The present disclosure relates to a drain, and more specifically to a drain formed from a single piece of material.
Internal volumes where the open end is smaller than the diameter of the volume itself are typically formed by preparing two or more separate pieces and welding the piece together to enclose the volume therein. Such manufacturing techniques result in welded seams that leave pockets in crevices therein which can become contaminated by dirt, bacteria and the like.
In one aspect, a drain including a base wall defining an outlet and a periphery, a side wall extending from the periphery of the base wall to produce an open end opposite the base wall, and a ledge formed into the side wall and extending inwardly therefrom to at least partially enclose a first volume between the ledge, the side wall, and the base wall. Where the ledge forms a neck having a first cross-sectional shape, where the first volume includes a second cross-sectional shape that is larger than the first cross-sectional shape, and where the base wall, side wall, and ledge are formed from a single piece of monolithic material.
In another aspect, a method of manufacturing a drain having a monolithic body, the method including providing a die with a first exterior surface, forming a first monolithic piece of sheet material over the first exterior surface of the die to produce the monolithic body, where the monolithic body has an internal volume having a first cross-sectional shape accessed via an aperture having a second cross-sectional shape that is smaller than the first cross-sectional shape, and removing the die from the internal volume via the aperture.
In another aspect, a die having an external surface configured to at least partially form an internal volume, the die including a head unit defining a die axis, where the head unit includes a first end and a second end opposite the first end, a first die segment removably coupled to the head unit, where the first die at least partially forms the external surface, and where when the first die segment is coupled to the head unit the resulting assembly produces an assembled cross-sectional shape taken normal to the die axis and passing through the first die segment, and wherein the first die segment can be completely detached from the head unit without extending outside the assembled cross-sectional shape during the detachment process.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
The multi-piece body 5002 includes a base wall 5004 defining the outlet 5008, and a side wall 5012 extending axially from the base wall 5004 to produce an open end 5016 opposite the base wall 5004. The drain 5000 also includes a ledge 5020 formed into and extending radially inwardly from the side wall 5012 and positioned proximate the open end 5016. The ledge 5020 extends along the entire circumference of the side wall 5012 to “neck down” the open end 5016 (see
As shown in
The top plate 16 of the drain 10 is a substantially planar element formed from a first piece of material separate from the monolithic body 12. The top plate 16 at least partially defines an internal aperture 28 sized to substantially correspond with the size and shape of the open end 30 of the monolithic body 12. As shown in
The drain pipe 20 of the drain 10 is a substantially cylindrical element at least partially defining a channel 36 therethrough. The drain pipe 20 is formed from a second piece of material separate from the monolithic body 12. When assembled, the drain pipe 20 is fused (e.g., welded, soldered, brazed, and the like) to the base wall 14 (described below) of the body 12 so that the channel 36 is substantially aligned with the outlet aperture 18 and open to the interior volume 40. In alternative embodiments, the drain pipe 20 may be mechanically fastened to the body 12 by brackets, fasteners, gaskets, press-fit, and the like (not shown).
As shown in
In the illustrated embodiment, the base wall 14 has a circular outer periphery and the side wall 26 extends axially therefrom to produce a substantially cylindrical shape whereby the first cross-sectional shape, taken normal to the axis 16, is circular and the first representative dimension 32 is a first diameter. However, in alternative embodiments, the periphery of the base wall 14 and the side wall 26 may have alternative cross-sectional shapes such as, but not limited to, square, rectangular, polygonal, and the like. In instances where alternative cross-sectional shapes are present, the side wall 26 may include a plurality of interconnected wall segments or portions (not shown) to produce the desired cross-sectional shape (e.g., four wall segments to produce a square cross-sectional shape, and the like).
The drain 10 also includes a ledge 34 formed into the side wall 26 and extending inwardly therefrom between the base wall 14 and the open end 30 to produce an interior opening or neck 42. The ledge 34 serves to at least partially enclose an interior volume 40 within the body 12 between the ledge 34, the side wall 26, and the base wall 14 while the neck 42 defines an aperture through which the volume 40 may be accessed.
As shown in
Together, the ledge 34, side wall 26, and base wall 14 at least partially enclose the interior drain volume 40 therein. In the illustrated embodiment, the resulting drain volume 40 produces at least one cross-sectional dimension that is larger than the smallest cross-sectional dimension of the neck 42.
In the illustrated embodiment, the body 12 is monolithic, such that it is formed from a single piece of continuous material without joints or seams. More specifically, the illustrated body 12 itself does not include any welds or seams (e.g., between the base wall 14, the side wall 26, and the ledge 34). The only seams present in the drain 10 include the connection interfaces between the body 12 and the drain pipe 20 and the body 12 and the top plate 16. By eliminating any joints or seams within the body 12 itself, the body 12 of the drain 10 does not include any pockets or crevices where bacteria and/or other contaminates may be captured or trapped—producing a more hygienic structure overall.
As shown in
As shown in
The body 110 also defines a first groove or aperture 142 at the interface of the first and second portions 118, 126, and a second groove or aperture 146 at the interface of the second and third portions 126, 134. As shown in
The head unit 104 also includes one or more torque pins 166 extending axially from the body 110 and configured to selectively engage with a corresponding one of the die segments 108a, b and transmit torque therebetween. More specifically, the torque pins 166 are configured to rotationally fix the die segments 108a, b relative to the body 110. In the illustrated embodiment, the head unit 104 includes a first torque pin 166 extending axially from the second portion 126 of the body 110 and configured to selectively engage with a corresponding radial segment 108a (discussed below), and a second torque pin 166 extending axially from the fourth portion 140 of the body 110 and configured to selectively engage with and end segment 108b (discussed below).
As shown in
In the illustrated embodiment, the die 100 includes one or more radial segments 108a and at least one end segment 108b. Together, the exterior surfaces of the segments 108a, b at least partially define the contour of the ledge 34, the side wall 26, and the base wall 14 (see
Each radial segment 108a of the die 100 includes an arcuate body 150 with an arcuate outer surface 154. Each radial segment 108a also includes first protrusion 170 extending axially from a first end of the arcuate body 150 and a locking member 158 extending from the inner surface 162 of arcuate body 150. As shown in
The first protrusion 170 of each radial segment 108a is sized and shaped to be at least partially received within the first groove 142 of the head unit 104. More specifically, the first protrusion 170 is sized and shaped so that it can be axially inserted into the first groove 142 whereby the interaction between the groove 142 and the protrusion 170 will restrict any radial movement between the segment 108a and the head unit 104.
The locking member 158 of the radial segment 108a is substantially “L” shaped having a radial leg 174 and an axial leg 178. The legs 174, 178 are sized and shaped so that the axial leg 178 may be at least partially inserted into and removed from the second groove 146. More specifically, the locking member 158 is sized and shaped so that it can be axially inserted into the second groove 148 whereby the interaction between the groove 148 and the locking member 158 will restrict any radial movement between the segment 108a and the head unit 104.
As shown in
At least one of the radial segments 108a defines an aperture 182 formed into the locking member 158 and configured to at least partially receive a portion of the first torque pin 166 therein. More specifically, when axially attaching the radial segment 108a to the head unit 104, the torque pin 166 is axially aligned with and received within the aperture so that the corresponding radial segment 108a and head unit 104 are rotationally fixed. In the illustrated embodiment, the radial segment 108a with the smallest angular width includes the aperture 182. Furthermore, while the illustrated torque pins 166 are included in the head unit 104, in alternative embodiments the segments 108a may include the pins 166 while the head unit 104 defines the aperture 182.
While the illustrated embodiment shows the plurality of five radial segments 108a producing a substantially cylindrical outer surface extending 360 degrees about the head unit 104 (e.g., the assembled cross-sectional shape is a circle), it is understood that in alternative embodiments the plurality of radial segments 108a may be coupled to a head unit 104 to produce other exterior shapes such as square, rectangular, polygonal, elliptical, and the like. In such embodiments, the radial segments 108a may still extend along and enclose the entire assembled cross-sectional shape.
As shown in
The end segment 108b also includes an aperture 200 configured to at least partially receive a portion of the second torque pin 166 therein. As discussed above, the torque pin 166 is configured to rotationally lock the end segment 108b to the head unit 104 such that the two elements rotate together as a unit.
While the illustrated end segment 108b is disk-shaped, it is understood that the exterior size and shape of the end segment 108b may be changed to adapt to the correspond with and align to the radial segments 108a of the die 100.
To manufacture the monolithic body 12 of the drain 10, the user first assembles the die 100. To do so, each of the individual radial segments 108a are coupled to the head unit 104 by axially inserting the first protrusion 170 and locking members 258 into the first and second grooves 142,146, respectively (see
With the radial segments 108a in place, the user may then axially introduce the end segment 108b onto the distal end of the head unit 104 (see
With the die 100 prepared, the user then forms a piece of sheet material (e.g., a piece of stainless steel sheet material, aluminum sheet material, steel sheet material, and the like) onto the assembled exterior surface of the die 100 (e.g., the exterior surface defined by the end segment 108b, the radial segments 108a, and the exterior exposed portions of the head unit 104). In the illustrated embodiment, this is done using a “metal spinning” process whereby the raw material (e.g., a planar disk of sheet material) and die 100 are spun together and the sheet material is formed against the exterior surface of the die using tools so that the sheet material takes on the contour of the exterior surface of the die 100. Such forming produces the base wall 14, outlet 18, side wall 26, and ledge 34. In alternative embodiments, other forms of material shaping could be used. For example, in some embodiments a separate external die may be paired with the illustrated die 100 for a pressing action. In still other embodiments other forms of shaping may be used to form the sheet material against the exterior surface of the die 100.
With the monolithic body 12 of the drain 10 formed, the user then axially removes the head unit 104 from the volume 40. More specifically, the head unit 104 is axially retracted from the volume 40 via the open end 30 in the removal direction 106 whereby the radial and end segments 108a, 108b remain within the formed volume 40. More specifically, the process of removing the head unit 104 causes each of the radial and end segments 108a, 108b to simultaneously detach from the head unit 104 allowing the head unit 104 to be removed from the neck 42 of the ledge 34.
With the head unit 104 removed, the radial segments 108a may then be removed through the aperture or neck 42 one at a time. Generally speaking, this is typically starting with the smallest segment and then removing any increasingly larger segments 108a in due course but any order may be used. With the radial segments 108 removed from the volume 40, the end segment 108b may then be removed last leaving the finished body 12.
In some embodiments, the finished body 12 may then be further assembled by welding or otherwise coupling the top plate 16 and drain pipe 20 to the body 12 in the appropriate locations.
Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the invention as described.
This patent application is a divisional application of U.S. patent application Ser. No. 17/518,490, filed Nov. 3, 2021, which is a non-provisional of and claims priority to U.S. Provisional Patent Application No. 63/109,334, filed Nov. 3, 2020. The contents of these applications are incorporated herein by reference.
Number | Date | Country | |
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63109334 | Nov 2020 | US |
Number | Date | Country | |
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Parent | 17518490 | Nov 2021 | US |
Child | 18587676 | US |