The present invention is directed to plumbing systems, particularly an improved plumbing routing system and methods of installation and use of same.
Poly B (polybutylene) and Kitec (polymer) plumbing piping were widely used in North America for plumbing supply lines in residential and commercial buildings from 1978 to 1995 (Poly B) and from 1998 to 2007 (Kitec). While polybutylene and polymer were flexible materials, easy to install, and cheaper than copper, significant problems emerged from their use. Since such materials cannot withstand water pressure and heat, residential and commercial buildings with Poly-B or Kitec plumbing were experiencing leaks, causing extensive water damage and mold. Both plumbing systems have failed, leading to class-action lawsuits, and are now subject to scrutiny from insurance companies, making them a primary remediation effort across North America.
However, replacing existing Poly B and Kitec plumbing lines in residential and commercial buildings can be time-consuming and costly. As plumbing lines are often installed inside the walls of buildings, significant demolition is often required to access the plumbing lines, such as the removal of large sections of drywall. Even after the appropriate walls have been removed to access the existing plumbing lines, it can be cumbersome and awkward to remove the lines and install new pipes. The replacement of drywall and finishings, and re-painting incur further costs. Additionally, plumbing replacement procedures typically involve shutting off the water supply for extended periods of time, negatively affecting the comfort of residents and also revenue, in the case of businesses such as hotels.
It is also desirable to install and route new plumbing lines in such a manner so as to make maintenance and replacement easier and less costly, and to avoid the disadvantages of replacing existing plumbing systems.
An alternative process for replacing and/or installing plumbing lines involves installing plumbing lines along the outside of the interior walls of a building and constructing a “bulkhead” along the top of the walls to conceal the plumbing lines and other utilities therein. Such bulkheads typically comprise drywall attached to a box frame made of wood or metal, and are not designed to be easily opened or removed for access to the plumbing lines therein, for example for maintenance purposes.
Other systems comprise discrete retaining clips fixed to the outside surface of a wall, for example by screwing the clips into studs behind the wall or using drywall anchors, to retain plumbing lines. The clips can include a mechanism for securing elongate caps or covers thereto to hide the plumbing lines from sight. However, mounting the clips can be labour intensive, requiring installers to ensure that each clip is level with adjacent clips. Drywall anchors may need to be installed in the event the required spacing of the clips is smaller than the spacing of wall studs. Additionally, depending on the spacing of the clips, the covers may be secured only loosely to the wall, resulting in unsightly gaps between the covers and wall and the potential for the covers to be inadvertently removed from the clips, for example in the event of an impact against the cover. Such impact can also damage the clip since the forces are localized to each clip. While the clips can be mounted closer together, such closer spacing may require the use of drywall anchors, thereby increasing installation time.
Additionally, while it is often desirable for plumbing systems to incorporate leak detection mechanisms such as water sensors, currently water sensors are placed only at strategic locations near fixtures, such as adjacent to toilets or under kitchen sinks, dishwashers, laundry machines, and the like. Water sensors are not conventionally installed within the walls of a building to monitor for leaks along the plumbing lines due to the difficulty of accessing portions of the system located within walls, building framing, and the like.
There remains a need for a system and method for routing new or replacing problematic plumbing lines (such as Poly B and Kitec) to address the insurance epidemic and develop a scalable and cost-effective solution for this problem. In addition, such a system and method ideally permit robust and efficient installation with minimal demolition, allow for future access of plumbing lines for maintenance and repair, and provide leak detection capability along a substantial portion of the system as opposed to only at strategic locations.
The present invention relates to improved plumbing routing systems and methods of installation and uses of same. Plumbing routing systems are provided herein for routing plumbing lines such as water supply lines. The plumbing routing systems may be installed with greatly reduced demolition in relation to conventional systems and methods. The systems may also be used to remediate existing plumbing systems by simply disconnecting the existing system from the water supply, installing the new routing system, running the new lines along the new routing system, and connecting the new lines to the water supply.
Broadly, in one aspect, the invention comprises a cap for a wall comprising upper and lower major surfaces, opposing end surfaces, a first curved lateral surface, a second curved lateral surface, and a pair of opposed flexible fins extending outwardly from the lower major surface for removably securing the cap within the wall.
In some embodiments, each fin comprises a shank and a curved barb inwardly facing the shank, or integrally connected to the shank. In some embodiments, the cap further comprises a bow connected between the shanks.
In some embodiments, the cap further comprises one or more tracks comprising one or more clip-retaining mechanisms, and extending outwardly from the lower major surface and positioned between the shanks along a length or portion thereof of the lower major surface.
In some embodiments, the clip-retaining mechanism comprises a groove extending between the opposed end surfaces of the cap, the grooves being defined by a plurality of rails extending outwardly from the lower major surface, each rail being spaced parallel and apart from adjacent rails and defining a pair of rail lips delimiting a slot for removably anchoring a plumbing-retaining member therein.
In another aspect, the invention comprises a method for concealing one or more plumbing lines within a wall using the above cap.
In another aspect, the invention comprises a system for routing one or more plumbing lines within a wall comprising the above cap.
In some embodiments, the system further comprises one or more plumbing-retaining members configured to grip the one or more plumbing lines and to be removably anchored to the one or more clip-retaining mechanisms of the one or more tracks.
In some embodiments, the plumbing-retaining member comprises a clip having a gripping portion for receiving and gripping the plumbing line, and a mounting portion for removably anchoring to the clip-retaining mechanism.
In another aspect, the invention comprises a method of routing one or more plumbing lines within a wall comprising:
In another aspect, the invention comprises a system for routing one or more plumbing lines within a wall comprising:
In some embodiments, the main portion comprises a base having upper and lower major surfaces, opposing end surfaces, opposed sides, a first lateral surface, a second lateral surface, and the flexible fins extending outwardly from the sides.
In some embodiments, the base supports the one or more tracks comprising the one or more clip-retaining mechanisms for securing one or more plumbing-retaining members configured to grip the one or more plumbing lines and to be removably anchored to the one or more clip-retaining mechanisms.
In some embodiments, the first and second lateral surfaces extend outwardly from the sides and perpendicular to the sides for resting against an outer surface of the wall.
In some embodiments, the flexible fins extend outwardly below the first and second lateral surfaces, the flexible fins being selected from flat or curved fins; fins comprising barbs; or a pair of fins extending upwardly and outwardly from the sides.
In some embodiments, each side comprises a cover-retaining mechanism for removably securing the cover to the main portion.
In some embodiments, the cover-retaining mechanism comprises first and second opposed pairs of top and bottom protrusions which define gaps therebetween for receiving and removably securing the cover, the cover defining notches and curved edges configured to snap fit between the gaps.
In some embodiments, the cover-retaining mechanism comprises opposed side lips defining cover-engaging shoulders for removably securing the cover thereon, the cover defining first and second cover lips defining side lip-engaging shoulders.
In yet another aspect, the invention comprises a method of routing one or more plumbing lines within a wall comprising:
Additional aspects and advantages of the present invention will be apparent in view of the description, which follows. It should be understood, however, that the detailed description and the specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the scope of the invention will become apparent to those skilled in the art from this detailed description.
The invention will now be described by way of an exemplary embodiment with reference to the accompanying simplified, diagrammatic, not-to-scale drawings. In the drawings:
Before the present invention is described in further detail, it is to be understood that the invention is not limited to the particular embodiments described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims.
Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges is also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the invention.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, a limited number of the exemplary methods and materials are described herein.
It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. The term “horizontal” means the orientation of a plane or line that is substantially parallel to the plane of the horizon. The term “vertical” means the orientation of a plane or line that is substantially at a right angle to the horizontal plane. The term “inward” refers to the direction towards a wall, and the term “outward” refers to the direction away from the wall.
The present invention relates to improved plumbing routing systems and methods of installation and uses of same. In some embodiments, the system is installed on the outer surface of walls of a building for which it is desired to install or replace plumbing lines. In some embodiments, the system is installed within a wall of a building for which it is desired to install or replace plumbing lines. In some embodiments, the system may comprise a leak detection system configured to issue an alarm signal to report a leak and/or to close shutoff valves of the plumbing system to prevent further fluid flow through the plumbing lines.
While the system is shown in the figures to be installed horizontally for ease of reference, it is to be understood that the system is configured to be installed either horizontally or vertically, allowing corresponding plumbing lines to be installed either horizontally or vertically.
The invention will now be described having reference to the accompanying Figures. In some embodiments, the system is installed on the outer surface of walls of a building for which it is desired to install or replace plumbing lines. The system (1) is shown unassembled in
As shown in
The track (10) further comprises a clip-retaining mechanism positioned on the front surface (22) of the body (20) to anchor the plumbing-retaining members (12) to the front surface (22) of the track (10). In some embodiments, the clip-retaining mechanism comprises one or more grooves (30) extending from the first end (26a) to the second end (26b) of the track (10), and defining a clip-anchoring channel (32). In some embodiments, the grooves (30) are formed in the body (20) itself. In some embodiments, the grooves (30) are formed by rails (34). In some embodiments, the rails (34) extend outwardly from the front surface (22) of the body (20). In some embodiments, the rails (34) extend perpendicularly from the front surface (22) of the body (20). The rails (34) are oriented to extend between the opposing first and second ends (26a, 26b) along the entire length of the first and second lengthwise sides (28a, 28b). Each rail (34) is spaced parallel and apart from adjacent rails (34) to form the grooves (30) therebetween for receiving the plumbing-retaining members (12). A pair of rail lips (36) delimit a slot (38) between them for anchoring the plumbing-retaining members (12) within the clip-anchoring channel (32).
The track (10) further comprises a cover-retaining mechanism for coupling a cover (16) to the track (10). In some embodiments, the first portion of the cover-retaining mechanism comprises first and second track lips (40a, 40b) extending lengthwise along the first and second lengthwise sides (28a, 28b) of the track (10). Each of the first and second track lips (40a, 40b) has inward or wall-facing sides (42a, 42b) forming cover-engaging shoulders (44a, 44b). In some embodiments, the first and second track lips (40a, 40b) may include beveled or angled outer edges to facilitate the installation of a cover (16) thereon.
In some embodiments, the track (10) comprises a snap line (46) in the form of a notch to define a removable fin (48). The snap line (46) is positioned proximate and parallel to the first lengthwise side (28a) and extends from the first end (26a) to the second end (26b) of the track (10). The snap line (46) allows the fin (48) to be bent and snapped off along the snap line (46), decreasing the height of the track (10) for use in limited space applications. In some embodiments, the track (10) may be formed of plastic using plastic extrusion or molding processes. In some embodiments, the track (10) may be formed of metal including, but not limited to, galvanized steel, using standard metal smithing processes.
The plumbing-retaining members (12) can be off-the-shelf plumbing securing clips known in the art, or clips configured to couple with the grooves (30) of the tracks (10). As shown in
As shown in
In some embodiments, other clip-retaining mechanisms can be used to secure the plumbing-retaining members to the tracks. In some embodiments, the body (20) of the track (10) defines apertures for receiving corresponding pegs of the plumbing-retaining members therein.
In some embodiments shown in
In some embodiments shown in
Each of the C-shaped and slide-shaped covers (16) further comprises a second portion of the cover-retaining mechanism for securing the cover (16) to the track (10). As shown in
In some embodiments, other cover-retaining mechanisms can be used to secure the covers (16) to the tracks (10). In some embodiments, the covers (16) can be secured to the tracks (10) with fasteners such as screws, or via an interference fit between the covers (16) and the tracks (10).
In some embodiments, outer and inner corner covers (98, 100) can be used to enclose plumbing lines (4) at outer (6) or inner corners (7) where two adjacent tracks (10) meet. As shown in
As with the covers (16), other mechanisms can be used to retain the corner covers (98, 100) to the tracks (10), including via fasteners such as screws or an interference fit between the corner covers (98, 100) and the tracks (10).
In some embodiments shown in
In some embodiments, the system (1) further comprises a leak detection and mitigation system (122) for determining the presence of a leak and taking the appropriate steps in response such as automatically triggering an alarm and/or shutting off supply to the plumbing lines.
In some embodiments shown in
A controller or central processing unit (“CPU”) (128) is electrically connected to the detection and/or contact strips (70, 126) and configured to detect a voltage change or short across the first and second strips of a pair of strips (70, 126). Such a voltage chance or short is indicative of a leak. For example, in normal operation, there should be no current flowing between the first and second strips of a pair of detection strips/transition strips (70, 126). In the event of a leak, when fluid electrically connects the strips (70, 126), the voltage thereacross should drop to zero or near zero to indicate a short.
In some embodiments shown in
The controller (128) sends a low voltage current (for example, ranging between about 12V to about 16V) through the tracing wires (132), which returns after passing through the resistor(s) (136) at the end(s) of the electric circuit (130). A “calibrate” command is activated and the controller (128) records the “calibrated voltage” returned from the resistor(s) (136) compared to the supply voltage. A voltage drop is expected due to ohms law, with the amount of the voltage drop determined by the length of the tracing wire (132). During normal operation, the controller (128) records the returned voltage several times a second and compares it to the calibrated voltage. The voltage drop exceeding a predetermined percentage indicates a leak (i.e., water contacting the system (1)), and triggers valves (142) to shut off the water, preventing further damage. If the voltage reading is zero, the controller (128) determines that there is a break in the tracing wires (132), and activates the valves (142) to shut off the water supply to the plumbing lines (4).
In some embodiments, the controller (128) can issue an alarm signal, such as an audible and/or visual alarm, in response to the detection of a leak. The controller (128) may also be connected to a monitoring system located on-site or off-site, via wired or wireless networks, and indicate a leak to the monitoring system.
In some embodiments shown in
In some embodiments, the detection strips (70) can be located on the tracks (10) as opposed to the covers (16). The detection strips (70) of adjacent tracks (10) can be electrically connected via transition tracks with contact strips similar in design to those of the transition covers (124), or the detection strips (70) of the tracks (10) can have an overhang on the first or second side thereof such that the detection strips (70) of a track (10) overlap and contact the detection strips (70) of a subsequent track (10).
In use, the tracks (10) of the system (1) are installed on the outer surface (2) of the interior walls (3) of a building according to the desired plumbing routing. In some embodiments, the track (10) is installed with the fin (48) in contact as closely as possible with the ceiling (5), even if uneven as with ceiling drywall mud. The tracks (10) are secured to the walls (3) using suitable attachment means (18) including, but not limited to, screws, fasteners, adhesives, and the like. In some embodiments, the attachment means (18) comprise screws driven into wall studs. One or more rows of screws may be used to secure the track (10) and provide additional stability. The plumbing-retaining members (12) are secured to the tracks (10) at the desired locations and intervals, and grip the plumbing lines (4) as shown in
Existing plumbing systems can be retrofit or remediated using the system (1) with greatly reduced need to remove drywall and access the previous plumbing lines by simply disconnecting the existing plumbing lines from the water supply and connecting new plumbing lines to the supply. The system (1) can be installed as described above without demolition, and the interiors of walls need to be accessed only to pass the new plumbing lines between rooms/floors if the lines cannot be routed along the exterior of the walls.
In some embodiments, the system is installed within a wall of a building for which it is desired to install or replace plumbing lines. Systems and methods for routing a plumbing line within a wall include the tracks having clip-retaining mechanisms and being attachable within the wall by flexible fins; the plumbing-retaining members for gripping the plumbing line and being removably anchored to the clip-retaining mechanisms; and various embodiments of caps and covers removably securable to conceal the plumbing line within the wall.
In some embodiments shown in
The fins (160a, 160b) may vary in configuration. In some embodiments, each fin (160a, 160b) comprises a shank (162a, 162b) and a curved barb (164a, 164b) inwardly facing the shank (162a, 162b). In some embodiments (144c), the barb (164a, 164b) is integrally connected to the shank (162a, 162b) (
In some embodiments, the cap (144d) comprises one or more lengths of track (10) comprising one or more clip-retaining mechanisms and extending outwardly from the lower major surface (148) and positioned between the shanks (162a, 162b) along the length or portion thereof of the lower major surface (148) (
The cap (144a-d) may vary in size and shape to be insertable into an aperture (8) within the wall (3). The cap (144a-d) may be cut to a size and shape to align properly with the aperture (8). In some embodiments, the cap (144a-d) has a substantially rectangular shape. In some embodiments, the cap (144a-d) has a substantially square shape. In some embodiments, the cap (144a-d) is flexible. In some embodiments, the cap (144a-d) is formed of plastic.
In some embodiments, a method for concealing plumbing lines (4), electrical wires, or other utilities within the wall (3) comprises removably securing any of the above caps (144a-c) within the wall (3). In some embodiments shown in
In some embodiments, a system and method for routing plumbing lines (4), electrical wires, or other utilities within a wall (3) comprises removably securing the cap (144d) comprising one or more tracks (10) within the wall (3). In some embodiments as shown in
As previously described and shown in
In some embodiments, a method of routing one or more plumbing lines (4) within a wall (3) comprises removably anchoring one or more plumbing-retaining members (12) configured to grip the one or more plumbing lines (4) to the one or more clip-retaining mechanisms (12a-g) of the cap (144d); partially pulling the one or more plumbing lines (4) through an aperture (8) formed within the wall (3) towards the cap (144d), the one or more plumbing-retaining members (12a-g) gripping the one or more plumbing lines (4); and snap-fitting the flexible fins (160a, 160b) of the cap (144d) within the wall (3) to removably secure the cap (144d) and the one or more plumbing lines (4) within the wall (3).
As shown in
In some embodiments, a system for routing one or more plumbing lines (4) within a wall (3) comprises a main portion (168) comprising one or more tracks (10) comprising one or more clip-retaining mechanisms (12a-g) and a pair of opposed flexible fins (160a, 160b) for removably securing the main portion (168) within the wall (3); and one or more covers (170) configured to be removably secured to the main portion (168).
In some embodiments shown in
In some embodiments, the main portion (168) comprises a base (172) having upper and lower major surfaces (174, 176), opposing end surfaces (178, 180), opposed sides (182, 184), a first lateral surface (186), a second lateral surface (188), and a pair of opposed fins (190a, 190b) extending outwardly from the sides (182, 184).
In some embodiments, the base (172) is flat (
The first and second lateral surfaces (186, 188) extend outwardly from the sides (182, 184) and perpendicular to the sides (182, 184) for resting against the outer surface (13) of the wall (3). In some embodiments, the first and second lateral surfaces (186, 188) are sloped or have substantially triangular-shaped cross-sections (
The fins (190a, 190b) extend outwardly below the first and second lateral surfaces (186, 188) for attaching the main portion (168) within the wall (3). In some embodiments, the fins (190a, 190b) are flexible. In some embodiments, the fins (190a, 190b) are formed of plastic.
The fins (190a, 190b) may vary in configuration. In some embodiments, the fins (190a, 190b) are flat or have substantially rectangular cross-sections (
Each side (182, 184) comprises a cover-retaining mechanism for securing the cover (170) to the main portion (168). In some embodiments, the cover-retaining mechanism comprises first and second opposed pairs of top and bottom protrusions (202a, 202b) which define gaps (204a, 204b) therebetween for receiving and removably securing the cover (170) (
The covers (170) may vary in configuration. In some embodiments, the cover (170) is substantially rectangular-shaped in cross-section and defines notches (212a, 212b) and curved edges (214a, 214b) at its sides (216a, 216b) so as to be received and removably snap fit within the gaps (204a, 204b) formed by the top and bottom protrusions (202a, 202b) (
In some embodiments, the cover (170) is substantially curved in cross-section (
In some embodiments, a method of routing one or more plumbing lines (4) within a wall (3) comprises removably securing the main portion (168) within the wall (3) by snap-fitting the flexible fins (190a, 190b) through an aperture (8) formed within the wall (3); removably anchoring one or more plumbing-retaining members (12) configured to grip the one or more plumbing lines (4) to the one or more clip-retaining mechanisms of the one or more tracks (10); snap-fitting the one or more plumbing lines (4) to the one or more plumbing-retaining mechanisms (12); and removably securing the cover (170) to the main portion (168).
Using the embodiment of
In some embodiments, the cover (170) is cut to the desired length and aligned with the main portion (168) and pressed thereto (
The particular embodiments disclosed above are illustrative only, as the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. While numerous changes may be made by those skilled in the art, such changes are encompassed within the scope of the subject matter defined by the appended claims. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope of the present disclosure.
Number | Date | Country | Kind |
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3,169,418 | Aug 2022 | CA | national |
This application claims the benefit of Canadian Patent Application No. 3,169,418 filed on Aug. 3, 2022, which claims benefit to U.S. Provisional Application No. 63/229,147, filed on Aug. 4, 2021. This application also is a continuation-in-part of U.S. Non-Provisional application Ser. No. 17/817,395, filed on Aug. 4, 2022, which also claims benefit to U.S. Provisional Application No. 63/229,147, filed on Aug. 4, 2021. Each of these applications is incorporated herein by reference in its entirety for all purposes.
Number | Date | Country | |
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63229147 | Aug 2021 | US |
Number | Date | Country | |
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Parent | 17817395 | Aug 2022 | US |
Child | 18364300 | US |