made shower pan, bath or other
floor (as herein defined) which may or may not be constructed in
conjunction with a vinyl liner or other water proofing membrane(s).
The drain body defines a drain aperture which is adapted to be
placed in registry with the floor of a mortar bed or other
hand-made shower floor, bath floor, floor, or other surface in such
a manner that the drain body is sufficiently recessed in the mortar
bed or below the shower, bath, or other floor to accommodate a
drain top, grate, or cover. A drain top, grate or cover, which can
be covered with stone, tile, concrete, stucco or other floor or
wall covering, is associated with the drain body in such a way that
(i) it covers the drain so that an upper surface of the drain cover
is substantially coplanar with an upper surface of the floor of the
mortar bed or other hand-made shower pan floor, (ii) both the
mortar bed or other hand-made shower pan floor and the drain top,
grate or cover can be covered with tile, stone, or other floor or
wall covering, so that the drain top, grate or cover will blend
into the flooring material used on the surrounding mortar bed or
other hand made shower pan floor, (iii) the drain top, grate or
cover is attachable to the drain or the mortar bed or other
hand-made shower pan floor, (iv) the drain top, grate or cover is
optionally removable and/or interchangeable with other drain tops,
grates and covers, (v) the drain top, grate or cover permits water
to drain into the drain apparatus along the outside perimeter of
the drain top, grate or cover and/or the drain apparatus, (vi) the
drain top, grate or cover also permits water or other liquid to
drain in a gap created when the drain cover is placed in registry
with the drain body, such that the peripheral edge of the drain
cover is spaced from the drain recess peripheral sidewall so as to
define a gap therebetween through which water or other liquid may
pass while flowing toward the drain aperture, and (vii) the drain
top, grate or cover also permits water to drain into a gap between
one or more of the perimeter tiled or tileable edges of the drain
top, grate or cover and one or more of the adjacent tiled or
tileable perimeter edges of the drain recess portion of the mortar
bed or other hand made shower pan floor, (viii) the drain is
sufficiently recessed into or below an upper surface of the mortar
bed or other hand made shower pan floor so that an upper surface of
the tiled or tileable drain top, grate, or cover when attached in
registry with the drain is substantially coplanar with the adjacent
upper surface of the tiled or tileable mortar bed or other hand
made shower pan, and the lower surface of the attached drain top,
grate or cover and the upper surface of the drain body floor are
spaced so that a sufficient gap is created so as to allow for water
to drain therethrough into the drain aperture, (ix) the drain top,
grate or cover substantially covers the entirety of the drain
aperture and the all or a portion of the drain apparatus from view
while permitting water to flow into and through the drain apparatus
and aperture, and (x) optionally, a removable strainer can be
placed between the drain top, grate or cover and the drain
aperture. The cover can be made of any appropriate material
including but not limited to plastic such as PVC or ABS,
polyurethane, polyethylene, metal such as copper, cast iron,
aluminum, steel, or building materials such as stone, concrete,
marble, cultured marble, mortar, stucco or any other material.
[0011] In yet another embodiment, a drain body is integrally formed
with a tiled or tileable surface or fixture that has a drain, in
such a manner that the drain body defines a drain aperture which is
adapted to be placed in registry with a tiled or tileable surface
or fixture that has a drain in such a manner as to be sufficiently
recessed to accommodate a drain top, grate, or cover. A drain top,
grate or cover, which can be covered with stone, tile, concrete,
stucco or other floor or wall covering, is associated with the
drain body in such a way that (i) it covers the drain so that an
upper surface of the drain cover is substantially coplanar with an
upper surface of the tiled or tileable surface or fixture, (ii)
both the tiled or tileable surface or fixture and the drain top,
grate or cover can be covered with tile, stone, or other floor or
wall covering, so that it will blend into the flooring material
used on the surrounding tiled or tileable surface or fixture, (iii)
the drain top, grate or cover is attachable to the drain or the
tiled or tileable surface or fixture, (iv) the drain top, grate or
cover is optionally removable and/or interchangeable with other
drain tops, grates and covers, (v) the drain top, grate or cover
permits water to drain into the drain apparatus along the outside
perimeter of the drain top, grate or cover and/or the drain
apparatus, (vi) the drain top, grate or cover also permits water or
other liquid to drain in a gap created when the drain cover is
placed in registry with the drain body, such that the peripheral
edge of the drain cover is spaced from the drain recess peripheral
sidewall so as to define a gap therebetween through which water or
other liquid may pass while flowing toward the drain aperture, and
(vii) the drain top, grate or cover permits water to drain into a
gap between one or more of the perimeter tiled or tileable edges of
the drain top, grate or cover and one or more of the tiled or
tileable perimeter edges of the drain recess portion of the tiled
or tileable surface or fixture, (viii) the drain is sufficiently
recessed into or below an upper surface of the tiled or tileable
surface or fixture so that an upper surface of the tiled or
tileable drain top, grate, or cover when attached in substantial
registry with the drain is substantially coplanar with the adjacent
upper surface of the tiled or tileable surface or fixture, and the
lower surface of the attached drain top, grate or cover and the
upper surface of the drain body floor are spaced so that a
sufficient gap is created so as to allow for water to drain
therethrough into the drain aperture, (ix) the drain top, grate or
cover covers substantially the entirety of the drain aperture and
the drain apparatus from view while permitting water to flow into
and through the drain apparatus and aperture, and (x) optionally, a
removable strainer can be placed between the drain top, grate or
cover and the drain aperture. The cover can be made of any
appropriate material including but not limited to plastic such as
PVC or ABS, polyurethane, polyethylene, metal such as copper, cast
iron, aluminum, steel, or building materials such as stone,
concrete, marble, cultured marble, mortar, stucco or any other
material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a front/top right perspective view of an assembled
shower or bath drain apparatus in accordance with an exemplary
embodiment of the present invention.
[0013] FIG. 2 is a front/top right perspective exploded view of the
shower or bath drain apparatus in accordance with an exemplary
embodiment of the present invention.
[0014] FIG. 3 is a front/top right perspective view of a drain body
in accordance with an exemplary embodiment of this invention.
[0015] FIG. 4 is a right side elevational view of the drain body in
accordance with an exemplary embodiment of this invention.
[0016] FIG. 5 is a bottom elevational view of a drain cover in
accordance with an exemplary embodiment of this invention.
[0017] FIG. 6 is a perspective view of an optional drain insert
adaptable for use with this invention.
[0018] FIG. 7 is a perspective view of the optional drain insert
connected to the drain body.
[0019] FIG. 8 is a cross-sectional side elevational view of the
assembled shower or bath drain apparatus in accordance with the
first embodiment of the present invention taken along line A-A of
FIG. 20.
[0020] FIG. 9 is a cross-sectional side elevational view of the
assembled shower or bath drain apparatus in accordance with a
second embodiment of the present invention taken along line A-A of
FIG. 20.
[0021] FIG. 10 is a perspective exploded view of the shower or bath
drain body shown in FIG. 7 with an example of an alternative drain
strainer exploded therefrom.
[0022] FIG. 11 is a perspective exploded view of the shower or bath
drain body shown in FIG. 10 with an example of an alternative drain
strainer attached thereto.
[0023] FIG. 12 is a cross-sectional side elevational view of the
assembled shower or bath drain apparatus shown in FIG. 8 with a
modified floor and drain insert assembly taken along line A-A of
FIG. 20.
[0024] FIG. 13 is a cross-sectional side elevational view of the
assembled shower or bath drain apparatus shown in FIG. 9 with a
modified floor and drain insert assembly taken along line A-A of
FIG. 20.
[0025] FIG. 14 is a cross-sectional side elevational view similar
to that shown in FIG. 8 but where strainer 40 and strainer cover 42
are replaced by strainer 110.
[0026] FIG. 15 is a cross-sectional elevational view similar to
that shown in FIG. 8, showing the use of spacers 190 to adjust the
level of cover C relative to pan floor surface P.
[0027] FIG. 16 is an exploded view of an alternative embodiment of
the drain apparatus in this invention.
[0028] FIG. 17 is a bottom elevational view of a drain cover in
accordance with the embodiment of this invention shown in FIG.
16.
[0029] FIG. 18 is a perspective view of a prefabricated shower pan
and integrated drain body prior to being covered with flooring
material in accordance with this invention.
[0030] FIG. 19 is the prefabricated shower pan of FIG. 18 after
having been covered with flooring material.
[0031] FIG. 20 is a top plan view of the pan and drain arrangement
of FIG. 18.
[0032] FIG. 21 is a cross-sectional side elevational view of the
assembled shower or bath drain apparatus in accordance with a
modified embodiment of the present invention taken along line A-A
of FIG. 20.
[0033] FIG. 22 is an exploded perspective view of the shower or
bath drain apparatus in accordance with the modified embodiment of
the invention shown in FIG. 21 showing the orientation thereof
relative to a partially prefabricated shower pan floor.
[0034] FIG. 23 is a cross-sectional side elevational view of the
assembled shower or bath drain apparatus in accordance with the
modified embodiment of the invention shown in FIG. 21 installed
with a partially prefabricated shower pan floor, waterproof
membrane/liner and floor covering.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENT(S)
[0035] Before describing in detail exemplary embodiments that are
in accordance with the present invention, it should be observed
that the embodiments reside primarily in combinations of structural
components and installation and use steps related to implementing
apparatus and methods for a drain comprising a drain body which
defines a drain aperture which is adapted to be placed in registry
with a floor or other drain conduit in such a manner as to be
sufficiently recessed within or below (i) a prefabricated shower
pan floor, (ii) the floor of a partially prefabricated shower pan,
(iii) a mortar bed or other hand made shower pan floor, (iv) a
tiled or tileable surface or fixture, to accommodate a drain top,
grate, or cover. A drain top, grate, or cover, which can be covered
with stone, tile or other floor or wall coverings is associated
with the drain body in such a way that (i) it covers all or a
portion of the drain body so that the drain top, grate or cover is
substantially coplanar with the untiled floor surface of (a) a
prefabricated shower pan floor, (b) a partially prefabricated
shower pan, (c) a mortar bed or other hand made shower pan floor,
(d) a tiled or tileable surface or fixture; (ii) both the drain
top, grate or cover and the surface surrounding or adjacent to the
drain top, grate or cover can be covered with tile, stone, or other
floor or wall covering, so that they will blend into the flooring
material used on the area surrounding or adjacent to the drain top,
grate or cover; (iii) the drain top, grate or cover is attachable
to the drain or the area surrounding the drain top, grate or cover;
(iv) the drain top, grate or cover may be removable and/or
interchangeable with other drain tops, grates and covers; (v) the
drain top, grate or cover permits water to drain into and though
the drain apparatus along the grate free outside perimeter edge(s)
of the drain top, grate or cover and/or the drain apparatus; (vi)
the drain top, grate or cover is sized and shaped to create a grate
free gap between the outside perimeter edges of the drain top,
grate or cover and/or the drain apparatus and one or more of the
tiled or untiled perimeter edges or surfaces of the area
surrounding the drain top, grate or cover to permit water to drain
into and though the drain apparatus; (vii) the drain top, grate or
cover also permits water or other liquid to drain in a gap created
when the drain cover is placed in registry with the drain body,
such that the peripheral edge(s) of the drain cover is spaced from
the drain recess peripheral sidewall so as to define a gap
therebetween through which water or other liquid may pass while
flowing toward the drain aperture; (viii) the drain is sufficiently
recessed into or below an upper surface of (A) a prefabricated
shower pan, or (B) a partially prefabricated shower pan, or (C) a
mortar bed or other hand-made shower pan floor, or (D) a tiled or
tileable surface or fixture, so that an upper surface of the tiled
or tileable drain top, grate, or cover when attached in substantial
registry with the drain is substantially coplanar with the adjacent
tileable or tiled upper surfaces of (A) a prefabricated shower pan,
or (B) a partially prefabricated shower pan, or (C) a mortar bed or
other hand made shower pan floor, or (D) a tiled or tileable
surface or fixture, and the lower surface of the attached drain
top, grate or cover and the upper surface of the drain body floor
are spaced so that a gap is created which is sufficient to allow
for water to drain therethrough into the drain aperture, (ix) the
drain top, grate or cover substantially covers the entirety of the
drain aperture and the drain apparatus from view while permitting
water to drain into and through the drain apparatus and drain
aperture, and (x) a removable strainer can be part of the drain
top, grate or cover, or placed between the drain top, grate or
cover and the drain body and/or the drain aperture.
[0036] Accordingly, the apparatus components have been represented
where appropriate by conventional symbols in the drawings, showing
only those specific details that are pertinent to understanding the
embodiments of the present invention so as not to obscure the
disclosure with details that will be readily apparent to those of
ordinary skill in the art having the benefit of the description
herein.
[0037] In this document, relational terms, such as "first" and
"second," "top" and "bottom," and the like, may be used solely to
distinguish one entity or element from another entity or element
without necessarily requiring or implying any physical or logical
relationship or order between such entities or elements.
[0038] The terms "comprises," "comprising," "comprise" or any other
variation thereof are intended to cover a non-exclusive inclusion,
such that a process, method, article, or apparatus that comprises a
list of elements does not include only those elements, but may
include other elements not expressly listed or inherent to such
process, method, article, or apparatus.
[0039] The term "plurality of" as used in connection with any
object or action means two or more of such object or action.
[0040] A claim element proceeded by the article "a" or "an" does
not, without more constraints, preclude the existence of additional
identical elements in the process, method, article, or apparatus
that includes the element.
[0041] Terms such as "wall or flooring material," "floor and wall
coverings" and "covering material" mean, encompass and comprise one
or more of ceramic, natural stone or other tile, stone, granite,
marble, cultured marble, or other stone surface, non slip finished
shower surfaces such as vinyl or plastic, stucco, concrete and
mortar surfaces which may be mixed with adhesives or other
substances, and any other material or materials used to provide a
finished surface.
[0042] The term "tiled" means, encompasses, and comprises any
surface having floor or wall covering materials, such as one or
more of ceramic, natural stone or other tile, stone, granite,
marble, cultured marble. or other stone surface, non slip finished
shower surfaces such as vinyl or plastic, stucco, concrete and
mortar surfaces which may be mixed with adhesives or other
substances, and any other material or materials used to provide a
finished surface
[0043] The term "non tileable" means, encompasses, and comprises
one or more surfaces or structural components which are not capable
of receiving wall or floor material or were not designed, marketed
or sold with the intention of being tileable or tiled, and in fact
are not tiled.
[0044] The term "tileable" means, encompasses, and comprises one or
more surfaces or structural components which are capable of
receiving wall or flooring material, whether through the use of
adhesives or any other means of attachment, such as clips, straps
or other mechanical fastening structure(s).
[0045] The term "prefabricated shower pan" means, encompasses, and
comprises any manufactured or fabricated tileable or tiled shower
pan to which floor or wall coverings are to be adhered and that has
one or more drains integrally associated into it at the time of
manufacture or fabrication, and may also have integrated therein at
the time of manufacture or fabrication a partial or complete floor
(which may be pitched), a splash wall, a curb, and/or a barrier
free entrance.
[0046] The term "partially prefabricated shower pan" means,
encompasses, and comprises any manufactured or fabricated tileable
or tiled shower pan to which floor or wall coverings are to be
adhered, that does not have a drain integrally associated into it
at the time of manufacture or fabrication, including (A) a
manufactured or fabricated one piece shower pan with component
elements such as a floor, a splash wall, a curb and/or a barrier
free entrance integrated at the time of manufacture, or (B) a
manufactured or prefabricated multi piece shower pan kit or set
which when assembled and installed in the field comprises a one
piece or multi-piece shower floor and which may include one or more
component elements such as a splash wall, pitched floor, a curb, a
barrier free entrance, or portions thereof, and, in either case A
or B above, the drain is installed in the floor of the shower pan
at any time after manufacture and prefabrication, usually in the
field and/or at or around the time of assembly and installation of
the shower pan.
[0047] Terms such as "mortar bed or other hand-made shower pan
floor" and "mortar bed and shower pan" mean, encompass and comprise
a shower floor, bath floor, a shower pan, a shower base, floor or
other surface that is partially of fully formed by a bed of mortar
or like material installed in the field or elsewhere on any
substrate, including but not limited to concrete, wood, or steel,
into which, in conjunction with, or below which, a drain is
installed, and the mortar bed may be waterproofed using a vinyl
liner, a membrane liner, hot mopping, or otherwise waterproofed,
and floor or wall coverings are or may be adhered to the surface of
the mortar bed.
[0048] Terms such as "tiled and/or tileable surface or fixture" and
"surface or fixture" mean, encompass, and comprise any fully or
partially tiled and/or tileable bathtub, bathroom floor, shower
floor, sink, fountain, fixture, floor, or other surface that has a
drain.
[0049] The term "non tileable and/or untiled surface" means,
encompasses or comprises a surface such as a floor, wall, shower
floor, bath floor, sink, shower pan, or any other surface which has
a drain integrated or associated with it, and such surface is not
tileable, nor is it designed to be tiled or tileable, and/or such
surface is in fact not tiled.
[0050] The term "drain" means, encompasses and comprises any kind
of drain made of any kind of material, including but not limited to
metal or plastics, and with any kind of connection to a drain
system such as a waste water system, including but not limited to a
trench drain, a solvent weld drain, a welded connection drain, a
hub (outside caulk) drain, a spigot drain, a hubless spigot drain,
a hubless drain, an inside caulk (gasket) drain, a hubbed (push on)
drain, a compression drain, and a clamping ring drain
[0051] Terms such as "drain top, grate or cover" and "drain cover"
mean, encompass and comprise anything that covers all or a portion
of a drain, whether it is manufactured as part of the drain or is
separately made and placed over or on top of all or a part of the
drain, and whether it is one piece or multiple pieces which in
combination cover all or a portion of the drain, and such drain
top, grate or cover may be made out of one or materials, including
but not limited to metals, such as cast iron, copper, steel,
aluminum, plastics such as PVC or ABS, polyurethane, polyethylene,
building products such as stone, tile, concrete, marble, cultured
marble, mortar, stucco or the like, or any other material suitable
as a drain top or cover.
[0052] A "drain body" means, encompasses and comprises preformed
drain bodies and other areas into which liquids may otherwise
drain, such as depressions in a shower, bath, basin or bathroom
floor, whether preformed or formed during the assembly of the
shower, bath, basin or floor.
[0053] The term "grate free" means any area over, near or in
registry with a drain into which water or other liquid may drain
which is substantially free of obstruction.
[0054] The inventions disclosed herein may be employed in sinks,
basins, showers, baths, shower pans, fixtures, and any other
surface or fixture that has a drain.
[0055] The present invention is directed to shower pans, drains and
drain tops, grates or covers which are used independently or in
combination with (i) a prefabricated shower pan, (ii) a partially
prefabricated shower pan, (iii) a mortar bed or a hand made shower
pan floor, and/or (iv) a tiled or tileable surface or fixture, and
which drain tops, grates or covers at least partially cover the
drain apparatus, where the drain cover is tileable, attachable,
(optionally) removable and interchangeable with other tileable or
non tileable drain tops, grates or covers which permit water to
drain through a gap between the tiled or tileable drain top, grate
or cover and the tiled or tileable area surrounding and/or adjacent
to the drain top, grate or cover, while substantially concealing
the drain apparatus and the drain aperture, and method of
installation and use.
[0056] As best shown in FIGS. 1-5, a preferred embodiment of the
invention comprises a drain body 10 adapted to be connected to a
(i) a prefabricated shower pan, (ii) a partially prefabricated
shower pan, (iii) a mortar bed or other hand made shower pan floor,
(iv) a tiled or tileable surface or fixture, or other shower,
shower pan, bath or sink floor, fixture, or floor of any type, for
example a conventional prefabricated waterproof shower or bath pan
of the type disclosed in U.S. Pat. No. 5,913,777. The drain body 10
may be connected to (i) a prefabricated shower pan, (ii) a
partially prefabricated shower pan, (iii) a mortar bed or other
hand made shower pan floor, (iv) a tileable or tiled surface or
fixture, by any suitable means, including but not limited to, being
integrally molded therewith during manufacture thereof, by
connection post-manufacture, or in situ in field. The shape of
drain body 10 is shown as rectangular in the drawings. However, it
is to be appreciated that drain body 10 may be made in any desired
shape without departing from the spirit or scope of the invention.
In addition, any number of drain structures of this invention may
be employed in any given application.
[0057] The drain body 10, in its simplest and preferred form as
shown in FIGS. 1-5, is comprised of a waterproof structure having a
floor section 12 which defines a drain aperture 13, and a
peripheral sidewall section 14. Structure for releasably and
interchangeably attaching a drain top, grate or cover 50 to drain
body 10 is employed, such as posts 32, 34, 36 and 38 which are
adapted to mate with corresponding sockets 52, 54, 56 and 58 on a
drain cover 50. Alternatively, cover 50 may releasably and
interchangeably attach to drain body 10 by any other connection
structure, such as by more or fewer posts and sockets, different
connection structure, or by being attached to and made part of the
threaded drain insert 40 (shown in FIGS. 5-6), which includes a
threaded collar 46 which is adapted to threadingly engage threaded
surface 16 of drain collar 15, or by any other manner which will
occur to those of skill in the art. Alternatively, cover 50 may
attach to the shower or bath pan floor. Corresponding connection
structure may be employed in association with the shower or bath
pan floor, such as connection posts or sockets similar to those
described elsewhere in this disclosure, or any other structure for
connecting cover 50 to the floor which will occur to those of skill
in the art.
[0058] Drain body 10 may, preferably but not by way of limitation,
include a depending collar section 15, the inside surface 16 of
which is threaded. Drain body 10 may also preferably but not by way
of limitation include a further depending collar section 18 which
is adapted to engage the interior of a drain pipe (not shown) of a
building's plumbing lines. Drain body 10 may have one or more of
the many types of connections, for example (i) from the drain body
to the waste water system; and (ii) from the drain body to the
drain top, grate or cover, including without limitation a threaded
connection, a hub connection, a no hub connection, a solvent weld
connection, a compression drain connection, a trench drain, a
welded drain connection, an outside caulk drain connection, an
inside caulk drain connection, a spigot drain connection, a hubless
spigot drain, a hubless drain, inside caulk(gasket) drain, hubbed
(push on) drain, a compression drain, a clamping ring drain,
etc.
[0059] Cover 50 is defined by peripheral edge 60, which, again, may
be manufactured in any desired shape, and is adapted to cover a
portion of drain body floor 12 so as to permit a tileable surface
above the drain and the drain aperture while simultaneously
concealing the drain aperture 13, the drain, and as much of floor
12 as is practicable and still have the required grate free area
for adequate drainage. When cover 50 is connected to drain body 10,
peripheral edge 60 of cover 50 is spaced from sidewall 14 so as to
define a gap or grate free area G there between through which water
may pass while flowing through the drain and toward drain aperture
13. In this way, water is permitted to exit the shower, bath, sink
or other such area without the drain aperture or drain 13 being
visible. Likewise, the peripheral edge 60 also forms a gap with
drain body floor 12.
[0060] The drain apparatus of this invention is preferably utilized
as part of (i) a prefabricated shower pan, (ii) a partially
prefabricated shower pan, (iii) a mortar bed or other hand made
shower pan floor, and/or (iv) a tiled or tileable surface or
fixture, whereby flooring or wall material such as tile may be
attached up to (i.e. adjacent) or upon peripheral wall 14 by epoxy,
concrete, or any suitable wall or flooring adhesive, and additional
flooring or wall coverings, if any, placed upon drain cover 50 with
an appropriate wall or flooring adhesive. In this way, the drain
top, grate or cover has a finished tiled look which matches the
area surrounding or adjacent to the drain top, grate or cover, with
the drain and drain aperture fully operational yet
unnoticeable.
[0061] A strainer made of any appropriate material, an example of
which is shown in FIG. 10, may be placed on drain floor 12 so as to
cover drain aperture 13, which strainer is intended to catch any
debris which would flow through the grate free area (i.e. gap G)
and which would otherwise flow into the drain aperture 13 but for
the strainer. The strainer may be held in place by nesting
apertures 112, 114, 116 and 118 with lugs or posts 32, 34, 36, and
38, or by any other appropriate structure occurring to one with
skill in the art, and will be accessible by removing the drain top,
grate or cover 50 for purposes of cleaning or replacing.
Alternatively, any of the standard types of strainers, such as that
shown in shown in FIGS. 6-7, may be employed.
[0062] To that end, a drain insert 40 may be employed in connection
with drain body 10 as shown in FIGS. 6-9. Insert 40 may include a
threaded collar 46 which is adapted to threadingly engage threaded
surface 16 of drain collar 15. Insert 40 may also include one or
more interchangeable drain tops, grates or covers, such as drain
grate 42, which defines one or more drainage apertures or grate
free areas 44. The drain grate with grate free areas may be
provided with any type of finish and/or any number of custom
designs. The drain assemblies of this invention may also be
provided with interchangeable drain grates with any imaginable
configuration(s) for the grate free area.
[0063] Alternatively, as shown in FIGS. 11-12, a strainer 110 may
be employed which, rather than being connected to a separate insert
such as drain insert 40, may be placed in registry with drain
aperture 13. As discussed above, strainer 110 may have disposed
therein apertures 112, 114, 116 and 118 adapted to fit over posts
32, 34, 36 and 38. Alternatively, a strainer such as strainer 110
may simply be placed upon floor 12 or connected or otherwise
positioned in registry therewith by any means known to the artisan,
such as by attachment to strainer body 40.
[0064] Drain body 10 need not necessarily employ a sidewall section
14. Rather, as the exemplary embodiment of FIG. 9 shows, the shower
or floor pan or other structure which functions as the shower,
bath, sink or other floor substrate may provide the sidewall
structure needed to constrain water flowing toward the floor drain.
In this case, drain body 10 need only be comprised of a floor
section 12. Once combined with the shower or bath pan or other
structure which functions as the shower, bath, sink or other floor
substrate, drain body 10 will be situated within the pan in such a
way that a drain plenum is formed by the drain body floor section
12 and the sidewalls 92 which form the drain recess into which the
drain body 10 has been positioned.
[0065] In such an embodiment, in all other respects the drain
apparatus is the same as described elsewhere herein. That is, a
drain top, grate, or cover 50 may be removably connected to drain
body 10 in any suitable manner, such as by the use of one or more
posts 32, 34, 36 and 38 which co-act with corresponding recesses
52, 54, 56 and 58 in cover 50. As can be seen in FIG. 8, drain body
floor 12 and sidewalls 14 form a plenum into which water drains
from the shower, bath, sink or other floor, which in turn drains
into drain aperture 13. Likewise, as seen in FIG. 9, drain body
floor 12 and sidewalls 92 form a similar plenum. Likewise, drain
body 10, whether with or without sidewalls 14, will form a similar
drain plenum when combined with floor or other substrates formed by
(i) a prefabricated shower pan, and/or (ii) a partially
prefabricated shower pan, and/or (iii) a mortar bed or other hand
made shower pan floor, and/or (iv) a tiled or tileable surface or
fixture, whether such substrate is constructed on site in whole or
in part.
[0066] As stated above, the shower, sink, bath, floor or other
surface or structure which functions as the shower, bath, sink,
floor or other substrate, may be of any type, such as (i) a
prefabricated shower pan, (ii) a partially prefabricated shower
pan, (iii) a mortar bed or other hand made shower pan floor, and/or
(iv) a tiled or tileable surface or fixture.
[0067] It is to be understood that the posts and sockets may be
reversed in whole or in part, such that any of the posts may be
connected to cover 50, and any of the sockets may be connected to
drain body 10. The post and socket arrangement disclosed herein is
but an example of the many ways in which drain top, grate, or 50
may be associated with the drain or drain body 12, it being
appreciated that any suitable attachment arrangement is
contemplated to be within the scope of this invention.
[0068] The invention is also directed to a method of installing a
tileable drain assembly over a drain or over another area that
drains into a drain or a drain aperture which has a grate free area
adjacent to one or more perimeter edges of a drain top, grate, or
cover 50 in accordance with this invention, which includes the
steps of: (1) connecting a drain body 10 of this invention to a
prefabricated shower pan, a partially prefabricated shower pan, a
mortar bed or other hand made shower pan floor, and/or a tiled or
tileable surface or fixture, the drain body 10 defining at least
one drain aperture 13 and optionally including a peripheral
sidewall 14 and, (2) installing the floor pan in a shower or bath
enclosure space (not shown) so that the drain aperture 13 is
substantially in registry with an existing floor drain; (3)
providing a drain top, grate or cover 50 which is sized and shaped,
when connected to the drain body 10, to provide a grate free area
or gap G between a peripheral edge 60 of the drain top, grate or
cover and the drain body sidewall 14 (and/or the adjacent
prefabricated shower pan, partially prefabricated shower pan,
mortar bed or other hand made shower pan floor, and/or a tiled or
tileable surface or fixture) to permit drainage of water through
said gap G.
[0069] Another method of installing a tileable drain assembly over
a drain or over another area that drains into a drain or a drain
aperture which has a grate free area adjacent to one or more of the
perimeter edges of a drain top, grate, or cover 50 in accordance
with this invention includes the steps of: (a) connecting a drain
body 10 of this invention to a floor drain, the drain body
including a peripheral sidewall 14; (2) installing flooring
material onto the adjacent shower, bath, sink or other floor in the
vicinity adjacent the peripheral sidewall of the drain body; (3)
providing a removable drain cover which is sized and shaped, when
connected to the drain body, to provide a gap G between the drain
body sidewall and the peripheral edge of the drain cover to permit
drainage of water through said gap; and (4) installing flooring
material on the drain cover.
[0070] Yet another method of installing a tileable drain assembly
over a drain or over another area that drains into a drain or a
drain aperture which has a grate free area adjacent to one or more
of the perimeter edges of a drain top, grate, or cover 50 in
accordance with this invention includes the steps of: (1)
connecting a drain body of this invention substantially in registry
with an existing floor drain; (2) providing a removable drain cover
which is sized and shaped, when connected to the drain body, to
provide a gap G between the drain body sidewall and a peripheral
edge of the drain cover to permit drainage of water through said
gap G.
[0071] A still further method of installing a tileable drain
assembly over a drain body or over another area that drains into a
drain or a drain aperture which has a grate free area adjacent to
one or more of the perimeter edges of a drain top, grate, or cover
50 in accordance with this invention includes the steps of: (1)
installing one or more of (a) a prefabricated shower pan, (b) a
partially prefabricated shower pan, (c) a mortar bed or other hand
made shower pan floor, (d) a tiled or tileable surface or fixture,
in a shower or bath enclosure space (not shown), each of the
prefabricated shower pan, partially prefabricated shower pan,
mortar bed or other hand made shower pan floor, or tiled or
tileable surface or fixture including a floor, so that the existing
floor drain is substantially in registry with a location on the
floor where a hidden shower or bath drain in accordance with the
teachings of this invention is to be employed; (2) connecting a
drain body 10 of this invention to the prefabricated shower pan,
partially prefabricated shower pan, mortar bed or other hand made
shower pan floor, or tiled or tileable surface or fixture by
creating an aperture in said prefabricated shower pan, partially
prefabricated shower pan, mortar bed or other hand made shower pan
floor or tiled or tileable surface or fixture into which is adapted
to be attached the drain body 10, the drain body 10, optionally
including a peripheral sidewall 14, and defining at least one drain
aperture 13; (3) providing a drain cover 50 which is sized and
shaped, when connected to the drain body 10, to provide a gap G
between the drain floor 12 and/or drain body sidewall 14 and a
peripheral edge 60 of the drain cover to permit drainage of water
through said gap G.
[0072] In use, when the drain apparatus of the instant invention is
connected to (i) a prefabricated shower pan, (ii) a partially
prefabricated shower pan, (iii) a mortar bed or other hand made
shower pan floor, and/or (iv) a tiled or tileable surface or
fixture, cover 50 may be removed to permit access to aperture 13
and/or to permit installation of insert strainer 40 or any other
strainer such as strainer 110 shown in FIGS. 10-11 for cleaning
and/or maintenance. Also, the building plumbing may be rooted out
without requiring removal of drain body 10 so long as cover 50 is
removed. When cover 50 is installed upon drain body 10, it is
intended to be virtually impossible to detect that a drain is even
present.
[0073] A representative, non-exhaustive, depiction of a type of
flooring material which may be used with the invention is shown in
FIGS. 2, 8-9 and 11-12 in the form of one or more pieces of
flooring tile 80. As stated above, floor or wall covering material
suitable for use with this invention may be one or more of ceramic,
natural stone or other tile, stone, granite, marble, cultured
marble, or other stone surface, non slip finished shower surfaces
such as vinyl or plastic, stucco, concrete, and mortar surfaces
which may be mixed with adhesives or other substances and any other
material or material used to provide a finished surface. As seen in
FIGS. 8-9, once flooring material 80 is installed in the shower or
bath pan 90 up to the area adjacent to the outer peripheral edge 14
of drain body 10 or pan interior sidewalls 92, and installed on top
of cover 50, the upper surface C of which is designed to be
coplanar with the upper surface P of the adjacent area of the
shower or bath pan (or mortar bed floor) 90, a contiguous finished
shower or bath surface is formed, and the drain is essentially
undetectable.
[0074] In addition, the drain body may be employed without the use
of a cover such as cover 50 in which case no flooring material will
be used to conceal the actual drain aperture or strainer insert 40,
or may employ a differently configured cover which acts as an
unconcealed drain top, grate or cover. (i.e. that is not covered
with flooring material). The drain body may be installed in or
below the upper surface of (i) a prefabricated shower pan, (ii) a
partially prefabricated shower pan, (iii) a mortar bed or other
hand made shower pan floor, (iv) a tiled or tileable surface or
fixture. In this way, a provider of products of this type may
significantly reduce attendant manufacturing costs by reducing the
number of molds employed in the manufacture of a variety of pan
sizes. In addition, management of inventory is simplified since a
single drain body 10 may be used for all prefabricated or
manufacture products having a drain, and while using
interchangeable tileable, non tileable, and designer drain tops,
grates or covers to establish separate product lines which can be
marketed and sold based on the finish of the drain top, grate or
cover. Alternatively, the different drain tops, grates or covers
can be supplied as part of a kit, or as accessories which can be
ordered or otherwise purchased separately, allowing for a wide
variety of combinations of tiled, tileable or non tileable drain
tops, grates or covers, with concealed or unconcealed drains, with
designer tops, including but not limited to, (i) a tileable drain
top, grate or cover with a concealed drain, (ii) a non tileable
drain top, grate, or cover with a standard grate free area design,
and an unconcealed drain, (iii) a non tileable drain top, grate or
cover with a designer drain top, grate or cover and an unconcealed
drain, or (iv) an unconcealed drain and an untiled designer drain
top, grate or cover, simply by substituting one drain top grate or
cover for another, i.e., removing the tileable cover 50 and
connecting any number of different tileable or non tileable drain
tops, grates or covers over drain aperture 13.
[0075] FIGS. 10-11 and 14 show a strainer insert 110 adapted to be
placed onto floor 12. Strainer 110 defines apertures 112, 114, 116
and 118 which are adapted to receive posts 32, 43, 36 and 38.
Alternatively, strainer 110 may be of any size or shape, so long as
it effectively covers drain aperture 13.
[0076] FIGS. 12-13 show a modified drain insert assembly, whereby
floor 12 of drain body 10 is recessed around drain aperture 13,
creating an annular recess or shoulder 19 into which strainer 42 of
drain insert 40 may be nested, so as to create a smooth transition
for water flowing from floor 12 into drain aperture 13.
Alternatively, a stand alone strainer such as that shown in FIGS.
10-11, preferably, but not by way of limitation, round shaped, may
be dropped into the annular recess defined by shoulder 19 and
attached thereto by any suitable means.
[0077] The exposed edges of cover 50 and/or flooring material 80
around gap G may be covered, beveled, ground or otherwise rendered
smooth so that it will not expose a user to any sharp edge which
may injure the user. Adhesively or clip-on attachable L-shaped
cover members 100 may be provided, by way of additional example, so
as to cover the edges of cover 50 and/or flooring material 80.
Alternatively, a flowable, hardenable material such as liquid
epoxy, or other resinous or plasticized material may be poured or
otherwise coated over the exposed edges.
[0078] Cover 50 may be, as stated above, removable, and additional
and/or replacement covers may be provided or sold separately to
permit variation in the appearance of the drain and/or shower,
bath, tub or basin. For example, a user may wish to use a first
covering material such as floor or sink/tub/basin tile on a first
cover member 50, and a second, different, covering material on a
second cover member 50. Additional replacement cover members 50 may
be provided with still further covering materials associated with
them. For example, a user may wish to employ a decorative covering
material on one cover member 50, and his or her favorite sports
team or celebrity on another, or a builder or hotelier may wish to
have a unique feature or logo tiled onto the drain top, grate or
cover, and so forth.
[0079] However, it is also to be understood that cover 50 may be
connectable to drain body 10 in a manner that will preclude the
removal thereof once connected. Also, drain body 10 and cover 50
may be manufactured as an integral unit.
[0080] It is to be understood that the drain assembly disclosed
herein may be employed without the prefabricated shower pan or
partially prefabricated shower pan referenced above. Drain body 10
may be installed in a mortar bed or other hand made shower pan by
creating a mud or mortar base for a shower, tub, etc., placing
drain body collar section 18 in registry with a floor or basin/sink
drain while sinking drain body 10 into said mud or mortar base, and
tiling over or up to the outer periphery of the drain body 10. One
or more covers 50 may then be interchangeably employed in the
manner discussed above.
[0081] It is also to be understood that the cover members 50 of
this invention may be of any shape or size. Drain body 10 may or
may not be correspondingly shaped as well.
[0082] Drain assemblies in accordance with this invention may be
located at essentially any position within a (i) a prefabricated
shower pan, (ii) a partially prefabricated shower pan, (iii) mortar
bed or other hand-made shower pan, and/or (iv) a tiled or tileable
surface or fixture. If the drain assembly is located near one or
more sidewalls (if any) of such pan or bed, one or more of the gaps
G surrounding the outer peripheral edges 60 of cover 50 may be
bounded by the sidewall, such that the outer boundary of gap G
along the edge of cover 50 facing the sidewall or sidewalls will be
the sidewall or sidewalls. Or, the cover 50 and/or covering
material 80 attached to cover 50 may be butted up against or in
close proximity to said sidewall or sidewalls.
[0083] The drain cover may alternatively be attached to the drain
apparatus through an attachment structure which allows the height
of the upper surface of the drain cover to be positioned so that it
is coplanar with an upper surface of the (A) prefabricated shower
pan, (B) partially prefabricated shower pan, (C) a mortar bed or
other hand made shower pan floor, or (D) a tiled or tileable
surface or fixture, adjacent to the drain top, grate, or cover,
such attachment structure including but not limited to: (i)
attaching a drain insert such as insert 40 to the drain by
threadingly attaching the drain, top, grate or cover to the drain
insert, rotating the drain insert down to the appropriate height,
and then attaching the drain top, grate or cover to the drain
insert, by screws, clips, snap-on posts, or other suitable
attachment mechanism or (ii) attaching the drain cover to posts on
the drain body floor with variably sized spacers to allow the
height of the non tileable drain cover to be coplanar with the
tiled prefabricated shower pan adjacent to the non tileable drain
top, grate, or cover, or (iii) any other method that allows the non
tileable drain top, grate or cover to be adjustably attached to the
drain cover apparatus at a height that is coplanar with the tiled
prefabricated shower pan surface.
[0084] FIG. 15 shows spacers 190 being used between drain body
floor 12 and the bottom of sockets 52, 54, 56 and 58, which permit
the adjustment of the height of upper surface C of cover 50 and
upper surface P of pan floor 90. In this way, the height of cover C
relative to the adjacent pan floor can be adjusted to accommodate
height variations in the drain body and pan assembly as well as
variations, if any, in the thickness of floor covering material
employed. It is to be understood that the configuration shown in
FIGS. 14 and 15 may be likewise employed in the configuration shown
in FIGS. 9 and 12-13.
[0085] FIGS. 16-17 show an alternative configuration for the drain
body and cover assembly. In this embodiment, drain body 10 and
cover 50 are circular in shape. The invention otherwise functions
in accordance with the principles described herein. Obviously,
drain body 10 and/or cover 50 may be sized and shaped in any
manner.
[0086] FIGS. 18-20 show a representative example of a prefabricated
shower or bath pan in accordance with this invention having the
drain body 10 of the instant invention associated therewith. Pan 90
may be comprised of a floor 212, sidewalls 214, a curb 216 and one
or more barrier-free thresholds 218. Any other configuration of a
prefabricated shower or bath pan known to those of skill in the art
may be employed. Drain body 10 may employ sidewalls 14 as shown in
FIG. 8, or be without sidewalls as shown in FIG. 9. Cover 50 is
associated therewith, so as to form gap G through which water may
drain.
[0087] In this embodiment, one or more drain bodies, such as any of
the drain bodies illustrated in FIGS. 1-17, are connected to pan
90, preferably during manufacture of pan 90. Pan 90 is installed
within, or forms the space for, a shower enclosure. Tailpiece 18 of
drain body 10 (shown in FIGS. 1-4 and 7-16) is placed in registry
with the existing floor drain (not shown) during installation of
pan 90. Pan 90 is otherwise installed as known to those of skill in
the art. Wall or flooring material 80 is then installed over pan 90
and cover 50 as shown in FIG. 19.
[0088] In addition, the drain apparatus disclosed herein may also
be employed with a partially prefabricated shower pan where the
drain is installed in the shower pan floor after manufacture,
usually in the field and at the time of installation of the
partially prefabricated shower pan. Such a partially prefabricated
shower pan may be comprised of any of the components shown in the
pan of FIG. 18, or additional or fewer components, depending upon
the needs of the application. Further additionally, the drain
apparatus disclosed herein may also be used in conjunction with a
mortar bed or other hand made shower pans, or any surface or
fixture in which a drain is to be installed. In either
installation, i.e. pans assembled and installed in the field (for
example, partially fabricated shower pans, mortar beds or other
hand made shower pan floors, and surfaces or fixtures into which
one or more drains are to be installed), the drain body must be
connected to the floor drain while at the same time being recessed
within the shower pan floor so that upon completion of the
installation, the tileable or tiled drain top, grate or cover will
be coplanar with the tileable or tiled shower pan floor or other
surface or fixture immediately adjacent thereto.
[0089] One manner of implementing such an arrangement is by the use
of a modified drain body 310 shown in FIGS. 21-23. Drain body 310
may have a floor section 312 which defines a drain aperture 313,
optional sidewalls 314, posts 332, 334, 336 and 338 for receiving
corresponding sockets in cover 50, and a drain body tail piece 318,
similar to that described in previous embodiments.
[0090] A floor mounting flange 322 is associated with drain body
310 in a manner which will be apparent from the description below.
A standard floor drain collar 320 is adapted to be positioned
within a subfloor 315, and has associated therewith one or more
bolts 326 which are threadingly or otherwise connected to drain
collar 320 in any manner which will occur to those of skill in the
art. In the example shown, bushings 324 are retained by
corresponding sockets in drain collar 320, which in turn receive
threaded bolts 326. When drain body 310 is placed upon floor drain
320, apertures in flange(s) 322 are aligned with bolts 326, and
retaining nuts 327 secured thereover to fasten drain body 312 to
floor drain collar 320.
[0091] As best seen in FIGS. 21-23, in the event a partially
prefabricated pan is to be employed to create the shower pan, a pan
floor 390 may be employed which is made up of two or more sections
or pieces 392A, 392B, which define corresponding cutouts 395A, 395B
which nest around the outer surfaces of drain body sidewalls 314.
Areas of reduced thickness such as shoulders 397A, 397B defined by
the sidewalls of cutouts 395A, 395B are slid between the substrate
such as subfloor and/or thinset 315 and drain body floor 312 upon
installation of pan floor sections 395A, 395B into an enclosure
space such as a shower or bath enclosure. Thereafter, additional
covering material such as a waterproof liner or membrane 400,
and/or mortar or thinset or other setting materials and/or
adhesives 410, and floor or wall covering material such as tile 80
over pan floor 392A, 392B and cover 50, may be installed to
complete the installation. It is also understood that the partially
prefabricated shower pan may have one piece shower pan floor, in
which case a hole is cut into a shower pan floor for purposes of
installing the drain and attaching it to the waste water system,
and such partially prefabricated shower pan may also have
additional component parts such as a curb, barrier free entrance,
splash walls, and water proofing materials which are also assembled
and installed in the field with the one piece shower pan floor.
[0092] Any other manner and/or structure of connecting a drain
cover to a wastewater drain pipe are contemplated to be within the
scope of application of the apparatus and methods described herein.
For example, the drain bodies shown and described herein are
likewise suited for use with compression drain and clamping ring
drain attachment arrangements.
[0093] Benefits, other advantages, and solutions to problems have
been described above with regard to specific embodiments of the
present invention. However, the benefits, advantages, solutions to
problems, and any element(s) that may cause or result in such
benefits, advantages, or solutions to become more pronounced are
not to be construed as a critical, required, or essential feature
or element of any or all the claims. The invention is defined
solely by the appended claims including any amendments made while
this application is pending and all equivalents of those claims as
issued.
* * * * *