Patent Application
20170096809
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.
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.
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.
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.
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. But 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.
Thus, an improved method for installing a floor drain to the correct height above a flooring slab and a plumbing trap is desired.
In an exemplary embodiment, an improved method of installing a drain fixture is disclosed. The method comprises installing a sub-floor plumbing system. Installing the sub-floor plumbing system comprises connecting a first end of a plumbing trap to a main drain outlet and connecting a first end of a removable drain pipe to a second end of the plumbing trap. The method next comprises sliding a sleeve over the removable drain pipe. Next, the method comprises building a flooring surface above and around the plumbing trap, the removable drain pipe, and the sleeve. Once the floor is built, the method comprises partly or fully removing the removable drain pipe from the sleeve, cutting the removable drain pipe to the desired length and re-inserting the removable drain pipe through the sleeve and into the plumbing trap.
In an exemplary embodiment, an improved plumbing installation kit is disclosed. The kit comprises a plumbing trap, at least one removable drain pipe, at least one sleeve, an optional adapter, an optional washer, an optional cap, and an optional drain pre-form.
Reference is now made to the following descriptions taken in conjunction with the accompanying drawings.
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.
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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.
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.
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.
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.
In
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
The improved drain installation 400 may further comprise a secondary inlet pipe 406 connected to a third end of the T-shaped adapter 402. The secondary inlet pipe 406 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 406 and the T-shaped adapter 402 such that gases and liquids cannot escape between the two.
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.
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.
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.
As disclosed herein, the plumbing traps and removable drain pipes 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.
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.
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.
