MONOLITHIC DRAIN, TOOLING, AND METHOD OF MANUFACTURING THE SAME

Abstract

A monolithic drain body 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.

Description

FIELD OF THE INVENTION

The present disclosure relates to a drain, and more specifically to a drain formed from a single piece of material.

BACKGROUND

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.

SUMMARY

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.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a prior art drain.

FIG. 2 is a top view of the prior art drain of FIG. 1.

FIG. 3 is a detailed side view of the prior art drain of FIG. 1.

FIG. 4 is a side view of a drain having improved hygienic properties.

FIG. 5 is a top view of the drain of FIG. 4.

FIG. 6 is a detailed side view of the drain of FIG. 4.

FIG. 7 is a side view of a body of the drain of FIG. 4.

FIG. 8 is a top view of the body of FIG. 7.

FIG. 9 illustrates multiple monolithic drain bodies.

FIG. 10 illustrates the drain of FIG. 4 with a circular top plate installed thereon.

FIG. 11 illustrates a die in a disassembled state.

FIG. 12 illustrates the die of FIG. 11 with two die segments installed on a head unit thereof.

FIG. 13 illustrates the die of FIG. 11 with three die segments installed on the head unit thereof.

FIG. 14 illustrates the die of FIG. 11 with five die segments installed on the head unit thereof.

FIG. 15 illustrates the die of FIG. 11 with all six die segments installed on the head unit thereof.

FIG. 16 illustrates the die of FIG. 11 with the end segment installed on the head unit thereof.

FIG. 17 is a bottom view of the die of FIG. 11.

FIG. 18 is a section view of FIG. 16 taken along line 18-18.

FIG. 19 is the section view of FIG. 18 with a monolithic drain body formed thereon.

FIG. 20 is a bottom view of an alternative embodiment of the die including a die segment having parallel side walls.

FIG. 21 is a section view taken along the centerline of a structure having an internal volume.

FIG. 22 illustrates another embodiment of the drain having a sloped base wall.

DETAILED DESCRIPTION

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.

FIGS. 1-3 illustrate a prior art embodiment of a drain 5000. The drain 5000 includes a multi-piece body 5002 defining an open end 5016 and an outlet 5008, a top plate 5006 coupled (e.g., welded) to the multi-piece body 5002 at the open end 5016, and a drain pipe 5010 coupled (e.g., welded) to the multi-piece body 5002 at the outlet 5008.

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 FIG. 2).

As shown in FIG. 1, the body 5002 is formed from multiple pieces of sheet material welded together. More specifically, the body 5002 includes a first piece of sheet material 5024 forming the base wall 5004 and a portion of the side wall 5012 (e.g., forming a shallow dish shape), and a second piece of sheet material 5028 welded to the first piece of sheet material 5024 forming the side wall 5012 and the ledge 5020. In the illustrated embodiment, the second piece of sheet material 5028 of the drain 5000 is formed as an elongated flat piece that is formed into an annular shape by welding the two distal ends together (e.g., forming an axial weld 5030 along the height of the side wall 5012). The resulting annular shape is then welded to the first piece of sheet material 5024 producing a circumferential weld 5032 around the entire body 5002. The resulting multi-piece welded drain structure has hygienic deficiencies as both welded seams 5030, 5032 provide pockets and crevices for contamination such as dirt, bacteria, gunk, and the like to become lodged and fester. Such pockets and crevices are also difficult, and in some cases impossible, to clean properly

FIGS. 4-10 illustrate the monolithic drain 10 having improved hygienic properties. The drain 10 has a monolithic body 12 defining an open end 30 and an outlet 18, a top plate 16 coupled to the open end 30 of the monolithic body 12, and a drain pipe 20 coupled to the outlet 18 of the monolithic body 12.

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 FIG. 5, the exterior shape of the plate 16 may be square, however in alternative embodiments, the exterior shape of the plate 16 may be rectangular, circular, elliptical, polygonal, or any other shape as needed (see FIG. 10). When assembled, the top plate 16 is fused (e.g., welded, soldered, brazed, and the like) to the open end 30 of the body 12 such that the internal aperture 28 substantially aligns with and is open to the open end 30 of the body 12. In alternative embodiments, the top plate 16 may be mechanically fastened to the body 12 by brackets, fasteners, press-fit, and the like (not shown).

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 FIGS. 4-10, the monolithic body 12 of the drain 10 defines a body axis 16. The body 12 also includes a base wall 14 defining the outlet 18 and having an outer periphery, and a side wall 26 extending from the outer periphery of the base wall 14 to produce an open end 30 opposite the base wall 14 (see FIG. 5). The size and shape of the side wall 26 also produces a first cross-sectional shape having a first representative dimension 32 (see FIG. 5). For the purposes of this application, the representative dimension of a cross-sectional shape may include any dimension that generally establishes the size of the cross-sectional shape. For example, a diameter may be a representative dimension for a circle, a diagonal may be a representative dimension for a square or rectangle, a diagonal may be a representative dimension for a polygon, and the like.

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 FIG. 5, the neck 42 produces a second cross-sectional shape that is smaller than the first cross-sectional shape of the interior volume 40 and includes a second representative dimension 38 that is less than the first representative dimension 32 of the interior volume 40 (e.g., the second cross-sectional area of the neck 42 is less than the first cross-sectional area of the volume 40 enclosed by the ledge 34, side wall 26, and base wall 14 when both cross-sections are taken perpendicular to the axis 16). As such, the ledge 34 serves to “neck down” the open end 30 of the body 12 and provide an upper surface 44 upon which a strainer, basket, or other elements may be supported when positioned within the drain 10. The ledge 34 is also positioned proximate the open end 30 of the body 12. In the illustrated embodiment, the neck 42 has a circular cross-sectional shape (e.g., the second cross-sectional shape is a circle) having a second representative dimension 38 that includes a second diameter that is less than the first diameter of the side wall 26. However, in alternative embodiments, different internal cross-sectional shapes may be formed. In still other embodiments, the shape of the first cross-sectional shape may be different than the second cross-sectional shape.

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.

FIGS. 11-19 illustrate a die 100 used to manufacture the monolithic body 12 of the drain 10. Generally speaking, the die 100 is configured so that the die 100 can be positioned within and form a structure 800 with an internal volume 804 having a first cross-sectional shape producing a first representative dimension 808 that is accessible via an opening or aperture 816 having a second cross-sectional shape that is smaller than the first cross-sectional shape and producing a second representative dimension 820 that is smaller than the first representative dimension 808. More specifically, after the internal volume 804 of the structure is formed by shaping the single piece of material about the die 100, the die 100 is configured to be subsequently removed from the resulting internal volume 804, in a first removal direction 812, through the aperture 816 (see FIG. 21). Stated differently, the die 100 is configured to produce an internal volume 804 that is larger than the aperture 816 through which the die 100 itself can be removed from the volume 804. As shown in FIG. 21, the relevant cross-sections are generally taken normal to the direction of removal 812.

As shown in FIGS. 11-19, the die 100 includes a head unit or base 104, and a plurality of die segments 108a, b each removably coupled to the head unit 104. Together, the combined exterior surfaces of the base 104 and die segments 108a, b define the size and shape of the interior surfaces 60 of the monolithic body 12 (e.g., the surfaces 60 of the body 12 at least partially defining the drain volume 40). Furthermore, the die 100 is configured so that a sub-portion of the die 100 (e.g., the head unit 104) can be individually removed from the drain volume 40 via the open end 30 whereby the remaining elements (e.g., the die segments 108a, b) can be removed individually afterwards.

As shown in FIG. 18, the head unit 104 of the die 100 includes a substantially cylindrical body 110 defining an axis 114 therethrough. More specifically, the body 110 includes a first portion 118 producing a first outer diameter 122, a second portion 126 extending axially from the first portion 118 to produce a second outer diameter 130 less than the first outer diameter 122, and a third portion 134 extending axially from the second portion 126 opposite the first portion 118 to produce a third outer diameter 138 less than the second outer diameter 130, and a fourth portion 140 extending axially from the third portion 134 to produce a fourth outer diameter 144 that is less than the third outer diameter 138 and a distal end 148.

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 FIG. 18, both the first groove 142 and the second groove 146 are open axially toward the distal end 148 of the head unit 104. While the illustrated first and second grooves 142, 146 are annular in shape and extend continuously along the entire periphery of the head unit 104, it is understood that in alternative embodiments the first groove 142 and/or second groove 146 may include a plurality of individual apertures or segments spaced along the periphery of the head unit 104.

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 FIG. 18, the die 100 also includes a plurality of die segments 108a, b that are each removably couplable to the head unit 104. More specifically, each die segment 108a, b is attached to the head unit 104 such that it can be detached from the head unit 104 without increasing the external dimensions of the die 100 perpendicular to the direction of removal 106. Stated differently, the fully assembled die 100 (e.g., with all die segments 108a, b attached to the head unit 104) produces an assembled cross-sectional shape taken normal to the axis 16 and passing through the die segments 108a. Each die segment 108a, b is configured so that it can be completely detached from the head unit 104 without having any of the die segments 108a, b extend outside the assembled cross-sectional shape. In the illustrated embodiment, each die segment 108a, b is attached to the head unit 104 so that each can be removed axially from the head unit 104. More specifically, the die segments 108a, b are configured so that the head unit 104 can simultaneously detach from all of the die segments 108a,b in a direction of removal 106.

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 FIG. 0.19). More specifically, the segments 108a, b determine the size and shape of the base wall 14, the bottom and interior surfaces 48, 52 of the ledge 34, and the portion 56 of the side wall 26 located axially between the bottom surface 48 of the ledge 34 and the base wall 14.

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 FIG. 18, the outer surface 154 of each radial segment 108a contributes to the overall size and shape of the body 12 of the drain 10 (see FIG. 19).

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 FIG. 15, the illustrated die 100 includes a plurality of radial segments 108a that, together, form a toroidal shape extending a complete 360 degrees around the head unit 104. More specifically, the exterior surfaces 154 of the radial segments 108a interact with each other to form a substantially smooth cylindrical shape. As shown in FIG. 15, the die 100 includes five radial segments 108a where the angular width of each radial segment 108a is different. However, in alternative embodiments, more or fewer segments 108a may be used with different or similar angular widths as needed to complete the entire 360 degree structure. In one alternative embodiment, at least one of the radial segments 108a′ may include parallel side walls in place of a wedge shape so that the piece can be more easily removed after the head unit 104 has been removed (see FIG. 20).

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 FIGS. 18, 19, and 16, the end segment 108b is substantially disk shaped having a body with an exterior periphery 186 that substantially corresponds with and aligns with the radial segments 108a of the die 100. During use, the end segment 108b includes a first portion 190 that is configured to at least partially form the base wall 14 of the body 12, and a second portion 194 that is configured to at least partially form the outlet 18 of the body 12. In some embodiments, the end segment 108b may be interchangeable such that different sized and located outlets 18 may be formed (not shown).

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 FIGS. 11-15). The radial segments 108a are typically inserted from largest to smallest but any order can suffice. While assembling the radial segments 108a to the head unit 104, the user takes care to align at least one of the radial segments 108a such that the corresponding torque pin 166 is received within its corresponding aperture 182. Since each of the assembled radial segments 108a are in contact with each other to form the finished structure, only one of the segments 108a need be secured with a torque pin 166 to allow the entire assembly to remain rotational fixed relative to the head unit 104.

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 FIG. 16). As discussed above, the end segment 108b encloses the distal end of the head unit 104 such that the exterior surfaces of the radial and end segments 108a, 108b produce a substantially continuous “cup” shape.

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.

FIG. 22 illustrates another embodiment of the drain 10′. The drain 10′ is substantially similar to the drain 10 so only the differences will be discussed herein. More specifically, the body 12′ of the drain 10′ includes a base wall 14′ that that is substantially frusto-conical in shape such that the base wall 14′ is oblique to the axis 16′ of the drain 10′ to encourage better drainage by directing any fluids contained within the volume 40′ into the drain pipe 20′ attached to the outlet 18′.

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.

Claims

1. A drain comprising: a base wall defining an outlet and a periphery;a side wall extending from the periphery of the base wall to define an open end opposite the base wall; anda 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, wherein the ledge forms a neck having a first cross-sectional shape, wherein the first volume includes a second cross-sectional shape that is larger than the first cross-sectional shape, and wherein the base wall, side wall, and ledge are formed from a monolithic material.

2. The drain of claim 1, wherein the monolithic material is a piece of sheet material.

3. The drain of claim 1, wherein the monolithic material is formed using a metal spinning technique.

4. The drain of claim 1, wherein the drain further comprises a drain pipe coupled to the outlet and in fluid communication with the first volume, wherein the drain pipe is formed from a second piece of material different than the monolithic material.

5. The drain of claim 1, wherein the drain further includes a top plate coupled to the open end of the side wall, wherein the top plate is formed from a second piece of material different than the monolithic material.

6. The drain of claim 1, wherein the drain defines a drain axis, and wherein at least a portion of the base wall is oblique to the drain axis.

7. The drain of claim 1, wherein the drain defines a drain axis, wherein the base wall has a circular periphery, and wherein the side wall extends axially from the periphery of the base wall.

8. The drain of claim 1, wherein the ledge extends inwardly from the side wall along the entire circumference of the side wall.

9. The drain of claim 1, wherein the first cross-sectional shape is a circle having a first diameter, and wherein the second cross-sectional shape is a circle having a second diameter greater than the first diameter.

10. A method of manufacturing a drain having a monolithic body, the method comprising: 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, wherein 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; andremoving the die from the internal volume via the aperture.

11. The method of claim 10, wherein the die includes a head unit and at least one die segment removably attached to the head unit, and wherein the head unit and at least one die segment together form the first exterior surface.

12. The method of claim 11, wherein removing the die from the internal volume includes removing the head unit from the internal volume via the aperture and subsequently removing the at least one die segment from the internal volume via the aperture.

13. The method of claim 11, wherein the die segment is one of a plurality of die segments, and wherein the plurality of die segments together form the first cross-sectional shape.

14. The method of claim 10, further comprising forming the first monolithic piece of sheet material over the first exterior surface using a metal spinning process.

15. The method of claim 10, wherein the first cross-sectional shape includes a circle having a first diameter, and wherein the second cross-sectional shape includes a circle having a second diameter smaller than the first diameter.

16. The method of claim 10, further comprising coupling a top plate formed from a second piece of material to the monolithic body.

17. The method of claim 10, further comprising coupling a drain pipe formed from a second piece of material to the monolithic body.

18. A die having an external surface configured to at least partially form an internal volume, the die comprising: a head unit defining a die axis, wherein 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, wherein the first die at least partially forms the external surface; andwherein 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.

19. The die of claim 18, wherein the head unit defines a first aperture that is open axially toward the second end, and wherein the first die segment includes a first protrusion configured to be at least partially received within the first aperture.

20. The die of claim 18, wherein the first die segment is one of a plurality of die segments, and wherein when each of the plurality of die segments are attached to the head unit the plurality of die segments completely extend along and enclose the assembled cross-sectional shape.