U.S. patent application number 15/477426 was filed with the patent office on 2018-06-07 for pre-form for drain installation.
The applicant listed for this patent is COFLEX S.A. DE C.V.. Invention is credited to Javier Canales, Eduardo Coronado, Humberto Flores-Villarreal, Pedro Gonzalez.
Application Number | 20180155914 15/477426 |
Document ID | / |
Family ID | 62239797 |
Filed Date | 2018-06-07 |
United States Patent
Application |
20180155914 |
Kind Code |
A1 |
Coronado; Eduardo ; et
al. |
June 7, 2018 |
PRE-FORM FOR DRAIN INSTALLATION
Abstract
A pre-form for drain installation is provided. The pre-form
comprises a cap portion, a bottom portion, and an outer portion.
The cap portion defines an interior for receiving a top end of an
upwardly extending drain pipe and is configured to cover an opening
of the drain pipe. The bottom portion is detachedly coupled to the
cap portion and comprises an aperture through which the drain pipe
may pass so as to enable the bottom portion to slide along the
length of the drain pipe. The outer portion is coupled to and
extends upwardly from the bottom portion so as to define a
perimeter for displacing concrete proximate to the drain pipe when
inserted into a wet concrete flooring surface.
Inventors: |
Coronado; Eduardo; (San
Pedro Garza Garcia, MX) ; Canales; Javier;
(Monterrey, MX) ; Gonzalez; Pedro; (San Pedro
Garza Garcia, MX) ; Flores-Villarreal; Humberto; (San
Pedro Garza Garcia, MX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
COFLEX S.A. DE C.V. |
Monterrey |
|
MX |
|
|
Family ID: |
62239797 |
Appl. No.: |
15/477426 |
Filed: |
April 3, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
29594612 |
Feb 21, 2017 |
|
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15477426 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E03F 2005/0416 20130101;
E04G 15/063 20130101; E03F 5/0407 20130101; E04B 5/32 20130101 |
International
Class: |
E03F 5/04 20060101
E03F005/04; E04B 5/32 20060101 E04B005/32; E04G 15/06 20060101
E04G015/06 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 6, 2016 |
MX |
MX/F/2016/003927 |
Claims
1. A method of installing a drain fixture, the method comprising:
installing a sub-floor plumbing system comprising an upwardly
extending drain pipe; positioning a pre-form on a top end of the
drain pipe, wherein the pre-form comprises: a cap portion that
substantially covers an opening of the drain pipe; a bottom portion
detachedly coupled to the cap portion; and an outer portion coupled
to and upwardly extending from the bottom portion; building a
concrete flooring surface proximate to the drain pipe; applying a
downward force to the pre-form so as to cause the cap portion to
detach from the bottom portion; sliding the pre-form down the
length of the drain pipe until the bottom portion is at least
partially inserted into the concrete flooring surface proximate to
the drain pipe while the concrete flooring surface is wet, wherein
the cap portion remains positioned on the top end of the drain
pipe; removing the pre-form after the concrete flooring surface
sets; cutting the drain pipe to a desired length, thereby resulting
in a shortened drain pipe; and installing a drain on a top end of
the shortened drain pipe.
2. The method of claim 1, wherein the cap portion, the bottom
portion, and the outer portion are cast using a common injection
mold.
3. The method of claim 1, wherein sliding the bottom portion of the
pre-form down the length of the drain pipe until the bottom portion
is at least partially inserted into the concrete flooring surface
comprises: displacing an amount of concrete proximate to the drain
pipe, wherein the amount of displaced concrete is defined by
dimensions of at least one of the bottom portion and the outer
portion
4. The method of claim 1, wherein building the concrete flooring
surface comprises: pouring concrete proximate to the drain pipe and
evenly spreading the concrete above the drain pipe area.
5. The method of claim 1, wherein applying a downward force to the
pre-form comprises applying a downward force to a top edge of the
outer portion.
6. The method of claim 1, wherein the bottom portion is inserted
into the concrete flooring surface until the concrete flooring
surface is substantially level with a marker disposed on an outside
surface of the outer portion.
7. The method of claim 1, wherein the top end of the drain pipe is
received within an interior of the cap portion when the pre-form is
positioned on the top end of the drain pipe.
8. The method of claim 1, wherein the cap portion is detachedly
coupled to the bottom portion via a perforated seam that is broken
when the downward force is applied to the pre-form.
9. The method of claim 1, wherein the bottom portion comprises an
aperture through which the drain pipe passes when the bottom
portion of the pre-form is slid down the length of the drain
pipe.
10. The method of claim 1, wherein the drain pipe is cut so that
the height of the shortened drain pipe does not extend above a
level of the finished flooring surface.
11. The method of claim 1, wherein installing the drain comprises:
coupling the drain to the top end of the shortened drain pipe; and
sealing a space between the drain and the concrete flooring
surface.
12. A pre-form for drain installation comprising: a cap portion
defining an interior for receiving a top end of an upwardly
extending drain pipe; a bottom portion detachedly coupled to the
cap portion and comprising an aperture through which the drain pipe
passes so as to enable the bottom portion to slide along the length
of the drain pipe; and an outer portion coupled to and extending
upwardly from the bottom portion so as to define a perimeter for
displacing concrete proximate to the drain pipe when inserted into
a wet concrete flooring surface.
13. The pre-form of claim 12, wherein the cap portion substantially
covers an opening of the drain pipe.
14. The pre-form of claim 12, wherein the cap portion is detachedly
coupled to the bottom portion via a perforated seam that is broken
when a downward force is applied to the bottom portion or the outer
portion.
15. The pre-form of claim 12, wherein the cap portion remains
positioned on the top end of the drain pipe.
16. The pre-form of claim 12, wherein the outer portion comprises a
marker for at least one of: identifying a height to which a
pre-form is to be inserted into a wet concrete surface; and
identifying a height to which the drain pipe is to be cut.
17. The pre-form of claim 12, wherein an outer edge of the bottom
portion is coupled to a bottom edge of the outer portion, and
wherein the bottom edge of the outer portion defines a perimeter
that is smaller than a perimeter defined by a top edge of the outer
portion.
18. The pre-form of claim 12, wherein the cap portion, the bottom
portion, and the outer portion are cast as one piece using a common
injection mold.
19. The method of claim 1, wherein building a concrete flooring
surface proximate to the drain pipe comprises building a thin set
mortar surface proximate to the drain pipe.
20. The pre-form of claim 12, wherein the concrete includes thin
set mortar.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a utility application of, and claims
priority to, U.S. Design Patent Application No. 29/594,612, filed
on Feb. 21, 2017, which claims priority to Mexican Design Patent
Application No. MX/f/2016/003927, filed on Dec. 6, 2016, the
entirety of both hereby incorporated by reference.
BACKGROUND
[0002] Most homes use basic systems for plumbing and drain systems.
A main water line usually comes into a home through its foundation.
From this location, the water line may run to a water heater, which
generates hot water.
[0003] A plumbing drain trap is a shaped pipe located below or
within a plumbing fixture such as a toilet, a sink, or a shower
drain. A trap can be a U-, S-, or J-shaped trap, although U- and
J-shaped traps are the most common traps used today. The various
shapes are each named for the bends in the traps, which are used to
prevent sewer gases from entering buildings through drain pipes.
The bends in the traps are shaped to retain a small amount of water
after use of the fixture. The water in the trap creates a seal that
prevents sewer gases from passing from the drain pipe back into the
building.
[0004] However, known plumbing traps have certain disadvantages.
Many installations require shallow traps in order to fit against a
concrete floor, whether that concrete floor is on a first floor or
a basement floor, or for a second story installation. In the United
States, basement floors are typically concrete floors so a shallow
trap must be used for basement drain fixtures. The height of a trap
seal is measured from the bottom of a trap arm at an outlet to the
top of the trap dip, also know as the crown weir. A standard trap
height may be 50 mm, for example, but a shallow trap may only have
a trap height of 15 mm, for example. When a shallow trap is used,
however, the amount of water in the trap is decreased compared to
the amount in a regular trap, and regular evaporation of water in
the trap may cause the water seal to be broken more quickly,
thereby allowing sewer odors and gases to enter into the
building.
[0005] In addition, in some other regions, such as Latin America,
floor drains are typically placed next to a toilet in addition to
in a shower. While traps connected to a shower drain or a toilet
are easy to refill on a regular basis by running the shower or
flushing the toilet, in order to maintain a proper seal for a floor
drain pipe with a known plumbing trap, water must be poured into
the drain on a regular basis. Otherwise, the water within the trap
may evaporate and the water seal may be broken if air can pass
through the bend in the trap, thereby allowing sewer odors and
gasses to enter into the building.
[0006] Further, installing floor drains can be difficult because
more than one professional is typically involved in the
installation process. In a standard installation, a plumber will
install the sub-floor plumbing components and then leave a drain
pipe extending above an estimated floor height that will extend to
a desired fixture. Then, a flooring specialist will finish the
flooring above the sub-floor plumbing. Concrete is often poured
around the drain pipe and then a finish flooring surface is
installed above the concrete. Once the concrete is poured, however,
it is difficult, if not impossible, to remove the drain pipe to cut
it to the proper height. In order to cut the drain pipe below the
flooring surface after the concrete is poured, the flooring
specialist must chisel the cement around the drain pipe so that
there is sufficient clearance for tools to cut the drain pipe below
the flooring surface. Understandably, manually chiseling cement
surrounding the drain pipe is often an approximated process and can
result in cracking of the drain pipe. As such, an installed floor
drain may not seal completely with the drain pipe or surrounding
concrete, thereby resulting in unwanted leaks. Additionally, if the
drain pipe is cut before the concrete is poured, it is difficult to
determine the desired length of the drain pipe necessary to make
the floor drain sit flush on the finished flooring surface.
[0007] Thus, an improved method for determining the height of the
drain pipe and installing a floor drain flush with the flooring
slab is desired.
BRIEF SUMMARY
[0008] In an exemplary embodiment, an improved method of installing
a drain fixture is provided. First, a sub-floor plumbing system
comprising an upwardly extending drain pipe is installed. Next, a
pre-form is positioned on a top end of the drain pipe. The pre-form
comprises a cap portion that substantially covers an opening of the
drain pipe as well as a bottom portion that is detachedly coupled
to the cap portion and an outer portion. Next, a concrete flooring
surface is built proximate to the drain pipe. While the concrete is
still wet, a downward force is applied to the bottom portion of the
pre-form so as to cause the cap portion to detach from the bottom
portion. The bottom portion of the pre-form is slid down the length
of the drain pipe until the bottom portion is at least partially
inserted into the concrete flooring surface proximate to the drain
pipe. The cap portion remains positioned on the top end of the
drain pipe. After the concrete sets, the cap portion and the bottom
portion of the pre-form are removed. The drain pipe is cut to a
desired length, thereby resulting in a shortened drain pipe.
Lastly, a drain may be installed on a top end of the shortened
drain pipe.
[0009] In an exemplary embodiment, a pre-form for drain
installation is provided. The pre-form comprises a cap portion, a
bottom portion, and an outer portion. The cap portion defines an
interior for receiving a top end of an upwardly extending drain
pipe and is configured to cover an opening of the drain pipe. The
bottom portion is detachedly coupled to the cap portion and
comprises an aperture through which the drain pipe may pass so as
to enable the bottom portion to slide along the length of the drain
pipe. The outer portion is coupled to and extends upwardly from the
bottom portion so as to define a perimeter for displacing concrete
proximate to the drain pipe when inserted into a wet concrete
flooring surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Reference is now made to the following descriptions taken in
conjunction with the accompanying drawings.
[0011] FIG. 1 depicts an elevational view of a first prior art
floor drain installation;
[0012] FIG. 2 depicts an elevational view of a second prior art
floor drain installation;
[0013] FIG. 3 depicts an perspective view of an improved drain
installation, in accordance with one embodiment of the present
disclosure;
[0014] FIG. 4 depicts a cutaway view of the improved drain
installation of FIG. 3, in accordance with one embodiment of the
present disclosure;
[0015] FIG. 5 depicts a depicts a magnified cutaway view of the
improved drain installation of FIG. 4, in accordance with one
embodiment of the present disclosure;
[0016] FIG. 6 depicts a cutaway view of an improved drain
installation, in accordance with one embodiment of the present
disclosure;
[0017] FIG. 7 depicts a cutaway view of the improved drain
installation of FIG. 3, in accordance with one embodiment of the
present disclosure;
[0018] FIG. 8A depicts a perspective view of a first pre-form of
the improved drain installation of FIG. 3, in accordance with one
embodiment of the present disclosure;
[0019] FIG. 8B depicts a perspective view of a second pre-form of
the improved drain installation of FIG. 3, in accordance with one
embodiment of the present disclosure; and
[0020] FIG. 9 depicts an perspective view of an improved drain
installation, in accordance with one embodiment of the present
disclosure.
[0021] FIG. 10 depicts a perspective view of a pre-form for drain
installation, in accordance with one embodiment of the present
disclosure.
[0022] FIG. 11 depicts a top view of the pre-form for drain
installation of FIG. 10, in accordance with one embodiment of the
present disclosure.
[0023] FIG. 12 depicts a bottom view of the pre-form for drain
installation of FIG. 10, in accordance with one embodiment of the
present disclosure.
[0024] FIG. 13 depicts a side view of the pre-form for drain
installation of FIG. 10, in accordance with one embodiment of the
present disclosure.
DETAILED DESCRIPTION
[0025] Various aspects of a drainage fitting and related methods
for installing a drainage fitting according to the present
disclosure are described. It is to be understood, however, that the
following explanation is merely exemplary in describing the devices
and methods of the present disclosure. Accordingly, any number of
reasonable and foreseeable modifications, changes and substitutions
are contemplated without departing from the spirit and scope of the
present disclosure.
[0026] FIG. 1 depicts an elevational view of a first prior art
floor drain installation 100. The first prior art drain
installation 100 may comprise a drain pipe 102 extending upwardly
from a plumbing trap 104 to a fixture, such as a floor drain 108.
The installation 100 may further comprises a drain outlet 106
connected to the main sewer line (not shown). Before the
installation 100 is completed, the drain pipe 102 extends above a
flooring slab and must be cut to the appropriate length to allow
the floor drain to sit flush with a finished flooring surface
112.
[0027] FIG. 2 depicts an elevational view of a second prior art
floor drain installation 200. The second prior art drain
installation 200 may comprise a first drain pipe 202 extending
upwardly from a connection 206 and a plumbing trap 204 to a
fixture, such as a floor drain 208. The connection 206 may also
connect to a second drain pipe 210, which may be connected to a
second fixture, such as a sink 218. A connection 212 may be
connected to the plumbing trap 204 at a second end. A third drain
pipe 214 may extend from the connection 212, which may be connected
to an elbow 218 and a third fixture, such as a toilet 216. A drain
outlet (not shown) may also extend from the second connection 212
and may be connected to the main sewer line. In an embodiment, the
first and second connections 206, 218 may be T- or Y-shaped
connections. Before the installation 200 is completed, the drain
pipes 202 and 214 extend above a flooring slab and must be cut to
appropriate lengths to allow the fixtures to sit flush with or on a
finished flooring surface.
[0028] As depicted in FIGS. 1 and 2, after installation, the
fixtures 108, 208, and 216 preferably sit flush with or on a
finished flooring surface 112 installed above a concrete slab 110.
In order to make such a prior art installation 100, 200, however, a
plumber will install the sub-floor plumbing components and then
leave the drain pipes 102, 202 extending above an estimated floor
height that will extend to a desired fixture. Then, a flooring
specialist will finish the flooring above the sub-floor plumbing.
Concrete 110 is often poured around the drain pipe and then the
finished flooring surface 112 is installed above the concrete 110.
Once the concrete 110 is poured, however, it is difficult, if not
impossible, to remove the drain pipes 102, 202 in order to cut them
to the proper height. In order to cut the drain pipes 102, 202
below the flooring surface after the concrete 110 is poured, the
flooring specialist must chisel the concrete 110 around the drain
pipes 102, 202 so that there is sufficient clearance for tools to
cut the drain pipes 102, 202 below the finished flooring surface
112, which can be a difficult process. But if the drain pipes 102,
202 are cut before the concrete 110 is poured, it is difficult to
determine the desired length of the drain pipes 102, 202.
[0029] FIG. 3 depicts a perspective view of an improved drain
installation 300, in accordance with one embodiment of the present
disclosure. FIG. 4 depicts a cutaway view of the improved drain
installation 300 of FIG. 3, in accordance with one embodiment of
the present disclosure. FIG. 5 depicts a magnified cutaway view of
the improved drain installation 300 of FIG. 4, in accordance with
one embodiment of the present disclosure.
[0030] As shown in FIGS. 3-5, the improved drain installation 300
may include a plumbing trap 312. In an embodiment, the plumbing
trap 312 may be an integral U-shaped trap, although in other
embodiments, it may be an S- or J-shaped trap. In an embodiment, an
adapter 302 may be removably or permanently connected to a first
end of the plumbing trap 312 at a first end of the adapter 302. In
other embodiments, the adapter 302 may be internally, or
integrally, formed and may be configured to be received within the
first end of the plumbing trap 312 at a first end of the adapter
302. In other embodiments, an adapter may not be required. A drain
outlet (not shown) may be removably or permanently connected to a
second end of the plumbing trap 312 and the drain outlet may be
connected to the main sewer line (also not shown). The drain
outlet, the plumbing trap 312, and/or the adapter 302 may be
permanently connected to each other with a plumbing cement or
adhesive or may be removably connected to each other through a
friction-fit type of engagement seal.
[0031] The improved drain installation 300 may further comprise a
removable drain pipe 306, which may be connected to a first end of
the plumbing trap 312 at a first end of the removable drain pipe
306.
[0032] The improved drain installation 300 may further comprise a
sleeve 304 received around the removable drain pipe 306 and may
extend to approximately an end of the removable drain pipe 306.
Both the removable drain pipe 306 and the sleeve 304 may extend
above a slab level of a flooring surface, requiring the removable
drain pipe 306 to be cut to size before a fixture 308 may be
attached to the end of the removable drain pipe 306. In an
embodiment, the fixture 308 may be a floor drain or a shower drain.
In an embodiment, the sleeve 304 may be a disposable sleeve or a
reusable sleeve.
[0033] In some embodiments, an adapter 302 may be received between
the plumbing trap 312 and the removable drain pipe 306. In such
embodiments, the plumbing trap 312 may be received within a first
end of the adapter 302 and the removable drain pipe 306 may be
received within a second end of the adapter 302. A washer 314 may
be received between the removable drain pipe 306 and the adapter
302 at the second end of the adapter 302 and may provide a seal
between the removable drain pipe 306 and the adapter 302 such that
gases and liquids cannot escape between the two. The first end of
the removable drain pipe 306 may further comprise an angled end
322.
[0034] The adapter 302 may be shaped with a first diameter at its
first end and a second, larger diameter at its second end connected
by an angled transition 324 between the two. The first diameter at
the first end may be sized and shaped to fit within the first end
of the plumbing trap 312. The second diameter at the second end may
be sized and shaped to receive the removable drain pipe 306. When
inserted into the adapter 302, the angled first end 322 of the
removable drain pipe 306 may interact with, but not pass beyond,
the angled transition 324 of the adapter 302. The second end of the
adapter 302 may further comprise an enclosed circumferential
shoulder 316 operable to receive the washer 314 within the
shoulder. The shoulder 316 may be sized and shaped to mate with the
washer 314 and may include a circumferential lower lip 318 operable
to engage with an inner circumferential shoulder 320 of the washer
314.
[0035] In FIGS. 3-5, the fixture 308 depicted is a floor drain.
When installing a floor drain, unlike when installing a toilet or a
sink, the removable drain pipe 306 is cut below the flooring
surface so that the floor drain can sit flush with the flooring
surface, allowing the water to drain. With a floor drain, a
pre-form 310 may be used and received around the sleeve 304 and the
removable drain pipe 306. The pre-form 310 may be shaped to
correspond to the shape of the desired floor drain fixture 308.
[0036] During installation, both a plumber and a flooring
specialist may be needed to properly install the improved drain
installation 300. The plumber may first connect the plumbing trap
312 to the main drain outlet (not shown) that is connected to the
sewer main (also not shown) below the flooring slab level. Next,
the plumber may insert the washer 314 into the shoulder 316 of the
adapter 302, or the washer 314 may be pre-installed into the
shoulder 316, and connect the adapter 302 to the first end of the
plumbing trap 312. The adapter 302 is operable to be inserted into
the first end of the plumbing trap 312 at the first end of the
adapter 302. Next, the plumber may connect the removable drain pipe
306 to the second end of the adapter 302. In an embodiment, the
shoulder 316 may be received in the adapter 302 or in the
integrally-formed P-shaped trap. The removable drain pipe 306 is
operable to be inserted into the second end of the adapter 302,
creating a seal between the removable drain pipe 306 and the
adapter 302 at the washer 314. If an adapter is not desired, the
plumber may connect the removable drain pipe 306 to the first end
of the plumbing trap 312. The shoulder 316 and the washer 314 may
be integrally formed at the first end of the plumbing trap 312.
Once the removable drain pipe 306 has been connected to either the
plumbing trap 312 or the adapter 302, the plumber may slide the
sleeve 304 over the removable drain pipe 306. The sleeve 304 may be
slid downwardly and proximate to the plumbing trap 312 or the
adapter 302. If the fixture 308 being installed is a floor drain,
the plumber may then slide the pre-form 310 over both the sleeve
304 and the removable drain pipe 306. The pre-form 310 may be slid
downwardly so that an upper edge of the pre-form 310 is
approximately level with the eventual height of the flooring slab
level. Once the sub-floor plumbing is complete, the plumber may
transition the project to the flooring specialist.
[0037] Next the flooring specialist may build the floor above the
sub-floor and around the sleeve 304 and the removable drain pipe
306. The flooring specialist may start with a concrete or wood
sub-floor (not shown) and then build a finished flooring surface
(also not shown) above the sub-floor. The finished flooring surface
may be made from tile, wood, finished concrete, or the like and may
be various thicknesses based on the chosen finished flooring
surface. The sub-floor and the finished flooring surface may extend
entirely around the sleeve 304. Once the flooring is complete, the
flooring specialist may finish the installation of the plumbing
fixture 308 or may transition the project back to the plumber to
finish installation of the plumbing fixture 308.
[0038] In the improved installation process, the flooring
specialist or the plumber does not need to alter the finished
flooring surface in any way in order to cut the removable drain
pipe 306 to the desired height. Unlike the prior art methods, which
required the flooring specialist or the plumber to chisel the
flooring surface or to guestimate the desired height of the drain
pipe, the current installation process allows the flooring
specialist or the plumber to precisely cut the removable drain pipe
306 to the desired height without needing to chisel the
sub-floor.
[0039] In order to finish installation of the plumbing fixture 308
in the improved installation process, either the flooring
specialist or the plumber can mark the desired height of the
removable drain pipe 306 or measure the distance from the end of
the removable drain pipe 306 to the finished flooring surface.
Next, either the flooring specialist or the plumber can remove the
removable drain pipe 306 from the plumbing trap 312 or the adapter
302, while leaving the sleeve 304 in place relative to the
sub-floor and the finished flooring surface. The sleeve 304 acts as
an insulator between the removable drain pipe 306 and the sub-floor
and the finished flooring surface and eliminates the traditional
adhesive interaction that would be present between concrete and a
traditional drain pipe. The sleeve 304 can be made from cardboard,
wax paper, plastic, or any other insulating material.
[0040] Once the removable drain pipe 306 is removed partly or
entirely from the sleeve 304 and the removable drain pipe 306 is
cut to the proper length, while the sleeve 304 maintains and
secures the aperture to allow the removable drain pipe 306 to be
re-inserted through the sleeve 304.
[0041] After cutting the removable drain pipe 306 to the proper
length, either the flooring specialist or the plumber may re-insert
the removable drain pipe 306 through the sleeve 304 and into either
the plumbing trap 312 or the adapter 302.
[0042] If an adapter is desired, the removable drain pipe 306 may
be inserted into the sleeve 304 until the angled end 322 of
removable drain pipe 306 interacts with the angled transition 324
of the adapter 302. Once re-inserted, the washer 314 again creates
a seal between the adapter 302 and the removable drain pipe 306.
During both removal and re-insertion of the removable drain pipe
306, the washer 314 may move within the shoulder 316 of the adapter
302, but if present, the circumferential lip 318 and
circumferential shoulder 320 arrangement prevent the washer 314
from being removed from the shoulder 316.
[0043] Before the removable drain pipe 306 is re-inserted into the
plumbing trap 312 and a proper seal is created, the flooring
specialist may remove the sleeve 304 from between the sub-floor and
finished flooring surface. If the fixture being installed is a
floor drain, the pre-form 310 may also be removed, leaving an
opening the same size and shape as the desired floor drain.
[0044] Once the removable drain pipe 306 has been cut to the
desired length, and re-inserted into the trap 312, the flooring
specialist can install the desired plumbing fixture 308. The
plumbing fixture 308 may create a seal between the end of the
removable drain pipe 306 and the finished flooring surface, or the
plumber may create a seal (or additional seal) with caulk or
another similar sealing material.
[0045] FIG. 6 depicts a cutaway view of an improved drain
installation 400, in accordance with one embodiment of the present
disclosure. Like the drain installation depicted in FIGS. 3-5, the
improved drain installation 400 may include a plumbing trap 412. In
an embodiment, the plumbing trap 412 may be an integral U-shaped
trap, although in other embodiments, it may be an S- or J-shaped
trap. A T-shaped adapter 402 may be connected to a first end of the
plumbing trap 412 and may be configured to be received within the
first end of the plumbing trap 412 at a first end of the T-shaped
adapter 402. The T-shaped adapter 402 allows two plumbing fixtures
to be installed in close proximity to each other, such as a floor
drain and a sink in a bathroom, and connect to a single plumbing
trap 412. An outlet pipe (not shown) may be connected to a second
end of the plumbing trap 412 and the outlet pipe may be connected
to the main sewer line (also not shown).
[0046] The improved drain installation 400 may further comprise a
removable drain pipe 406a connected to a second end of the T-shaped
adapter 402. The removable drain pipe 406a may be configured to be
received within a shoulder formed in the second end of the T-shaped
adapter 402. Washers 414a may be received between the removable
drain pipe 406a and the T-shaped adapter 402 at the second end of
the T-shaped adapter 402 and may provide a seal between the
removable drain pipe 406a and the T-shaped adapter 402 such that
gases and liquids cannot escape between the two.
[0047] The improved drain installation 400 may further comprise a
secondary inlet pipe 406b connected to a third end of the T-shaped
adapter 402. The secondary inlet pipe 406b may be configured to be
received within a shoulder formed in the third end of the T-shaped
adapter 402. Washer 414b may be received between the secondary
inlet pipe 406b and the T-shaped adapter 402 at the third end of
the T-shaped adapter 402 and may provide a seal between the
secondary inlet pipe 406b and the T-shaped adapter 402 such that
gases and liquids cannot escape between the two.
[0048] The improved drain installation 400 may further comprise one
or more sleeves (not shown) received around the removable drain
pipe 406a and may extend from proximate to the second and third
ends of the T-shaped adapter 402 to approximately ends of the
removable drain pipe 406a. The removable drain pipe 406a and the
sleeve may extend above a slab level of a flooring surface,
requiring the removable drain pipe 406a to be cut to size before
fixtures may be attached to the end of the removable drain pipe
406a. In an embodiment, the fixtures may be floor drains, shower
drains, or a combination thereof. The method of installing the
improved drain installation 400 is similar to that described above
in relation to the installation of the improved drain installation
300.
[0049] FIG. 7 depicts a cutaway view of the improved drain
installation 300 of FIG. 3, in accordance with one embodiment of
the present disclosure. As shown in FIG. 7, the removable drain
pipe 306 may be encircled by the sleeve 304, but may further
comprise an end cap 702. The end cap 702 may be placed on the open
second end of the removable drain pipe 306 and may cap the
removable drain pipe 306 so that gases and liquids do not escape
into the room.
[0050] FIG. 8A depicts a perspective view of a first pre-form 310a
of the improved drain installation of FIG. 3, in accordance with
one embodiment of the present disclosure. FIG. 8B depicts a
perspective view of a second pre-form 310b of the improved drain
installation of FIG. 3, in accordance with one embodiment of the
present disclosure. The pre-forms 310a, 310b may be sized and
shaped to fit a desired floor drain and may be round, square,
tapered, etc. The pre-forms 310a, 310b may advantageously prevent
concrete from falling within the drain pipe and into the plumbing
trap during installation.
[0051] FIG. 9 depicts an perspective view of an improved drain
installation 900, in accordance with one embodiment of the present
disclosure. In an embodiment, a first end of a drain pipe 902 may
be connected to a first end of a plumbing trap 904 and a drain
pre-form 906 may be received around a second end of the drain pipe
902. The first end of the drain pipe 902 may be cemented into the
plumbing trap 904, while the drain pre-form 906 may be received
around the second end of the drain pipe 902 and is operable to
slide up and down the length of the drain pipe 902. In addition,
the drain pre-form 906 is operable to be removed from the second
end of the drain pipe 902.
[0052] In an embodiment, the drain pipe 902 may be cut to a desired
length so that a floor drain 908 sits below a finished flooring
level, and may be cut on-site or may be pre-cut to raise the drain
pre-form 906 to a desired height above the plumbing trap 904. A
plumber may slide the drain pre-form 906 downwardly around the
drain pipe 902 to an approximate height of a finished flooring
surface. The drain pre-form 906 may be sized and shaped to fit a
desired floor drain and may be round, square, tapered, etc. The
pre-form 906 may advantageously prevent concrete from falling
within the drain pipe and into the plumbing trap during
installation.
[0053] In operation, after the plumber installs the sub-floor
plumbing--i.e., the drain pipe 902, the plumbing trap 904, and the
drain pre-form 906--and the concrete slab has been poured around
the sub-floor plumbing, a flooring specialist may install the
finished flooring surface above the concrete slab and finish the
installation of the drain. After the finished flooring surface has
been laid to a desired height, which is preferably slightly above
an upper surface of the drain pre-form 906, the flooring specialist
may remove the drain pre-form 906 from the second end of the drain
pipe 902 and cut the drain pipe 902 to a desired length. In order
to cut the drain pipe 902 to a desired length after the finished
flooring surface is installed, a specialty tool, such as a PVC wire
saw, may be needed to cut the drain pipe 902 without damaging the
finished flooring surface or the drain pipe 902. After cutting the
drain pipe 902 to the desired length, the flooring specialist may
cement the floor drain 908 into the second end of the drain pipe
902 so that an upper surface of the floor drain 908 may be flush,
or slightly below, a surface of the finished flooring surface.
[0054] FIG. 10 depicts a perspective view of an exemplary pre-form
1000 for drain installation, whereas FIGS. 11, 12, and 13 depict a
top view, a bottom view, and a side view of the pre-form 1000,
respectively. Pre-form 1000 may refer to any pre-form described
herein, including pre-form 310, pre-form 310a, pre-form 310b,
and/or pre-form 906.
[0055] The pre-form 1000 may generally include a cap portion 1002,
a bottom portion 1004, and an outer portion 1006. As shown in FIG.
10, the cap portion 1002 may include a circular piece that extends
upward (e.g., substantially vertically) from the bottom portion
1004. In some embodiments, the cap portion 1002 may be
substantially cylindrical. Alternatively, side walls of the cap
portion 1002 that extend upward from the bottom portion 1004 may be
angled and/or slanted. For example, the cap portion 1002 may be
wider at its base (e.g., at a proximal end adjacently coupled to,
substantially flush with, and/or on a plane parallel to the bottom
portion 1004) than at its top (e.g., at a distal end that is
positioned a distance away from the bottom surface). As shown in
FIGS. 10-12, the top of the cap portion 1002 may include a
substantially flat and solid circular surface. One or more raised
supports 1008 may be disposed on an outside (e.g., top) surface of
the top of the cap portion 1002 to ensure structural integrity of
the cap portion 1002.
[0056] The base (e.g., the proximal end) of the cap portion 1002
may be coupled to the bottom portion 1004 of the pre-form 1000. In
some embodiments, the cap portion 1002 may be detachably coupled to
inner edges of the bottom portion 1004 via a perforated seam 1010.
When force is applied to the pre-form 1000 during installation as
described below, the cap portion 1002 may separate from the bottom
portion 1004.
[0057] The bottom portion 1004 may include a substantially flat and
solid square surface. The bottom portion 1004 may also include a
variety of other shapes such as a rectangle, a circle, and/or the
like so as to conform to a shape of a drain. One or more raised
supports 1012 may be disposed on a top surface of the bottom
portion 1004 to ensure structural integrity of the bottom portion
1004.
[0058] Outer edges of the bottom portion 1004 may be coupled to the
outer portion 1006 of the pre-form 1000. The outer portion 1006 may
include one or more substantially flat and solid surfaces (e.g.,
walls) that extend upwardly from the outer edges of the bottom
portion 1004. In some embodiments, the outer portion 1006 may
extend substantially vertically from the outer edges of the bottom
portion 1004. In other embodiments, and as shown in FIG. 13, the
outer portion 1006 may extend upwardly from the outer edges of the
bottom portion 1004 at an angle so that a perimeter of the outer
portion 1006 at a bottom end (e.g., at the outer edges of the
bottom portion 1004) is smaller than a perimeter of the outer
portion 1006 at a top end (e.g., at the end extended a distance
away from the bottom portion 1004).
[0059] The pre-form 1000 may be manufactured from PVC, ABS, or any
other rigid material. In some embodiments, the pre-form 1000 may be
made from a single plastic mold. For example, each of the cap
portion 1002, the bottom portion 1004, and the outer portion 1006
may be cast from a common mold and/or during a common plastic
injection process. Alternatively, one or more of the cap portion
1002, the bottom portion 1004, and the outer portion 1006 may be
cast from different molds.
[0060] The pre-form 1000 may be used when installing a plumbing
system. For example, during installation of a subfloor plumbing
system, the pre-form 1000 may be placed on top of an
upwardly-extending drain pipe (not pictured). In some embodiments,
the cap portion 1002 of the pre-form 1000 may be placed on top of
the upwardly-extending drain pipe so that a top end of the drain
pipe is received within the interior of the cap portion 1002 (e.g.,
the underside of the cap portion 1002). In this manner, the cap
portion 1002 of the pre-form 1000 may cover an opening of the drain
pipe so as to prevent unwanted debris or concrete mixture from
entering the drain pipe opening during the pouring of concrete
and/or drain pipe installation. The pre-form 1000 may rest on the
top of the drain pipe until the concrete subfloor has been
poured.
[0061] While the concrete subfloor is being poured and while the
poured concrete subfloor is still wet (e.g., before the poured
concrete subfloor has settled), the cap portion 1002 may be
separated from the bottom portion 1004 of the pre-form 1000. For
example, a plumber (e.g., a worker, a drain pipe installer, a
concrete pourer, and/or the like) may apply a downward force on the
outer portion 1006 of the pre-form 1000, thereby breaking the
perforated seam 1010 between the cap portion 1002 and the bottom
portion 1004.
[0062] Once the perforated seam 1010 is broken and the cap portion
1002 is separated from the bottom portion 1004 (as well as the
outer portion 1006), the remaining portions (e.g., the bottom
portion 1004 and the outer portion 1006) of the pre-form 1000 may
be slid down around the outside surface the upwardly-extending
drain pipe until it is resting in the wet concrete subfloor. As the
remaining portions of the pre-form 1000 are slid down, the cap
portion 1002 may remain positioned atop the upwardly-extending
drain pipe to prevent unwanted debris from entering the drain pipe
opening.
[0063] The remaining portions of the pre-form 1000 resting in the
wet concrete of the poured subfloor may be pressed down into the
wet concrete. For example, a plumber may apply downward force on
the bottom portion 1004 and/or the outer portion 1006 so that the
remaining portions of the pre-form 1000 are at least partially
inserted into the wet concrete subfloor. In some embodiments, the
remaining portions of the pre-form 1000 may be inserted into the
wet concrete subfloor until the wet concrete subfloor surpasses
and/or is substantially even (e.g., level) with a marker on an
outside surface of the outer portion 1006.
[0064] Once inserted into the wet concrete subfloor, the remaining
portions of the pre-form 1000 may displace a desired amount of wet
concrete immediately surrounding the drain pipe so as to allow
sufficient room for cutting the upwardly-extending drain pipe and
installing a floor drain. For example, the bottom portion 1004 may
downwardly displace wet concrete within an area defined by a
perimeter of the outer portion 1006. By displacing the concrete
subfloor using the remaining portions of the pre-form 1000, the
drain pipe may be cut at a location below a finished floor level
(e.g., at a location below a top edge of the pre-form 1000 and/or
at a location below the concrete subfloor). In some embodiments, a
top edge of the outer portion 1006 and/or another marker on an
outside surface of the outer portion 1006 may be used as a marker
for how deep into the concrete the pre-form is to be inserted as
well as a marker for where the drain pipe is to be cut.
[0065] After the concrete subfloor has settled and is dry, the cap
portion 1002 may be removed from the top of the drain pipe so that
the drain pipe may be cut to a desired height and/or length.
Additionally, the remaining portions of the pre-form 1000 may be
removed from the concrete subfloor so that the drain pipe may be
cut and/or so that a floor drain may be installed. Once the drain
pipe is cut, a floor drain may be installed into the concrete
subfloor and on a top end (e.g., at the opening) of the drain
pipe.
[0066] As disclosed herein, the plumbing traps, removable drain
pipes, and/or pre-forms may be constructed from PVC, ABS, cast
iron, brass, copper, or any other material suitable for plumbing
pipes. Similarly, the adapter and T-shaped adapter may be
constructed from PVC, ABS, cast iron, brass, copper, or any other
material suitable for plumbing pipe adapters. The washers may be
constructed from plastic, foam, or any other material suitable to
provide a seal between the removable drain pipes and the adapters.
As discussed previously, the sleeve may be constructed from
cardboard, wax paper, plastic, or any other non-adhesive material
suitable to permit the removable drain pipe not to adhere to the
sub-floor concrete and to allow movement of the removable drain
pipes relative to the flooring. The cap may be constructed from
PVC, ABS, cast iron, brass, copper, or any other material suitable
for capping a plumbing pipe. Each of the components described
herein may be sized and shaped to meet the plumbing needs of each
individual plumbing fixture installation.
[0067] It should be appreciated that the breadth and scope of the
invention(s) is not limited by any of the above-described exemplary
embodiments, but should be defined only in accordance with the
following claims and their equivalents. Moreover, the above
advantages and features are provided in described embodiments, but
shall not limit the application of the claims to processes and
structures accomplishing any or all of the above advantages.
[0068] Additionally, the section headings herein are provided for
consistency with the suggestions under 37 CFR 1.77 or otherwise to
provide organizational cues. These headings shall not limit or
characterize the invention(s) set out in any claims that may issue
from this disclosure. Specifically and by way of example, although
the headings refer to a "Technical Field," the claims should not be
limited by the language chosen under this heading to describe the
so-called technical field. Further, a description of a technology
in the "Background" is not to be construed as an admission that
technology is prior art to any invention(s) in this disclosure.
Neither is the "Brief Summary" to be considered as a
characterization of the invention(s) set forth in the claims found
herein. Furthermore, any reference in this disclosure to
"invention" in the singular should not be used to argue that there
is only a single point of novelty claimed in this disclosure.
Multiple inventions may be set forth according to the limitations
of the multiple claims associated with this disclosure, and the
claims accordingly define the invention(s), and their equivalents,
that are protected thereby. In all instances, the scope of the
claims shall be considered on their own merits in light of the
specification, but should not be constrained by the headings set
forth herein.
* * * * *