US20090277114A1 - Drain installation kit - Google Patents

Drain installation kit Download PDF

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Publication number
US20090277114A1
US20090277114A1 US12/506,660 US50666009A US2009277114A1 US 20090277114 A1 US20090277114 A1 US 20090277114A1 US 50666009 A US50666009 A US 50666009A US 2009277114 A1 US2009277114 A1 US 2009277114A1
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United States
Prior art keywords
drain
guide bar
upper flange
installation kit
guide
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US12/506,660
Inventor
Fumitake Nishi
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TILE SHOP
Tile Shop LLC
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TILE SHOP
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Publication date
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Priority to US12/506,660 priority Critical patent/US20090277114A1/en
Assigned to THE TILE SHOP, LLC reassignment THE TILE SHOP, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NISHI, FUMITAKE
Publication of US20090277114A1 publication Critical patent/US20090277114A1/en
Abandoned legal-status Critical Current

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    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47KSANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
    • A47K3/00Baths; Douches; Appurtenances therefor
    • A47K3/28Showers or bathing douches
    • A47K3/40Pans or trays

Definitions

  • This disclosure relates to construction techniques and, more particularly, to constructing sloped concrete floors.
  • sloped floors e.g., made of concrete
  • Sloped floors are often desirable for draining water or other liquids.
  • a floor that is unevenly sloped, sloped too steeply, or conversely, not steeply enough, can drain poorly and/or be uncomfortable to walk on.
  • an unevenly sloped shower pan can drain poorly and can be uncomfortable for a person to stand on.
  • a drain installation kit can help an unskilled person construct a sloped surface leading to a drain, such as a shower pan.
  • a conventional drain once assembled, usually includes a number of components. Although an unskilled person may be able to assemble the needed parts, constructing an evenly sloped floor having an aperture for the drain can be more challenging.
  • Some installation kits include a number of sloped form members that can be positioned radially around the center of the drain to assist in aligning the center of the sloping floor aperture with the center of the drain.
  • form members in such conventional kits can be inadvertently moved during the construction process, meaning that the center of the sloping floor aperture can become misaligned from the center of the drain. Such misalignment can result in improper drainage, which can lead to water pooling and other adverse effects. Water pooling, in particular, can lead to structural damage, microorganism incubation, and is at least aesthetically displeasing.
  • the present invention provides a drain installation kit adapted to maintain alignment of the center of a sloping floor aperture with the center of a drain throughout the construction process.
  • the kit includes an upper flange that is rigidly connectable to a drain base and multiple sloping guide bars that are rigidly connectable in a radial fashion to the upper flange.
  • a user can use this preferred embodiment by assembling it, adding cementitious material between the guide bars, and making an upper surface of the cementitious material flush with a top edge of the guide bars.
  • the drain installation kit allows for greater adjustability of the height of the drain plate housing than in conventional drain kits.
  • the drain installation kit provides a fixed attachment point while still providing adjustability of the drain plate housing height, whereas attachment points in conventional drain installation kits are fixed only when the drain plate housing is adjusted tightly downwards in order to sandwich the attachment points against the drain assembly.
  • the drain installation kit provides independent and unconnected attachment points for each guide bar, so that movement of one guide bar does not automatically move another guide bar as in conventional drain installation kits.
  • Some guide bar embodiments can provide a greater degree of stability, thereby inhibiting any tendency of the guide bar to tilt.
  • the drain installation kit allows the construction of a concrete floor with a consistent slope. In such embodiments, the construction can be substantially performed without skilled labor. In some embodiments, the drain installation kit allows the construction of a sloping floor without regard to the dimensions or shape of the installation area. In some embodiments, the drain installation kit allows for an extension of a sloped surface by combining multiple instances of the same component, wherein conventional drain kits, specially designed extension components were required. In some embodiments, the drain installation kit centrally anchors sloping guide bars without additional structure used in conventional drain kits.
  • Some embodiments of the present invention can be manufactured significantly more efficiently.
  • the drain installation kit is less expensive to produce because it includes fewer components than conventional installation kits.
  • Some guide bar embodiments can be manufactured more uniformly and/or using less material, while maintaining sufficient structural integrity. Additional advantages provided by some embodiments of the present invention will be apparent from the following description.
  • FIG. 1 is a top plan view depicting an illustrative drain installation with a plurality of illustrative guide bars having their respective leading ends attached to an upper flange;
  • FIG. 2 a is a side elevational view of an illustrative guide bar
  • FIG. 2 b is a side elevational view of an illustrative guide bar
  • FIG. 2 c is a side elevational view of an illustrative guide bar
  • FIG. 3 a is a top plan view of a shower drain and adjacent flooring built in accordance with an illustrative drain installation kit
  • FIG. 3 b is a top plan view of the illustrative shower drain of FIG. 3 a without the adjacent flooring;
  • FIG. 4 is a side elevational, partially sectional view of the parts depicted in FIG. 3 a;
  • FIG. 5 is a top perspective view of an illustrative upper flange
  • FIG. 6 a is a perspective view depicting the trailing and leading ends of illustrative guide bars
  • FIG. 6 b is a side elevational view depicting the joinder of two illustrative guide bars
  • FIG. 6 c is a top plan view of the illustrative guide bars depicted in FIG. 6 b;
  • FIG. 7 is a top plan view of an illustrative drain installation made by interconnecting multiple guide bars together in end-to-end relation to one another;
  • FIG. 8 is a perspective view of one illustrative drain installation kit application
  • FIG. 9 is a side elevational, sectional view of one illustrative drain installation kit application.
  • FIG. 10 is a perspective view of one illustrative drain installation kit application.
  • recess is used to denote an opening. Recess is used to describe both openings that extend partially through a surface and openings that may extend fully through a surface.
  • an object's height refers generally to its extent in direction T of FIGS. 2 b - 2 c
  • an object's length refers generally to its extent in direction L of FIGS. 2 b - 2 c
  • an object's width refers generally to its extent in direction W of FIG. 3 a.
  • FIG. 1 shows a top plan view of an illustrative assembled drain installation kit 10 .
  • a drain installation kit can include a plurality of guide bars 12 , having their respective leading ends 13 detachably attached to an illustrative upper flange 14 about a drain plate 18 . Their respective trailing ends 15 can abut an upstanding wall 16 that defines the outermost boundaries of the shower, swimming pool, or other sloped floor to be constructed.
  • Guide bars 12 are often supported by a substantially flat support surface 11 , which, in one embodiment, would be the slab of the structure within which the sloped surface is being built.
  • Embodiments of a drain installation kit are not restricted to sloped floors of rectangular configuration only.
  • the guide bars 12 may be used to build sloped floors of any predetermined geometric configuration.
  • a guide bar 12 may be cut at any location along the length thereof to conform it to the size of a space having an extent less than the length of an uncut guide bar 12 , and the leading end 13 of one or more additional guide bars may be attached to the trailing end 15 of one or more installed guide bars to enable use of the guide bars in spaces having an extent greater than the length of a single guide bar.
  • FIG. 2 a shows an illustrative guide bar 12 that has a height extent at its leading end 13 that is less than its height extent as its trailing end 15 . Accordingly, when its bottom wall or bottom edge 17 rests atop the substantially flat support surface 11 and when its leading end 13 is attached to the upper flange 14 , the top wall or top edge 19 of the guide bar will be disposed relative to a horizontal plane at a predetermined angular slope defined by the height difference.
  • the guide bar 12 may have a trailing projection 44 which extends from its trailing end 15 as shown in FIG. 2 a.
  • the guide bar 12 can have a leading projection 46 , which extends from its leading end 13 as shown in FIG. 2 a.
  • the openings 42 of FIG. 2 a are defined by trusses, which comprise the support structure of the guide bars 12 .
  • Guide bars with truss support structures are often made of a smaller quantity of material, while maintaining sufficient structural integrity. The smaller quantity of material often leads to a guide bar that is less expensive to manufacture and lighter, making it easier for an installer to handle.
  • the openings 42 in each guide bar 12 enhance the bond between the guide bar and a suitable cementitious mixture that is used to form the sloped floor.
  • the illustrative openings 42 depicted in FIG. 2 a advantageously allow more cementitious mixture to pass through the guide bar 12 than in conventional drain kits, providing for a stronger bond than in conventional applications.
  • guide bars with truss support structures can be manufactured more uniformly.
  • the cross-sectional area of each of the trusses can be approximately equal.
  • every truss having approximately equal cross-sectional areas can finish cooling at roughly the same time, thereby minimizing imperfections (e.g., bending and/or cracking due to stress). This provides a distinct advantage over support structures that define circular openings.
  • FIGS. 2 b and 2 c show additional embodiments of the guide bar 12 in which the openings 42 of FIG. 2 a can be replaced and/or supplemented by additional structural features.
  • FIGS. 2 b and 2 c show embodiments in which the guide bar 12 can have one or more openings 118 in its bottom edge 17 or top edge 19 .
  • the bottom edge 17 has openings 118
  • the bottom edge 17 would not be supported along its entire extent by the slab 11 .
  • cementitious mixture would not be made flush with the entire top edge 19 of the guide bar 12 when added.
  • openings 118 allow for additional cementitious mixture to pass through the guide bar 12 , thus strengthening the bond between the mixture and the guide bar 12 .
  • the openings 118 can take a variety of shapes and configurations, and are not limited to those shown in the embodiments present here.
  • both the bottom edge 17 and the top edge 19 may contain the openings 118 .
  • the width of the bottom edge 17 can be greater than that of the top edge 19 , thereby increasing the stability of the guide bar 12 .
  • FIGS. 3 a, 3 b, and 4 show one illustrative drain installation kit assembled with components of a drain assembly 22 .
  • a conventional drain assembly can include a drain pipe 24 , a drain base 25 with a drain base flange 28 , and an upper flange.
  • FIGS. 3 a, 3 b, and 4 show the conventional upper flange replaced by one embodiment of the upper flange 14 included with an illustrative drain installation kit.
  • the illustrative upper flange 14 can be secured to the drain base flange 28 by a plurality of screws 20 .
  • the upper flange 14 is internally threaded and threadedly receives an externally threaded conventional post 30 .
  • the post 30 is integrally formed with a housing 32 , which receives a drain plate 18 .
  • FIGS. 3 a and 3 b further show the leading end of one guide bar 12 attached directly to the upper flange 14 .
  • the upper flange 14 has multiple attachment points, which in this embodiment include a plurality of flange recesses 34 .
  • the flange recesses 34 can be adapted to receive a portion of a member (e.g., a pin, a screw, a bolt, a nail, or other similar members).
  • Each guide bar can have a leading projection 46 as shown in FIG. 2( a )-( c ).
  • a guide bar recess 52 can pass through the leading projection from top to bottom, for receiving the member.
  • FIG. 3 b shows one embodiment where a guide bar 12 is detachably attached to the upper flange 14 , with guide bar recess 52 aligned with flange recess 34 .
  • attachment of the guide bar 12 to the upper flange 14 can be achieved in a variety of ways, and is not limited solely to the embodiment described above. Although a detachable attachment may be preferable in some applications where the guide bar may need to be repositioned, the attachment need not be detachable.
  • the guide bar may be permanently attached to the upper flange, especially in applications where the guide bar 12 can be left in place after it has been attached.
  • the guide bar 12 may similarly be permanently attached in a variety of ways, as is known in the art. As just one example, the guide bar may be permanently attached with an adhesive. Additionally, in some applications, the upper flange 14 may not be necessary, and the guide bar 12 may be attached directly to a conventional upper flange included in a conventional drain assembly.
  • FIG. 4 shows a side elevational view of an illustrative guide bar 12 attached to the upper flange 14 .
  • the leading projection 46 of the guide bar 12 sits atop the upper flange 14 and is detachably attached to the upper flange 14 in accordance with the description provided above.
  • the leading projection 46 extends inwardly towards the drain only as far as the edge of the drain plate 18 .
  • the drain plate 18 can be positioned without regard to the structure that attaches the guide bars 12 to the upper flange 14 .
  • the height of the drain plate 18 is adjusted after the cementitious mixture is added, but before it dries. Being able to adjust the position of the drain plate 18 at this time can be important in order to make the tile and the drain plate 18 as level as possible.
  • FIG. 5 shows one embodiment of an upper flange 14 configured for use in the embodiments depicted in FIGS. 3 a, 3 b, and 4 .
  • the upper flange 14 in this embodiment has multiple flange recesses 34 radially spaced about a center drain opening 35 .
  • the drain opening 35 can be configured to receive the conventional post 30 and drain plate housing 32 shown in FIG. 4 .
  • the drain opening 35 includes partial internal threading 36 for threadedly receiving a corresponding post.
  • the upper flange 14 may be attached to the drain base 25 of FIG. 4 with the screws 20 previously described inserted through one or more openings 37 on the upper flange 14 .
  • Weep holes 38 may also be included in the upper flange to allow moisture to seep down into the drain.
  • FIG. 6 a shows one embodiment of a connection between multiple guide bars 12 , 112 .
  • a trailing projection 44 extends from the trailing end 15 of one guide bar 12 .
  • a guide bar recess 54 can pass through the trailing projection 44 from top to bottom, for receiving a member 56 .
  • An additional guide bar 112 has a leading projection 46 with a guide bar recess 52 .
  • the member 56 can join the guide bars 12 , 112 when it is inserted into both guide bar recesses 52 , 54 .
  • Each guide bar 12 , 112 can have the same predetermined slope, with the trailing and leading projections dimensioned and placed to maintain a substantially even slope from the leading end of one guide bar, through the joinder of the bars, and extending to the trailing end of a second guide bar.
  • FIG. 6 b shows a side elevational view in which two of the same illustrative guide bars 12 are connected together in one embodiment to extend a predetermined slope.
  • the guide bars 12 are positioned so that the guide bar recess 52 in the first guide bar's leading projection 46 is aligned with the guide bar recess 54 in the second guide bar's trailing projection 44 .
  • the corresponding guide bar recesses can align along axis 50 , and a pin or other suitable member can be inserted to secure both guide bars together.
  • FIG. 6 c shows a top plan view of the guide bars in FIG. 6 b.
  • the first guide bar 12 is unsupported along its bottom edge 17 by the slab 11 .
  • cementitious material can be added to the space between the bottom edge 17 and the support surface to assist the respective members and upstanding wall in maintaining the first guide bar in position.
  • a shim made from some kind of scrap e.g., wood, drywall, etc.
  • FIG. 7 shows the use of multiple guide bars 12 enabling the building of larger sloped floors.
  • An illustrative drain installation kit may have any number of guide bars 12 , which can be connected as needed to extend the overall effective length of a single guide bar 12 .
  • any guide bar 12 can also be cut to a shorter length whenever required.
  • the top surface of the leading end 13 of an additional guide bar is positioned at a height substantially equal to the height of the top surface of the trailing end 15 of a guide bar 12 to which it is connected, in linear or end-to-end relation.
  • the drain pipe housing 32 is first unscrewed from a conventional drain assembly and the illustrative upper flange 14 is attached in place of the conventional upper flange.
  • the respective leading ends 13 of the guide bars 12 are then secured to the drain by attaching the leading projection 46 of each guide bar to the upper flange 14 .
  • the guide bars are attached by aligning each leading projection guide bar recess 52 with a respective flange recess 34 of the upper flange 14 and inserting a pin or other suitable member.
  • the height of the drain plate 18 can then be adjusted to a desired height depending upon the thickness of the surface 21 , to provide a flush joint with the surface.
  • Additional guide bars 12 can be used if required by the application.
  • additional guide bars 12 can be used if the sloped floor is oversized (relative to the length of guide bars 12 ) as depicted in FIG. 7 or if the sloped floor has an “L”-shaped or other relatively unusual geometric configuration.
  • the cementitious mixture e.g., mud
  • the cementitious mixture is introduced into the area bordered by upstanding side walls 16 and divided by the upstanding guide bars and the cementitious mixture is spread throughout the area, including within the opening maintained between the housing 32 and the upper flange 14 , which solidly secures the drain plate housing 32 once the cementitious mixture dries.
  • the cementitious mixture is spread flush with the top edge 19 of each guide bar 12 along its extent. Excess cementitious mixture is removed and the surface is smoothed by conventional, well-known concrete working techniques.
  • the surface 21 such as tiling, is then installed atop a relatively thin layer of cementitious material that overlies the cementitious mixture in the well-known way and the drain plate 18 is finally adjusted before the cementitious mixture dries in order to provide a flush joint between the top of the drain plate and the surface 21 .
  • the surface 21 is tiling, the job is completed by filling the cracks between the tiles with grout in the well-known way. In this way, the center of the radially-positioned guide bars 12 can be nearly perfectly aligned with the center of the drain. Misalignment can lead to water pooling, and pooling can be aesthetically displeasing and can cause structural damage.
  • FIG. 8 shows another embodiment of a drain installation kit.
  • the guide bars 12 in this embodiment can be attached directly to support surface 11 to provide a sloped surface leading to an aperture 60 in the support surface 11 .
  • Each illustrative guide bar can include a guide bar recess 62 which can pass through the leading end 13 of each guide bar 12 .
  • the guide bars 12 can be positioned radially about the aperture 60 as desired and attached to the support surface 11 by inserting a pin or other suitable member through the guide bar recess 62 and connecting it with the support surface. For example, a nail can be inserted into the guide bar recess 62 and driven into the support surface 11 .
  • the attachment can be detachable or may not be detachable. Cementitious material can then be spread in between the guide bars to form a sloped surface leading to the aperture 60 .
  • FIG. 9 shows one embodiment of an installed drain kit similar to the embodiment depicted in FIG. 8 .
  • the guide bars 12 can be positioned around an aperture 60 , which in one embodiment can be a sump well.
  • the guide bars 12 can be attached to the support surface 11 in accordance with the description provided above, and a sloped surface can be constructed with cementitious mixture in the usual way.
  • FIG. 10 shows another embodiment of an installed drain kit.
  • the guide bars 12 in this embodiment can be positioned in a substantially parallel formation 68 .
  • the trailing edge 15 of each guide bar 12 can be attached to a support wall 66 .
  • a cementitious mixture can be spread in between and flush with the guide bars 12 to form a sloped, substantially planar surface.
  • An outer surface, such as tiling, can be installed atop the substantially planar surface in the usual way.
  • this embodiment advantageously provides a sloped, substantially planar drain for urging water away from the support wall 66 .
  • this embodiment can be implemented around the foundation of a building 72 .
  • the illustrative guide bars can also be positioned in a radial formation 70 , which as shown in FIG. 10 , can be used to create a drain surface around the corner of the building 72 .
  • Embodiments of the present invention may include one or more of the following features.
  • the upper flange may be configured to connect to a drain plate housing.
  • the upper flange may be internally threaded in order to threadedly receive a drain plate housing.
  • the multiple attachment points on the upper flange may be radially spaced about the center of the upper flange.
  • the attachment points include flange recesses formed within a surface of the upper flange.
  • the flange recesses may extend partially through the upper flange.
  • the flange recesses extend fully through the upper flange.
  • Some embodiments have an upper flange with cylindrically formed flange recesses capable of receiving a cylindrically shaped pin.
  • Some drain installation kits have guide bars with a protrusion that can be inserted into a flange recess on the upper flange. Some guide bars have a guide bar recess capable of receiving a member. In some embodiments, the guide bar recess may extend partially and/or fully through the guide bar. In some embodiments, the multiple attachment points on the upper flange may include protrusions that can extend into a guide bar recess in the guide bar. Some guide bars are dimensioned so that they do not obstruct the movement of an adjustable drain plate housing when they are attached to the upper flange. In some drain installation kits, the first ends of the guide bars are substantially fixed with respect to the drain base when attached to the upper flange.
  • the guide bars are positioned so as to create a substantially planar drain surface.
  • the support structure of some guide bar embodiments can be trusses.
  • Some drain installation kits have guide bars which are positioned so as to urge water away from a central area.
  • the width of a guide bar's bottom edge is greater than that of its top edge.
  • drain installation kit embodiments of a drain installation kit are disclosed.
  • the drain installation kit can be practiced with embodiments other than those disclosed.
  • the disclosed embodiments are presented for purposes of illustration only and not limitation.

Abstract

The present invention provides a drain installation kit adapted to maintain alignment of the center of a sloping floor aperture with the center of a drain throughout the construction process. In a preferred embodiment, the kit includes an upper flange that is rigidly connectable to a drain base and multiple sloping guide bars that are rigidly connectable in a radial fashion to the upper flange. A user can use this preferred embodiment by assembling it, adding cementitious material between the guide bars, and making an upper surface of the cementitious material flush with a top edge of the guide bars. Embodiments of the present invention provide a variety of advantages over conventional drain installation kits. For example, many embodiments provide improved functionality, many embodiments are easier for do-it-yourselfers to use, and many embodiments can be manufactured more efficiently.

Description

    CROSS-REFERENCE TO RELATED APPLICATION
  • This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 60/884,124, filed Jan. 9, 2007, which is hereby incorporated by reference.
  • TECHNICAL FIELD
  • This disclosure relates to construction techniques and, more particularly, to constructing sloped concrete floors.
  • BACKGROUND
  • Many skilled craftspersons can construct sloped floors (e.g., made of concrete) using techniques that are well-known in the field. Sloped floors are often desirable for draining water or other liquids. However, even the most skilled craftsperson can have trouble reproducing the same, evenly sloped floor on all occasions. A floor that is unevenly sloped, sloped too steeply, or conversely, not steeply enough, can drain poorly and/or be uncomfortable to walk on. For example, an unevenly sloped shower pan can drain poorly and can be uncomfortable for a person to stand on.
  • Do-it-yourselfers sometimes desire to install sloped surfaces without the expense of hiring a skilled craftsperson. A drain installation kit can help an unskilled person construct a sloped surface leading to a drain, such as a shower pan. A conventional drain, once assembled, usually includes a number of components. Although an unskilled person may be able to assemble the needed parts, constructing an evenly sloped floor having an aperture for the drain can be more challenging. Some installation kits include a number of sloped form members that can be positioned radially around the center of the drain to assist in aligning the center of the sloping floor aperture with the center of the drain.
  • Unfortunately, form members in such conventional kits can be inadvertently moved during the construction process, meaning that the center of the sloping floor aperture can become misaligned from the center of the drain. Such misalignment can result in improper drainage, which can lead to water pooling and other adverse effects. Water pooling, in particular, can lead to structural damage, microorganism incubation, and is at least aesthetically displeasing.
  • SUMMARY
  • The present invention provides a drain installation kit adapted to maintain alignment of the center of a sloping floor aperture with the center of a drain throughout the construction process. In a preferred embodiment, the kit includes an upper flange that is rigidly connectable to a drain base and multiple sloping guide bars that are rigidly connectable in a radial fashion to the upper flange. A user can use this preferred embodiment by assembling it, adding cementitious material between the guide bars, and making an upper surface of the cementitious material flush with a top edge of the guide bars.
  • Some embodiments of the present invention provide significant functional advantages over conventional drain installation kits. In some embodiments, the drain installation kit allows for greater adjustability of the height of the drain plate housing than in conventional drain kits. In some embodiments, the drain installation kit provides a fixed attachment point while still providing adjustability of the drain plate housing height, whereas attachment points in conventional drain installation kits are fixed only when the drain plate housing is adjusted tightly downwards in order to sandwich the attachment points against the drain assembly. In some embodiments, the drain installation kit provides independent and unconnected attachment points for each guide bar, so that movement of one guide bar does not automatically move another guide bar as in conventional drain installation kits. Some guide bar embodiments can provide a greater degree of stability, thereby inhibiting any tendency of the guide bar to tilt.
  • Some embodiments of the present invention provide similar functionality as conventional drain installation kits, but with substantially greater ease for the unskilled person. In some embodiments, the drain installation kit allows the construction of a concrete floor with a consistent slope. In such embodiments, the construction can be substantially performed without skilled labor. In some embodiments, the drain installation kit allows the construction of a sloping floor without regard to the dimensions or shape of the installation area. In some embodiments, the drain installation kit allows for an extension of a sloped surface by combining multiple instances of the same component, wherein conventional drain kits, specially designed extension components were required. In some embodiments, the drain installation kit centrally anchors sloping guide bars without additional structure used in conventional drain kits.
  • Some embodiments of the present invention can be manufactured significantly more efficiently. In some embodiments, the drain installation kit is less expensive to produce because it includes fewer components than conventional installation kits. Some guide bar embodiments can be manufactured more uniformly and/or using less material, while maintaining sufficient structural integrity. Additional advantages provided by some embodiments of the present invention will be apparent from the following description.
  • BRIEF DESCRIPTION OF THE FIGURES
  • The following drawings are illustrative of particular embodiments of the present invention and therefore do not limit the scope of the invention. The drawings are not to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description. Embodiments of the present invention will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements.
  • FIG. 1 is a top plan view depicting an illustrative drain installation with a plurality of illustrative guide bars having their respective leading ends attached to an upper flange;
  • FIG. 2 a is a side elevational view of an illustrative guide bar;
  • FIG. 2 b is a side elevational view of an illustrative guide bar;
  • FIG. 2 c is a side elevational view of an illustrative guide bar;
  • FIG. 3 a is a top plan view of a shower drain and adjacent flooring built in accordance with an illustrative drain installation kit;
  • FIG. 3 b is a top plan view of the illustrative shower drain of FIG. 3 a without the adjacent flooring;
  • FIG. 4 is a side elevational, partially sectional view of the parts depicted in FIG. 3 a;
  • FIG. 5 is a top perspective view of an illustrative upper flange;
  • FIG. 6 a is a perspective view depicting the trailing and leading ends of illustrative guide bars;
  • FIG. 6 b is a side elevational view depicting the joinder of two illustrative guide bars;
  • FIG. 6 c is a top plan view of the illustrative guide bars depicted in FIG. 6 b;
  • FIG. 7 is a top plan view of an illustrative drain installation made by interconnecting multiple guide bars together in end-to-end relation to one another;
  • FIG. 8 is a perspective view of one illustrative drain installation kit application;
  • FIG. 9 is a side elevational, sectional view of one illustrative drain installation kit application; and
  • FIG. 10 is a perspective view of one illustrative drain installation kit application.
  • DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
  • The following detailed description is exemplary in nature and is not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the following description provides practical illustrations for implementing exemplary embodiments of the present invention. Constructions, materials, dimensions, and manufacturing processes suitable for making embodiments of the present are known to those of skill in the field of the invention. Those skilled in the art will recognize that many of the examples provided have suitable alternatives that can be utilized.
  • Throughout the following description, the term recess is used to denote an opening. Recess is used to describe both openings that extend partially through a surface and openings that may extend fully through a surface. Moreover, as used in this description, an object's height refers generally to its extent in direction T of FIGS. 2 b-2 c, an object's length refers generally to its extent in direction L of FIGS. 2 b-2 c, and an object's width refers generally to its extent in direction W of FIG. 3 a.
  • FIG. 1 shows a top plan view of an illustrative assembled drain installation kit 10. A drain installation kit can include a plurality of guide bars 12, having their respective leading ends 13 detachably attached to an illustrative upper flange 14 about a drain plate 18. Their respective trailing ends 15 can abut an upstanding wall 16 that defines the outermost boundaries of the shower, swimming pool, or other sloped floor to be constructed. Guide bars 12 are often supported by a substantially flat support surface 11, which, in one embodiment, would be the slab of the structure within which the sloped surface is being built.
  • Embodiments of a drain installation kit are not restricted to sloped floors of rectangular configuration only. The guide bars 12 may be used to build sloped floors of any predetermined geometric configuration. For example, a guide bar 12 may be cut at any location along the length thereof to conform it to the size of a space having an extent less than the length of an uncut guide bar 12, and the leading end 13 of one or more additional guide bars may be attached to the trailing end 15 of one or more installed guide bars to enable use of the guide bars in spaces having an extent greater than the length of a single guide bar.
  • FIG. 2 a shows an illustrative guide bar 12 that has a height extent at its leading end 13 that is less than its height extent as its trailing end 15. Accordingly, when its bottom wall or bottom edge 17 rests atop the substantially flat support surface 11 and when its leading end 13 is attached to the upper flange 14, the top wall or top edge 19 of the guide bar will be disposed relative to a horizontal plane at a predetermined angular slope defined by the height difference. In some embodiments, the guide bar 12 may have a trailing projection 44 which extends from its trailing end 15 as shown in FIG. 2 a. In additional embodiments, the guide bar 12 can have a leading projection 46, which extends from its leading end 13 as shown in FIG. 2 a.
  • The openings 42 of FIG. 2 a are defined by trusses, which comprise the support structure of the guide bars 12. Guide bars with truss support structures are often made of a smaller quantity of material, while maintaining sufficient structural integrity. The smaller quantity of material often leads to a guide bar that is less expensive to manufacture and lighter, making it easier for an installer to handle. In some instances, the openings 42 in each guide bar 12 enhance the bond between the guide bar and a suitable cementitious mixture that is used to form the sloped floor. The illustrative openings 42 depicted in FIG. 2 a advantageously allow more cementitious mixture to pass through the guide bar 12 than in conventional drain kits, providing for a stronger bond than in conventional applications.
  • In many instances, guide bars with truss support structures can be manufactured more uniformly. The cross-sectional area of each of the trusses can be approximately equal. In guide bars made of plastic, every truss having approximately equal cross-sectional areas can finish cooling at roughly the same time, thereby minimizing imperfections (e.g., bending and/or cracking due to stress). This provides a distinct advantage over support structures that define circular openings.
  • FIGS. 2 b and 2 c show additional embodiments of the guide bar 12 in which the openings 42 of FIG. 2 a can be replaced and/or supplemented by additional structural features. For example, FIGS. 2 b and 2 c show embodiments in which the guide bar 12 can have one or more openings 118 in its bottom edge 17 or top edge 19. In embodiments in which the bottom edge 17 has openings 118, the bottom edge 17 would not be supported along its entire extent by the slab 11. In embodiments in which the top edge has openings 118, cementitious mixture would not be made flush with the entire top edge 19 of the guide bar 12 when added. These openings 118 allow for additional cementitious mixture to pass through the guide bar 12, thus strengthening the bond between the mixture and the guide bar 12. Those skilled in the art will appreciate that the openings 118 can take a variety of shapes and configurations, and are not limited to those shown in the embodiments present here. For example, both the bottom edge 17 and the top edge 19 may contain the openings 118. In some embodiments, the width of the bottom edge 17 can be greater than that of the top edge 19, thereby increasing the stability of the guide bar 12.
  • FIGS. 3 a, 3 b, and 4 show one illustrative drain installation kit assembled with components of a drain assembly 22. A conventional drain assembly can include a drain pipe 24, a drain base 25 with a drain base flange 28, and an upper flange. FIGS. 3 a, 3 b, and 4 show the conventional upper flange replaced by one embodiment of the upper flange 14 included with an illustrative drain installation kit. As with a conventional drain assembly, the illustrative upper flange 14 can be secured to the drain base flange 28 by a plurality of screws 20. The upper flange 14 is internally threaded and threadedly receives an externally threaded conventional post 30. The post 30 is integrally formed with a housing 32, which receives a drain plate 18.
  • FIGS. 3 a and 3 b further show the leading end of one guide bar 12 attached directly to the upper flange 14. In the embodiment depicted, the upper flange 14 has multiple attachment points, which in this embodiment include a plurality of flange recesses 34. The flange recesses 34 can be adapted to receive a portion of a member (e.g., a pin, a screw, a bolt, a nail, or other similar members). Each guide bar can have a leading projection 46 as shown in FIG. 2( a)-(c). A guide bar recess 52 can pass through the leading projection from top to bottom, for receiving the member. FIG. 3 b shows one embodiment where a guide bar 12 is detachably attached to the upper flange 14, with guide bar recess 52 aligned with flange recess 34.
  • As is known, attachment of the guide bar 12 to the upper flange 14 can be achieved in a variety of ways, and is not limited solely to the embodiment described above. Although a detachable attachment may be preferable in some applications where the guide bar may need to be repositioned, the attachment need not be detachable. The guide bar may be permanently attached to the upper flange, especially in applications where the guide bar 12 can be left in place after it has been attached. The guide bar 12 may similarly be permanently attached in a variety of ways, as is known in the art. As just one example, the guide bar may be permanently attached with an adhesive. Additionally, in some applications, the upper flange 14 may not be necessary, and the guide bar 12 may be attached directly to a conventional upper flange included in a conventional drain assembly.
  • FIG. 4 shows a side elevational view of an illustrative guide bar 12 attached to the upper flange 14. The leading projection 46 of the guide bar 12 sits atop the upper flange 14 and is detachably attached to the upper flange 14 in accordance with the description provided above. In one illustrative embodiment, the leading projection 46 extends inwardly towards the drain only as far as the edge of the drain plate 18. When all guide bars are attached in such a manner, space is maintained between the upper flange 14 and the housing 32. The space in this embodiment allows the height of the drain plate to be freely adjusted without interference from the guide bars 12 or any other part of the drain installation kit. In this way, the drain plate 18 can be positioned without regard to the structure that attaches the guide bars 12 to the upper flange 14. In an illustrative embodiment, the height of the drain plate 18 is adjusted after the cementitious mixture is added, but before it dries. Being able to adjust the position of the drain plate 18 at this time can be important in order to make the tile and the drain plate 18 as level as possible.
  • FIG. 5 shows one embodiment of an upper flange 14 configured for use in the embodiments depicted in FIGS. 3 a, 3 b, and 4. The upper flange 14 in this embodiment has multiple flange recesses 34 radially spaced about a center drain opening 35. The drain opening 35 can be configured to receive the conventional post 30 and drain plate housing 32 shown in FIG. 4. In the embodiment shown, the drain opening 35 includes partial internal threading 36 for threadedly receiving a corresponding post. The upper flange 14 may be attached to the drain base 25 of FIG. 4 with the screws 20 previously described inserted through one or more openings 37 on the upper flange 14. Weep holes 38 may also be included in the upper flange to allow moisture to seep down into the drain.
  • FIG. 6 a shows one embodiment of a connection between multiple guide bars 12, 112. In the embodiment shown, a trailing projection 44 extends from the trailing end 15 of one guide bar 12. A guide bar recess 54 can pass through the trailing projection 44 from top to bottom, for receiving a member 56. An additional guide bar 112 has a leading projection 46 with a guide bar recess 52. The member 56 can join the guide bars 12, 112 when it is inserted into both guide bar recesses 52, 54. Each guide bar 12, 112 can have the same predetermined slope, with the trailing and leading projections dimensioned and placed to maintain a substantially even slope from the leading end of one guide bar, through the joinder of the bars, and extending to the trailing end of a second guide bar.
  • FIG. 6 b shows a side elevational view in which two of the same illustrative guide bars 12 are connected together in one embodiment to extend a predetermined slope. The guide bars 12 are positioned so that the guide bar recess 52 in the first guide bar's leading projection 46 is aligned with the guide bar recess 54 in the second guide bar's trailing projection 44. In this embodiment, the corresponding guide bar recesses can align along axis 50, and a pin or other suitable member can be inserted to secure both guide bars together. FIG. 6 c shows a top plan view of the guide bars in FIG. 6 b. In some embodiments, the first guide bar 12 is unsupported along its bottom edge 17 by the slab 11. In some instances, cementitious material can be added to the space between the bottom edge 17 and the support surface to assist the respective members and upstanding wall in maintaining the first guide bar in position. In some embodiments, a shim made from some kind of scrap (e.g., wood, drywall, etc.) can rest on top of the slab and provide additional support to the bottom edge 17.
  • FIG. 7 shows the use of multiple guide bars 12 enabling the building of larger sloped floors. An illustrative drain installation kit may have any number of guide bars 12, which can be connected as needed to extend the overall effective length of a single guide bar 12. In addition, any guide bar 12 can also be cut to a shorter length whenever required. In most embodiments, the top surface of the leading end 13 of an additional guide bar is positioned at a height substantially equal to the height of the top surface of the trailing end 15 of a guide bar 12 to which it is connected, in linear or end-to-end relation.
  • With reference to FIGS. 3 a, 3 b, and 4, to install one illustrative drain kit, the drain pipe housing 32 is first unscrewed from a conventional drain assembly and the illustrative upper flange 14 is attached in place of the conventional upper flange. The respective leading ends 13 of the guide bars 12 are then secured to the drain by attaching the leading projection 46 of each guide bar to the upper flange 14. The guide bars are attached by aligning each leading projection guide bar recess 52 with a respective flange recess 34 of the upper flange 14 and inserting a pin or other suitable member. The height of the drain plate 18 can then be adjusted to a desired height depending upon the thickness of the surface 21, to provide a flush joint with the surface. Additional guide bars 12 can be used if required by the application. For example, additional guide bars 12 can be used if the sloped floor is oversized (relative to the length of guide bars 12) as depicted in FIG. 7 or if the sloped floor has an “L”-shaped or other relatively unusual geometric configuration.
  • When all guide bars have been installed, the cementitious mixture (e.g., mud) is introduced into the area bordered by upstanding side walls 16 and divided by the upstanding guide bars and the cementitious mixture is spread throughout the area, including within the opening maintained between the housing 32 and the upper flange 14, which solidly secures the drain plate housing 32 once the cementitious mixture dries. The cementitious mixture is spread flush with the top edge 19 of each guide bar 12 along its extent. Excess cementitious mixture is removed and the surface is smoothed by conventional, well-known concrete working techniques. The surface 21, such as tiling, is then installed atop a relatively thin layer of cementitious material that overlies the cementitious mixture in the well-known way and the drain plate 18 is finally adjusted before the cementitious mixture dries in order to provide a flush joint between the top of the drain plate and the surface 21. When the surface 21 is tiling, the job is completed by filling the cracks between the tiles with grout in the well-known way. In this way, the center of the radially-positioned guide bars 12 can be nearly perfectly aligned with the center of the drain. Misalignment can lead to water pooling, and pooling can be aesthetically displeasing and can cause structural damage.
  • It should be apparent that an unskilled laborer can measure the guide bars 12 and cut them to length if required, or connect additional guide bars and cut them to length if required, and position the guide bars atop the slab 11 with the respective leading ends 13 thereof secured to the upper flange 14. No special skills are then required to introduce a cementitious mixture into the area bounded by the upstanding walls 16 and to smooth the cementitious material until it is flush with at least part of the guide bars' top edges, thereby ensuring an optimal slope in the finished sloping floor. In this way, sloping floors are provided in showers or other rooms having floors that slope to a drain, swimming pools, and the like. Significantly, the slope will be duplicated each time the drain installation kit is used and the steps of installation are followed, even if the sloping floor is built by unskilled laborers.
  • FIG. 8 shows another embodiment of a drain installation kit. The guide bars 12 in this embodiment can be attached directly to support surface 11 to provide a sloped surface leading to an aperture 60 in the support surface 11. Each illustrative guide bar can include a guide bar recess 62 which can pass through the leading end 13 of each guide bar 12. The guide bars 12 can be positioned radially about the aperture 60 as desired and attached to the support surface 11 by inserting a pin or other suitable member through the guide bar recess 62 and connecting it with the support surface. For example, a nail can be inserted into the guide bar recess 62 and driven into the support surface 11. As those in the art will appreciate, the attachment can be detachable or may not be detachable. Cementitious material can then be spread in between the guide bars to form a sloped surface leading to the aperture 60.
  • FIG. 9 shows one embodiment of an installed drain kit similar to the embodiment depicted in FIG. 8. The guide bars 12 can be positioned around an aperture 60, which in one embodiment can be a sump well. The guide bars 12 can be attached to the support surface 11 in accordance with the description provided above, and a sloped surface can be constructed with cementitious mixture in the usual way.
  • FIG. 10 shows another embodiment of an installed drain kit. The guide bars 12 in this embodiment can be positioned in a substantially parallel formation 68. In this embodiment, the trailing edge 15 of each guide bar 12 can be attached to a support wall 66. A cementitious mixture can be spread in between and flush with the guide bars 12 to form a sloped, substantially planar surface. An outer surface, such as tiling, can be installed atop the substantially planar surface in the usual way. Upon complete installation, this embodiment advantageously provides a sloped, substantially planar drain for urging water away from the support wall 66. As seen in FIG. 10, this embodiment can be implemented around the foundation of a building 72. In addition, the illustrative guide bars can also be positioned in a radial formation 70, which as shown in FIG. 10, can be used to create a drain surface around the corner of the building 72.
  • Embodiments of the present invention may include one or more of the following features. The upper flange may be configured to connect to a drain plate housing. In some drain installation kits, the upper flange may be internally threaded in order to threadedly receive a drain plate housing. The multiple attachment points on the upper flange may be radially spaced about the center of the upper flange. In some embodiments, the attachment points include flange recesses formed within a surface of the upper flange. The flange recesses may extend partially through the upper flange. In some embodiments, the flange recesses extend fully through the upper flange. Some embodiments have an upper flange with cylindrically formed flange recesses capable of receiving a cylindrically shaped pin. Some drain installation kits have guide bars with a protrusion that can be inserted into a flange recess on the upper flange. Some guide bars have a guide bar recess capable of receiving a member. In some embodiments, the guide bar recess may extend partially and/or fully through the guide bar. In some embodiments, the multiple attachment points on the upper flange may include protrusions that can extend into a guide bar recess in the guide bar. Some guide bars are dimensioned so that they do not obstruct the movement of an adjustable drain plate housing when they are attached to the upper flange. In some drain installation kits, the first ends of the guide bars are substantially fixed with respect to the drain base when attached to the upper flange. In some embodiments, the guide bars are positioned so as to create a substantially planar drain surface. The support structure of some guide bar embodiments can be trusses. Some drain installation kits have guide bars which are positioned so as to urge water away from a central area. In some embodiments, the width of a guide bar's bottom edge is greater than that of its top edge.
  • Thus, embodiments of a drain installation kit are disclosed. One skilled in the art will appreciate that the drain installation kit can be practiced with embodiments other than those disclosed. The disclosed embodiments are presented for purposes of illustration only and not limitation.

Claims (27)

1. A drain installation kit for constructing a sloped floor that is made of cementitious material and adapted to drain liquid into a drain, the kit comprising:
a plurality of guide bars, each guide bar having a leading end and a trailing end, the leading end (a) being configured to rigidly connect to an upper flange that is rigidly connected to a drain base and (b) having a smaller height than the trailing end; and
instructions for using the drain installation kit.
2. The drain installation kit of claim 1, further comprising a plurality of members adapted to assist in rigidly connecting the guide bars to the upper flange.
3. The drain installation kit of claim 2, wherein each guide bar has a guide bar recess, and each member is adapted to be inserted partially into the guide bar recess and partially into one of a plurality of flange recesses of the upper flange.
4. The drain installation kit of claim 2, wherein the members are pins.
5. The drain installation kit of claim 1, wherein each guide bar includes top and bottom edges, the bottom edge being wider than the top edge.
6. The drain installation kit of claim 1, wherein each guide bar includes trusses that define a plurality of openings adapted to allow cementitious material to pass through the guide bar.
7. The drain installation kit of claim 1, wherein the trailing end of a first of the plurality of guide bars is configured to connect with the leading end of a second of the plurality of guide bars.
8. The drain installation kit of claim 7, wherein the first guide bar includes a first top edge extending at a first angular slope between the leading and trailing ends of the first guide bar and the second guide bar includes a second top edge extending at a second angular slope between the leading and trailing ends of the second guide bar, the first angular slope being substantially equal to the second angular slope.
9. The drain installation kit of claim 1, wherein, when a drain plate housing is adjustably connected to the upper flange, the rigid connection between the guide bars and the upper flange does not obstruct adjustment of the height of the drain plate housing.
10. A method of assisting a user in constructing a sloped floor that is made of cementitious material and adapted to drain liquid into a drain, comprising:
providing a drain installation kit that includes a plurality of guide bars, each guide bar having a leading end and a trailing end, the leading end having a smaller height than the trailing end; and
instructing the user to:
(a) install a drain base within a support area,
(b) rigidly connect an upper flange to the drain base,
(c) position at least some of the plurality of guide bars radially about the drain base,
(d) rigidly connect the at least some of the plurality of guide bars to the upper flange,
(e) add cementitious material to the support area, and
(f) make an upper surface of the cementitious material flush with the top edges of the plurality of guide bars.
11. The method of claim 10, wherein instructing the user to rigidly connect one of the plurality of guide bars to the upper flange comprises instructing the user to insert a member partially into a flange recess of the upper flange and partially into a guide bar recess of the guide bar.
12. The method of claim 10, further comprising instructing a user to optionally connect the leading end of at least one guide bar to the trailing end of at least one of the guide bars that is to be rigidly connected to the upper flange.
13. The method of claim 10, further comprising instructing a user to connect a drain plate housing to the upper flange and to adjust the height of the drain plate housing, wherein the rigid connection between the guide bars and the upper flange does not obstruct adjustment of the height of the drain plate housing.
14. A drain installation kit for constructing a sloped floor that is made of cementitious material and adapted to drain liquid into a drain, the kit comprising:
a drain base configured to be installed in a support area;
an upper flange having a plurality of attachment points, the upper flange being configured to rigidly connect to the drain base;
a drain plate housing adapted to connect to the upper flange, the height of the drain plate housing when connected to the upper flange being adjustable; and
a plurality of guide bars, each guide bar having a leading end and a trailing end, the leading end (a) being configured to rigidly connect to the upper flange at any one of the plurality of attachment points and (b) having a smaller height than the trailing end.
15. The drain installation kit of claim 14, wherein the upper flange has a first surface and each of the plurality of attachment points includes a flange recess formed in the first surface of the upper flange.
16. The drain installation kit of claim 15, wherein the flange recess extends partially through the upper flange.
17. The drain installation kit of claim 15, further comprising a plurality of members, wherein each guide bar includes a guide bar recess proximate the leading end and each member is configured to be partially inserted into one of the flange recesses and partially into one of the guide bar recesses for rigidly connecting the leading end of the guide bar to the upper flange.
18. The drain installation kit of claim 17, wherein the member is a pin.
19. The drain installation kit of claim 15, where each guide bar includes a protrusion proximate the leading end configured to be received within one of the flange recesses for rigidly connecting the leading end of the guide bar to the upper flange.
20. The drain installation kit of claim 14, wherein the plurality of attachment points are spaced equidistantly from the center of the upper flange.
21. The drain installation kit of claim 14, wherein each guide bar includes top and bottom edges, the bottom edge being wider than the top edge.
22. The drain installation kit of claim 14, wherein each guide bar defines a plurality of openings adapted to allow cementitious material to pass through the guide bar.
23. The drain installation kit of claim 22, each guide bar includes top and bottom edges and the top edge or the bottom edge has at least one opening.
24. The drain installation kit of claim 22, wherein each guide bar includes trusses that define at least some of the plurality of openings.
25. The drain installation kit of claim 14, wherein the trailing end of a first guide bar is configured to connect with the leading end of a second guide bar.
26. The drain installation kit of claim 25, wherein the first guide bar includes a first top edge extending at a first angular slope between the leading and trailing ends of the first guide bar and the second guide bar includes a second top edge extending at a second angular slope between the leading and trailing ends of the second guide bar, the first angular slope being substantially equal to the second angular slope.
27. The drain installation kit of claim 14, wherein the rigid connection between the guide bars and the upper flange does not obstruct adjustment of the height of the drain plate housing.
US12/506,660 2007-01-09 2009-07-21 Drain installation kit Abandoned US20090277114A1 (en)

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US8239974B2 (en) * 2008-12-29 2012-08-14 Josef Erlebach Elongated shower drain
US8505131B2 (en) 2010-07-27 2013-08-13 Perimedrain Systems, LLC Trench drain system and method of installation on level floor surface, paticulary for shower rooms
US10106970B2 (en) 2011-11-18 2018-10-23 Schluter Systems L.P. Tileable drain systems and related methods
FR3033239B1 (en) * 2015-03-06 2017-10-06 Wirquin Plastiques Sa DEVICE FOR AIDING THE PRODUCTION OF A MACONNE RECEIVER, THE DEVICE COMPRISING GUIDES INTENDED TO FORM ONE OR MORE SLOPES TO MASONATE

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