BACKGROUND OF THE INVENTION
1. Field of the Invention
This present invention pertains to a bathtub drain and overflow system and more particularly to a bathtub overflow assembly.
2. Description of the Related Art
Water drains from a bathtub through a bathtub drain system or assembly. The bathtub has a drain opening. The drain system includes an L-shaped drain pipe, which is sometimes referred to as a bathtub drain shoe and which includes a 90-degree elbow that has female threads on one end and a length of drain pipe on the other end. The female threads of the elbow is placed below the drain opening. A short piece of pipe that has male threads on a lower end and a radially-extending flange on the upper end is referred to as a drain body or a drain basket or a drain flange. The lower end of the drain flange is passed through the drain opening in the bathtub, and the flange end remains above and surrounds the drain opening. Plumber's putty can be used around the underside of the flange to provide a seal against the bathtub. The male threads are screwed into the female threads of the elbow to provide a drainage flow path. A washer or a gasket may be used around the male threads adjacent to the underside of the bathtub. The elbow may have a radially-extending flange that presses against the washer or gasket or underside of the bathtub as the male threads of the drain body are screwed into the female threads of the elbow.
A bathtub typically has an overflow port some distance above the bottom inside surface of the bathtub and some distance below an upper edge of the bathtub. The drain opening is typically near one end of a standard bathtub, and the overflow port is typically near the drain opening. An overflow fitting, typically an elbow, is placed outside the bathtub around the overflow port, and a faceplate is placed inside the bathtub and fastened to the overflow fitting for sealing the overflow fitting to the outside of the bathtub at the overflow port. One or two screws are typically used to fasten the faceplate to the overflow fitting.
A problem can arise when one wishes to change the appearance of the faceplate, such as changing one finish for a different finish. One may not be able to readily find an exact replacement faceplate in the desired finish.
SUMMARY OF THE INVENTION
The present invention provides a bathtub overflow assembly, which includes a holder for attachment to an overflow fitting and a faceplate that attaches to the holder using a snap-fit connection or a threaded connection, where a screw is not used to attach the faceplate to the holder. The holder is preferably elongate and rectangular or oval in shape and has a length greater than the diameter of an overflow port in a bathtub. The holder is preferably fastened to the overflow fitting using one or more screws. The holder preferably has a first part of a snap-fit connection, and the faceplate preferably has a second part of the snap-fit connection. The faceplate is pressed into engagement with the holder for the snap-fit connection. The holder preferably has a pair of posts that project perpendicularly out of an outer surface of the holder. Each post preferably has a shoulder near a free end of the post. The faceplate preferably has a pair of walls, where each wall has an opening designed, configured and sized to receive a respective shoulder for engaging the faceplate with the holder in a snap-fit engagement. Alternatively, each of the holder and the faceplate preferably has a threaded element, where the faceplate is attached to the holder by placing the threaded elements together and rotating the faceplate with respect to the holder.
A bathtub drain and overflow assembly includes a drain pipe having a drain elbow, a drain flange sized for receipt in the drain elbow, an overflow pipe having an overflow fitting on one end, a tee fitting for receiving the drain pipe and the overflow pipe, and the bathtub overflow assembly kit described in the paragraph above.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the invention can be obtained when the detailed description of exemplary embodiments set forth below is considered in conjunction with the attached drawings, which can be described as follows.
FIG. 1 is a side elevation in partial cross-section of a bathtub fitted with a bathtub drain and overflow system, according to the present invention.
FIG. 1A is a side elevation of a bathtub overflow fitting that has one central threaded bore hole.
FIG. 1B is a side elevation of a bathtub overflow fitting that has two threaded bore holes.
FIG. 2 is a perspective view of a holder, according to the present invention.
FIG. 3 is a top plan view of the holder of FIG. 2.
FIG. 4 is a bottom plan view of the holder of FIG. 2.
FIG. 5 is a side elevation in cross-section of the holder as seen along the line 5-5 in FIG. 3.
FIG. 6 is a side elevation in cross-section of the holder as seen along the line 6-6 in FIG. 3.
FIG. 7 is a side elevation in cross-section of the holder as seen along the line 7-7 in FIG. 4.
FIG. 8 is a perspective view of a bathtub overflow faceplate, according to the present invention.
FIG. 9 is a bottom plan view of the faceplate of FIG. 8.
FIG. 10 is side elevation in cross-section of the faceplate as seen along the line 10-10 in FIG. 9.
FIG. 11 is side elevation in cross-section of the faceplate as seen along the line 11-11 in FIG. 9.
FIG. 12 is a perspective view of a bathtub overflow faceplate, according to the present invention.
FIG. 13 is a side elevation in partial cross-section of a bathtub fitted with a bathtub drain and overflow system, according to the present invention.
FIG. 14 is a side elevation in partial cross-section of a holder attached to an overflow fitting and a faceplate attached to the holder, according to the present invention.
FIG. 15 is an exploded view of the components shown in FIG. 14.
FIG. 16 is a perspective view of an alternative embodiment of a holder, according to the present invention.
FIG. 17 is a perspective view of an alternative embodiment of a bathtub overflow faceplate, according to the present invention.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
FIG. 1 is a side elevation in partial cross-section of a bathtub drain flange fitting 10 in a threaded engagement with a bathtub drain shoe 12 that comprises a 90-degree elbow 14 formed integral with or attached to a drain pipe 16. A partial view in cross-section of a bathtub 18 shows a drain opening 18a and an overflow port 18b. The bathtub drain flange fitting 10 is received in the drain opening 18a, and a drain stopper 15 is received in the bathtub drain flange fitting 10. An overflow fitting 20 is connected to an overflow pipe 22, which is connected to a tee 24. Tee 24 has an upper opening 24a for receiving the overflow pipe 22, a side opening 24b for receiving the drain pipe 16 and an outlet 24c connected to a drain trap 26, which is connected to a plumbing system 28.
The overflow fitting 20 in FIG. 1 is attached to the bathtub 18 at the overflow port 18b. A gasket 20a provides a seal between an external surface 18c of the bathtub 18 and the overflow fitting 20. A holder 30, which is not visible in FIG. 1, is attached to the overflow fitting 20 by one or two screws, as described further in the paragraphs below, particularly with reference to FIGS. 1A, 1B, 14 and 15. The holder 30 has a length that is greater than the diameter of the overflow port 18b. The holder 30 presses against an inside surface 18d of the bathtub 18. The one or two screws have external threads, and the overflow fitting 20 has one or two bores that are defined by internal threads. The screws pass through the holder 30 and are threaded and tightened into the bores, which fastens the overflow fitting 20 to the bathtub 18 and presses the gasket 20a against the outside surface 18c of the bathtub 18 to provide a seal between the overflow fitting 20 and the bathtub 18. A faceplate 40 is attached to the holder 30 with a snap-fit connection assembly for covering and hiding the holder 30 and the overflow port 18b.
FIG. 1A is a side elevation of an overflow fitting 21 as seen from looking into an opening that is connected to a bathtub at its overflow port. Overflow fitting 21 has a central tubular shaft 21a, which has a longitudinal bore 21b defined by internal threads. A screw is received in bore 21b for fastening overflow fitting 21 to a bathtub, as will be explained further below. Overflow fitting 21 has a flange 21c for receiving a gasket for sealing overflow fitting 21 to a bathtub. FIG. 1B is a side elevation of an overflow fitting 23 as seen from looking into an opening that is connected to a bathtub at its overflow port. Overflow fitting 23 has two screw holes 23a and 23b for receiving two screws for fastening overflow fitting 23 to a bathtub, as will be explained further below. Overflow fitting 23 has a flange 23c for receiving a gasket for sealing overflow fitting 23 to a bathtub. Overflow fittings 21 and 23 are two standard types of overflow fittings that are commonly used. In the prior art, a faceplate with one screw hole is used with overflow fitting 21, and a faceplate with two screw holes is used with overflow fitting 23.
FIG. 2 is a perspective view of the holder 30. Holder 30 has an elongated oval shape and a longitudinal length that is greater than the diameter of the overflow port 18b so that the holder 30 can abut the inner surface 18d of the bathtub 18 for fastening the overflow fitting 20 to the bathtub 18. Holder 30 has three holes 30a, 30b and 30c, which are sized and designed to allow the shank of a screw to pass through the holes while retaining the head of the screw on an upper or outer surface 30d of the holder 30. Holes 30a and 30b are located near opposing ends of the holder 30 and have elongated oval shapes, which accommodates different spacings between threaded bores in the overflow fitting 20. Hole 30c is located in the center of holder 30 and is a circular hole. Some standard overflow fittings have one central threaded bore, as shown in FIG. 1A, and another standard overflow fitting has two threaded bores, as shown in FIG. 1B. Two screws are passed through the holes 30a and 30b for an overflow fitting with two threaded bores. One screw is passed through hole 30c for an overflow fitting with one threaded bore. The screw or screws are threaded into the bore or bores 20b and tightened to fasten the overflow fitting 20 to the bathtub 18. An example with two screws 74a and 74b is described below with reference to FIGS. 14 and 15.
FIG. 3 is a top plan view of holder 30. FIG. 4 is a bottom plan view of holder 30. FIG. 5 is a side elevation of holder 30 in cross-section as seen along the line 5-5 in FIG. 3. FIG. 6 is a cross-section of holder 30 as seen along the line 6-6 in FIG. 3. FIG. 7 is a cross-section of holder 30 as seen along the line 7-7 in FIG. 4. Holder 30 has two upright, cantilevered posts 30e and 30f at its center on opposing sides of the central hole 30c along the perimeter of the holder 30. The posts 30e and 30f extend upwardly from the upper or outer surface 30d. Posts 30e and 30f each have a rectangular transverse cross-section and a shoulder 30g near a distal end 30h. The shoulders 30g can be best seen in FIG. 6. The shoulders 30g and the distal end 30h form one-half of an arrowhead because the posts 30e and 30f are thicker at the shoulder 30g than at a point proximal to the upper/outer surface 30d of the holder 30. The shoulder 30g is defined by this difference in thickness. The cantilevered posts 30e and 30f with their shoulders 30g are a first part of a snap-fit connection assembly for receiving and holding the faceplate 40. A pair of U-shaped walls 30i and 30j project upwardly from the upper surface 30d on opposing sides of the central hole 30c. The posts 30e and 30f are between and are spaced away from the walls 30i and 30j. The posts 30e and 30f and the walls 30i and 30j form a discontinuous box 30k in the center of the holder 30 surrounding the central hole 30c. The box 30k provides a means for centering a second part of the of the snap-fit connection assembly, which is on the faceplate 40. The bottom plan view of holder 30 in FIG. 4 shows a lower or inner surface 30m, a perimeter wall 30n and reinforcing ribs 30p. A relatively thin sheet is defined between the upper surface 30d and the lower surface 30m relative to the perimeter wall 30n being thicker. The perimeter wall 30n and the reinforcing ribs 30p preferably have the same thickness. The reinforcing ribs 30p surround the holes 30a, 30b and 30c. Segments of the reinforcing ribs 30p extend between the holes 30a, 30b and 30c and the perimeter wall 30n, and other segments extend between the holes. The reinforcing ribs 30p add structural strength to the holder 30. Holder 30 could be made as an open structure having the shape shown in FIG. 4 for the reinforcing ribs 30p, without the sheet defined between the upper surface 30d and the lower surface 30m, which would provide more open flow area through which overflow water could flow.
FIG. 8 is a perspective view of the underside or inside 40a of the faceplate 40. FIG. 9 is a bottom plan view of the faceplate 40. FIG. 10 is a cross-section of faceplate 40 as seen along the line 10-10 in FIG. 9. FIG. 11 is a cross-section of faceplate 40 as seen along the line 11-11 in FIG. 9. Faceplate 40 has a perimeter wall 40b around about two-thirds or three-fourths of its perimeter. A gap in the wall is defined by edges 40c and 40d in the perimeter wall 40b. The perimeter wall 40b spaces the faceplate 40 away from the inner surface 18d of the bathtub 18. The gap in the wall 40b provides a flow channel for water to overflow from the bathtub 18 into the overflow fitting 20 for preventing or reducing overflow from the bathtub 18 in the event that the drain opening 18a is stoppered and sealed while water continues to flow into the bathtub 18. FIGS. 10 and 11 show the inside 40a and an opposing outside 40e of faceplate 40.
The second part of the of the snap-fit connection assembly comprises a pair of opposing walls 40f and 40g that project from an under surface 40h of the faceplate 40. The wall 40f has a rectangular opening 40i, and the wall 40g has a rectangular opening 40j. The second part of the of the snap-fit connection assembly preferably includes opposing walls 40m and 40n, which connect with the walls 40f and 40g to form a box 40k.
After the holder 30 is fastened to the overflow fitting 20, its box 30k and its posts 30e and 30f project outwardly away from the inside surface 18d of the bathtub 18 around the overflow port 18b. One fastens the faceplate 40 by first aligning the faceplate box 40k with the holder box 30k such that the shoulders 30g on posts 30e and 30f align with the openings 40i and 40j in walls 40f and 40g, respectively. One then presses on a central portion of the outside 40e of faceplate 40, which causes the faceplate box 40k to slide along the outside of the holder box 30k, and the cantilevered posts 30e and 30f flex or bend inwardly as the shoulders 30g ride along the walls 40f and 40g until the shoulders 30g snap into the openings 40i and 40j, respectively, thereby fastening the faceplate 40 to the holder 30.
FIG. 12 is a perspective view of the underside or inside of a faceplate 50, which is an alternative embodiment of faceplate 40. Faceplate 50 corresponds in all aspects with faceplate 40, except the perimeter of faceplate 50 in FIG. 12 is square with rounded corners rather than circular. This is merely an aesthetic difference. Faceplate 50 functions in the same manner as described above for faceplate 40 in FIGS. 8-11.
FIG. 13 is a side elevation in cross section of a bathtub overflow assembly 60, according to the present invention, installed in the bathtub 18 of FIG. 1. With reference to FIG. 1, a partial view in cross-section of the bathtub 18 shows the drain opening 18a and the overflow port 18b. An overflow fitting 20n is connected to an overflow pipe 22n, which is connected to a tee 24n, which is connected to a plumbing system 28n. The bathtub overflow assembly 60 is attached to the bathtub 18 at the overflow port 18b. A bathtub drain flange fitting 10n is received in the bathtub drain opening 18a and is in a threaded engagement with a bathtub drain shoe 12n that comprises a 90-degree elbow 14n formed integral with or attached to a drain pipe 16n, which connects to the tee 24n. A drain stopper 15n is received in the bathtub drain flange fitting 10n. A gasket 62 provides a seal between an external surface 18c of the bathtub 18 and the overflow fitting 20n. A holder 64 is attached to the overflow fitting 20n by one or two screws, which are not visible in FIG. 13. The holder 64 has a length that is greater than the diameter of the overflow port 18b. The holder 64 presses against the inside surface 18d of the bathtub 18. A faceplate 66 is attached to the holder 64 with a snap-fit connection assembly for covering and hiding the holder 64 and the overflow port 18b.
FIG. 14 is a cross section of a bathtub overflow assembly 70, according to the present invention, installed in a bathtub 80 and connected to an overflow fitting 82. FIG. 15 is an exploded view of the components shown in FIG. 14. Overflow fitting 82 has bore holes 82a and 82b defined by internal threads. A holder 72 having the design characteristics described with reference to FIGS. 2-7 is fastened to the overflow fitting 82 using screws 74a and 74b. Screws 74a and 74b have external threads that threadedly engage the internal threads that define the bore holes 82a and 82b in the overflow fitting 82. A gasket 84 provides a seal between the overflow fitting 82 and an outside surface of the bathtub 80. A faceplate 76 having the design characteristics described with reference to FIGS. 8-11 is fastened to the holder 72 by the snap-fit connection described above with reference to FIGS. 8-11.
Alternative embodiments of the snap-fit connection assembly are available. A snap-fit connection assembly typically uses flexible parts, such as a plastic, to connect two parts together by pushing the parts' interlocking components together. Holder 72 is preferably made of a plastic material, and faceplate 76 is preferably made of a metal material. The snap-fit connection described for connecting faceplate 76 to holder 72 is known as a cantilever type of snap-fit connection. Two other types of snap-fit connections are annular and torsional. An example of an annular snap-fit connection is a snap fastener used to fasten two pieces of cloth together rather than using a button. The box 30k shown in FIGS. 2 and 3 could be replaced with a circular wall, preferably having a protuberance near the surface 30d. The box 40k shown in FIG. 8 could be replaced with a circular wall having a diameter slightly less than the diameter of the circular wall on the holder, preferably with a slight protuberance on a distal end. Upon pressing the faceplate into engagement with the holder, the holder wall would expand slightly to accept the protuberance on the faceplate wall until the protuberance on the faceplate wall snaps into a recess at the protuberance on the holder wall. A ball-and-socket connection can also be an annular snap-fit connection. U.S. Pat. No. 10,686,648 to Beck et al. is incorporated by reference to provide more information about snap-fit connections. For the torsional type of snap-fit connection, the holder (or the faceplate) can have the box 30k or the circular wall of the annular snap fit. Another wall is provided that circumscribes the wall on the holder, but is spaced a slight distance away so that an annulus is defined between the two walls. The faceplate (or the holder) has a wall sized and designed to fit snugly in the annulus, thereby providing a friction fit or interference fit that fastens the faceplate to the holder.
FIG. 16 is a perspective view of an alternative holder 100. Holder 100 has an elongated oval shape and a longitudinal length that is greater than the diameter of an overflow port in a bathtub. Holder 100 has three holes 100a, 100b and 100c, which are sized and designed to allow the shank of a screw to pass through the holes while retaining the head of the screw on an upper or outer surface 100d of the holder 100. Holes 100a and 100b are located near opposing ends of the holder 100 and have elongated oval shapes, which accommodates different spacings between threaded bores in an overflow fitting. Hole 100c is located in the center of holder 100 and is a circular hole. The three holes 100a, 100b and 100c serve the same purpose as was described above for holder 30 in FIG. 2. The box 30k in FIG. 2 has been replaced with a tube 102 for the holder 100 in FIG. 16. Tube 102 is formed integral with or is attached to holder 100. Tube 102 surrounds the centralized hole 100c and is preferably centered on the holder 100. Tube 102 has external threads 102a.
FIG. 17 is a perspective view of an underside or inside 110a of a faceplate 110. Faceplate 110 has a perimeter wall 110b, which has a plurality of oval-shaped openings 110c for allowing water to flow into an overflow fitting and drain system. The perimeter wall 110b spaces the faceplate 110 away from an inner surface a bathtub. The openings 110c in the wall 110b provides a flow channel for water to overflow from the bathtub into the overflow fitting for preventing or reducing overflow from the bathtub in the event that a drain opening is stoppered and sealed while water continues to flow into the bathtub. A tube 112 replaces the box 40k shown in in FIG. 8. Tube 112 is formed integral with or is attached to the faceplate 110. Tube 112 is preferably centered in the faceplate 110. Tube 112 has internal threads 112a that define a bore 112b. Tube 112 is designed, sized and configured to threadedly engage the tube 102 on the holder 100. Faceplate 110 is fastened to the holder 100 by screwing the tube 112 onto the tube 102. The threading arrangement can be reversed with tube 112 having external threads and tube 102 having internal threads, in which case tube 112 can be replaced with a solid threaded stud since the hollow tubular structure would not be needed.
The present invention provides an elongate holder that is longer than a diameter of a bathtub overflow port. The holder preferably has at least three holes through which a screw can pass for fastening the holder to an overflow fitting. Two holes, which are located proximal to opposing distal ends of the holder, are used to receive a screw in each for fastening the holder to an overflow fitting that has two holes with internal threads. The screws have external threads that engage the internal threads. For an overflow fitting that has just one bore defined by internal threads, where the bore is centered in an opening of the overflow fitting, one screw is passed through a central opening in the holder for fastening the holder to the overflow fitting. A wall of the bathtub around its overflow port is squeezed between the overflow fitting, which is located outside the bathtub, and the holder, which is located inside the bathtub, by tightening the one or two screws that are passed through the holder and screwed into the overflow fitting. A designer may prefer to use a ribbed structure for the holder, which has a great deal of open area for allowing water to flow through the holder so that the holder impedes water flow as little as possible. A designer may prefer to use a flat bar as the holder. Characteristics of the holder preferably include: (1) a length that is greater than the diameter of the overflow port so that the bathtub wall can be sandwiched between the holder and the overflow fitting; (2) pass-through screw holes for fastening the holder to either an overflow fitting that has one threaded bore hole or to an overflow fitting that has two threaded bore holes; and (3) a means for receiving, engaging and holding a faceplate, where the means is preferably centralized on the holder.
A faceplate is connected to the holder for covering and hiding the overflow port in the bathtub and the holder. The faceplate can have any shape that a designer chooses to use. The faceplate should be designed and configured to allow water to pass though or around the faceplate and into the overflow fitting. The faceplate can be flat with holes or slots or cup-shaped as suggested by the drawings described above. A cup-shaped faceplate comprises a front plate and a perimeter wall. The front plate and/or the perimeter wall can have slots or holes The faceplate is connected to the holder without having screw heads visible from inside the bathtub, which is how faceplates have typically been attached in the prior art.
The holder has a first part of a means for connecting a faceplate to the holder. The faceplate has a second part of a means for connecting a faceplate to the holder. Various snap-fit or interference-fit connection assemblies have been described and suggested above for connecting a faceplate to a holder, thereby describing various means for connecting a faceplate to a holder. A threaded connection has been described above as another means for connecting a faceplate to a holder. The threading arrangement in the threaded connection can be with the holder having internal or external threads, thereby providing more than one means for connecting a faceplate to a holder.
The prior art has some examples of a snap-fit or interference-fit type of connection for a faceplate, but it is believed that such prior art connections provide an engagement around the inside of the perimeter wall of the faceplate. The means for engaging the faceplate with the holder, as described for the present invention above, is located in the center of the faceplate rather than at the perimeter wall. So, in one embodiment of the present invention, there is no engagement between the perimeter wall of the faceplate and the holder, regardless whether such engagement could be an interference-fit or snap-fit or a threaded engagement. However, another embodiment could have the opposing distal ends of the holder engaged with the faceplate with some minor design changes, in which, for example, the distal ends could engage notches on an inside wall of the faceplate or elements similar to the upright, cantilevered posts 30e and 30f shown in FIG. 2 could be located near or at the opposing distal ends of the holder for engaging a receiving structure in the faceplate or in its perimeter wall.
Other prior art examples do not use the standard overflow fittings shown in FIGS. 1A and 1B. In the present invention, a holder is connected to an overflow fitting that is located entirely outside the bathtub rather than protruding into the bathtub. Some prior art examples have an overflow fitting that protrudes into the bathtub and provides a means for connecting a faceplate to the overflow fitting. The faceplate of the present invention is not connected directly to an overflow fitting and is instead connected to a holder that is located inside the bathtub, and the holder is connected to an overflow fitting, which is located outside the bathtub without any significant protrusion into the bathtub. In one embodiment, the present invention consists of a holder, which can be attached to an overflow fitting located outside of and around a bathtub overflow port, and a faceplate, where the faceplate connects directly to the holder without any connection means being visible to a person looking at the faceplate from inside the bathtub, without any other separate parts being needed to connect the faceplate to the holder, which would then be an indirect connection. The holder is preferably connected directly to an overflow fitting, which would be located entirely outside of a bathtub, preferably by one or more screws, and the faceplate is connected directly to the holder, with the holder having a first part of a means for connecting the faceplate to the holder and the faceplate having a second part of the means for connecting the faceplate to the holder, without any other component being required to fasten the faceplate to the holder or to fasten the holder to the overflow fitting.
Having described the invention above, various modifications of the techniques, procedures, materials, and equipment will be apparent to those skilled in the art. It is intended that all such variations within the scope and spirit of the invention be included within the scope of the appended claims.
Patent Grant
12012735
