Patent Application
20130160203
The present invention relates generally to drain fittings utilized in shower or bath installations.
The construction of drain assemblies in tile shower installations has conventionally involved the use of a well-known, two-piece drain to which a shower pan is sealably attached beneath a mortar bed. The term “two-piece” drain is used because this type of drain typically includes at least two components that compress and seal the shower pan between the two components to secure the shower pan to the drain. Tile is typically applied over the mortar bed and the mortar bed serves as a conduit to direct water to the shower pan and the water is drained over the shower pan and into a waste drain through weep holes formed in sides of the two-piece drain.
Recently, a different type of assembly has become popular for use in shower floors that involves the use of a bonded (or bondable) waterproof membrane. In general, a bondable waterproof membrane bonds directly to the mortar bed (or a suitable equivalent) and protects the mortar bed (and any underlying structure such as the subfloor) from contact with moisture from the shower. The incorporation of bondable waterproof membranes in floor drain installations has generally required that drain fittings other than the conventional two-piece drains be developed. This is because conventional two-piece floor drains were designed to connect to shower pan liners below the mortar bed and so did not provide for a secure, watertight connection to bondable waterproof membranes at the top of the drain assembly.
For this reason, drain fittings having so-called “integrated bonding flanges” have been developed for use with bonded waterproof membranes. A typical integrated bonding flange installation is illustrated in
While the integrated bonding flange system has proved popular with tile installers (or “tile setters”), there exists a sometimes significant time delay between the point in time that a plumber installs the plumbing for the integrated bonding flange drain and the point in time at which a tile installer completes the tile shower installation utilizing the integrated bonding flange drain. As such, it is sometimes difficult for the plumber to properly ascertain the height at which the various components of the drainage system should be installed to ensure that the tile setter can properly complete the installation. In addition, as the integrated bonding flange drain protrudes some distance above the subfloor (it is generally seated on a bed of mortar, or equivalent structure, by the tile setter), the integrated bonding flange drain can be exposed to potentially damaging forces during the intervening days, weeks or months after the plumber installs the drainage components and before the tile setter completes the installation.
Thus, while the bonded waterproof membrane shower system is increasing in popularity, problems have arisen relating to the discontinuity in time between the work performed by the plumber and the finished tile installation performed by the tile setter.
The present invention provides a segmented drain system, including a drain body, operable to substantially irremovably mate with a drain fitting installed in a bath or shower area, and a bonding flange body, adjustable relative to the drain body. An integrated bonding flange extends from the bonding flange body, the integrated bonding flange and can be operable to be sealably attached to a bondable waterproof membrane to provide a substantially water-tight seal between the membrane and the bonding flange body. A seal can be oriented between the integrated bonding flange body and the drain body, the seal being operable to provide a slidable, substantially water-tight interface between the integrated bonding flange body and the drain body.
In accordance with another aspect of the invention, a method for preparing a shower or bath area for installation of a bondable waterproof membrane is provided, including: installing a segmented drain system on a conventional drain fitting, the segmented drain system including: a drain body, operable to mate with a drain fitting installed in a bath or shower area; a bonding flange body, adjustable relative to the drain body; an integrated bonding flange, extending from the bonding flange body, the integrated bonding flange being operable to be sealably attached to a bondable waterproof membrane to provide a substantially waterproof seal between the membrane and the bonding flange body; and a seal, oriented between the integrated bonding flange body and the drain body, the seal being operable to provide a slidable, substantially water-tight interface between the integrated bonding flange body and the drain body; and temporarily removing the bonding flange body from the drain body to limit damage being done to the integrated bonding flange during completion of work in or adjacent to the shower or bath area.
In accordance with another aspect of the invention, a method for installing an integrated bonding flange in a shower or bath drain for use with a bondable waterproof membrane is provided, including: slidably disposing a bonding flange body within a drain body installed on a conventional drain fitting, the bonding flange body including an integrated bonding flange, extending from the bonding flange body, the integrated bonding flange being operable to be sealably attached to a bondable waterproof membrane to provide a substantially waterproof seal between the membrane and the bonding flange body; and adjusting an elevation of the integrated bonding flange relative to the drain body by sliding the bonding flange body within the drain body.
There has thus been outlined, rather broadly, relatively important features of the invention so that the detailed description thereof that follows may be better understood, and so that the present contribution to the art may be better appreciated. Other features of the present invention will become clearer from the following detailed description of the invention, taken with the accompanying drawings and claims, or may be learned by the practice of the invention.
Before the present invention is disclosed and described, it is to be understood that this invention is not limited to the particular structures, process steps, or materials disclosed herein, but is extended to equivalents thereof as would be recognized by those of ordinarily skilled in the relevant arts. It should also be understood that terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting.
It must be noted that, as used in this specification and the appended claims, the singular forms “a” and “the” include plural referents, unless the context clearly dictates otherwise. Thus, for example, reference to a drain fitting can include one or more of such drain fittings.
Definitions
In describing and claiming the present invention, the following terminology will be used in accordance with the definitions set forth below.
As used herein, the term “subfloor” is to be understood to refer to flooring structure of a dwelling through which (or adjacent or below which) a shower drain is to be installed. Examples of subfloors include flooring surfaces formed of plywood, particle board, concrete, steel, and the like. It is to be understood that the term subfloor is not to be limited by any commonly used meaning ascribed to the term by any particular field of construction or architectural endeavor.
As used herein, the term “integrated bonding flange” is to be understood to refer to a portion of drain fittings designed for use with a waterproofing membrane. One example of a product that incorporates an integrated bonding flange is integrated bonding flange drain sold by Schluter Systems companies under the trade name KERDI-DRAIN.
As used herein, the terms “upper,” “lower,” “elevation,” “height,” and the like, are to be understood to refer to relative locations and/or displacements of various elements or components relative to a condition in which a drain system (or an integrated bonding flange) is oriented in its usable, upright orientation. These such terms are used to more clearly claim and describe the various elements or components of the invention and are not to be construed as limiting the invention to any particular embodiment. In the upright orientation, the drain system (or the integrated bonding flange) will be oriented so as to be operably installable within the subfloor and operably attachable to the plumbing dictated by a particular installation.
As used herein, the term “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. As an arbitrary example, an object that is “substantially” enclosed is an object is either completely enclosed or nearly completely enclosed. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context. However, generally speaking the nearness of completion will be so as to have the same overall result as if absolute and total completion were obtained.
The use of “substantially” is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result. As an arbitrary example, a composition that is “substantially free of particles would either completely lack particles, or so nearly completely lack particles that the effect would be the same as if it completely lacked particles. In other words, a composition that is “substantially free of an ingredient or element may still actually contain such item as long as there is no measurable effect thereof.
As used herein, the term “about” is used to provide flexibility to a numerical range endpoint by providing that a given value may be “a little above” or “a little below” the endpoint.
As used herein, a plurality of items, structural elements, compositional elements, and/or materials may be presented in a common list for convenience. However, these lists should be construed as though each member of the list is individually identified as a separate and unique member. Thus, no individual member of such list should be construed as a de facto equivalent of any other member of the same list solely based on their presentation in a common group without indications to the contrary.
Concentrations, amounts, and other numerical data may be expressed or presented herein in a range format. It is to be understood that such a range format is used merely for convenience and brevity and thus should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. As an illustration, a numerical range of “about 1 to about 5” should be interpreted to include not only the explicitly recited values of about 1 to about 5, but also include individual values and sub-ranges within the indicated range. Thus, included in this numerical range are individual values such as 2, 3, and 4 and sub-ranges such as from 1-3, from 2-4, and from 3-5, etc., as well as 1, 2, 3, 4, and 5, individually. This same principle applies to ranges reciting only one numerical value as a minimum or a maximum. Furthermore, such an interpretation should apply regardless of the breadth of the range or the characteristics being described.
Invention
Illustrated generally at 100 in
In general, the conventional system 100 includes an integrated bonding flange drain 112 that includes an upper flange 114 to which a bonded waterproof membrane (a portion of which is shown by example at 136 in
Preferably, it is only after the mortar bed 131 has been prepared that the integrated bonding flange drain 112 is installed within the drain fitting 122 and properly seated on or within the mortar bed. A series of openings 133 is often formed around the perimeter of the flange 114 of the drain to aid in securing the flange on or in the mortar bed. A fleece webbing 132 is sometimes adhered over a large surface of the flange 114 of the drain. A bondable (or bonded) waterproof membrane 136 can typically be adhered to the fleece webbing to ensure a completely watertight installation of the waterproof membrane to the drain.
The lower section 118 of the integrated bonding flange drain 112 can be coupled to the plumbing system of the dwelling by way of drain fitting 122. The drain fitting can be coupled to gooseneck 124, which can be in turn coupled to a remaining portion 126 of the plumbing system. Details of the plumbing system are generally well known in the art and are not expounded upon herein in detail.
It will be appreciated that the spacing of the flange portion 114 of the drain above an upper surface of the subfloor 130 can affect the integrity of the overall tile installation process. If the flange is disposed too closely to the subfloor, the thickness of the mortar bed may be inadequate. If the flange is disposed too high above the subfloor, the mortar bed may have to be made too thick for a proper installation. Accordingly, it is important that, when the plumbing components are assembled, the drain fitting 122 be installed such that the drain 112, when coupled to the fitting 122 (after the mortar bed has been laid), is disposed in the proper location relative to the subfloor 130.
However, it is generally the plumber who assembles the various components of the plumbing (e.g., “plumbs” the shower), and not the tile setter. In addition, the plumber generally plumbs the shower many days, weeks, or even months before the tile setter finishes the installation by installing the drain 112, the bondable waterproof membrane, the tile and grout, etc. Accordingly, in the past it has been difficult for the plumber to properly install the various plumbing components and ensure that the drain 112, when finally coupled to drain fitting 122, will be disposed at the proper elevation. The present invention can be advantageously used to address these shortcomings in prior art systems.
One embodiment of the present invention is shown in top view in
An upper section 16 of the mock drain 12 can be sized to fit within the cavity 128 formed in the subfloor 130 of the shower area. As discussed above, the cavity can be sized to receive a corresponding section (116 in
The mock drain 12 can be provided to the plumber charged with plumbing the shower area and can be used to ensure that the plumber correctly installs and sizes the various plumbing components of the installation. The mock drain can also ensure that the integrated bonding flange drain (112 in
In the past it has been found that plumbers have, at times, failed to set the various plumbing components into the correct position, resulting in the drain 112 not properly fitting in the drain fitting 122 when the tile setter arrives to finish the shower installation. When this has happened, the tile setter has had to either repair the plumber's installation prior to proceeding with his or her portion of the work, or has had to wait while someone else does the repair. The present inventor has found, however, that if a plumber utilizes the mock drain 12 when installing the plumbing components, the tile setter is much more likely to arrive at the job site with the plumbing components properly installed. The tile setter can simply remove the mock drain when he or she is ready to proceed with the shower installation with the knowledge that the plumbing will properly accommodate the drain 112 when it is time to install the drain.
To aid the tile setter in removing the mock drain 12, one or both of the top section 16 and the cap section 34 can include engagement structure 38 that can be configured to be engaged by the tile setter (or his or her assistant) to withdraw the mock drain from the drain fitting 122 prior to installing the integrated bonding flange drain 112 in the drain fitting. The engagement structure can take a variety of forms and can be operable to facilitate application of a rotating motion to the mock drain by the user (e.g., to twist or unscrew the mock drain from the drain fitting), and/or can be operable to facilitate application of a translational motion to the mock drain by the user (e.g., to allow the tile setter to remove the mock drain from the drain fitting). In the embodiment shown in the figures, the engagement structure includes a pair of slots 38 that can be engaged by one or more hook- shaped tools (not shown) to allow the tile setter to pull and/or twist the mock drain from the drain fitting 122. In addition to general slot structure, it is contemplated that the engagement structure can include protrusions that can be engaged by hand or by tool, or can include one or more apertures large enough to enable an operator to engage the mock drain with his or her fingers, etc.
In one embodiment of the invention the cap section 34 can be removably attached to the upper section 16 of the mock drain 12 by way of a removable press fit, snap-fit or by use of fasteners such as screws, bolts, etc. (not shown in the figures). In this manner, the engagement structure can be disposed within the mock drain and can be accessed by removing the cap from the mock drain. The cap section can cover a majority of open space defined by the upper section 16 to substantially completely seal the upper section to ensure that debris does not enter the drain fitting 122 (and thus the plumbing system) while the mock drain is installed in the drain fitting. When slots 38 are utilized to facilitate relatively easy removal of the mock drain, it is contemplated that “trap” sections (not shown) can be formed beneath the slots to ensure that any debris that enters the slots is not allowed to fall into or through the drain fitting 122.
The upper section 16 of the mock drain 12 can include a diameter (“D,” in
As shown in
The subfloor 130 illustrated in the figures is generally a wooden structure such as plywood or particle board. It is to be understood, however, that the mock drain 12 can also be used in installations in which the subfloor is concrete, as might be the case, for example, when the shower area is disposed in a concrete slab of a home, or in outside applications near pools, etc. In addition, while the intermediate section 20 of the mock drain is shown having generally tapering side walls, it is to be understood that the shape of the intermediate section can vary, and can include, for example, a generally rounded “bowl” shape.
It is to be understood that, to function best, the mock drain 12 should be installed by the plumber on or over the drain fitting 122 in a manner that allows the mock drain to be relatively easily removed at a later time. If, for example, the plumber accidentally bonds the mock drain within the drain fitting, the tile installer can be faced with a very difficult extraction process. To minimize the possibility of this type of mistake, the present invention can include structure that forces or encourages the plumber to attach the mock drain to the plumbing system in a removable manner, e.g., in a manner that allows removal of the mock drain without damage being done to the drain fitting or to the supporting plumbing system, including the drain fitting 122.
As shown in
Turning now to
The segmented drain system 212 provides a number of advantages over conventional systems. One such advantage is provided by allowing vertical adjustability of various components of the segmented drain system. For example, the drain system can provide vertical adjustability to the integrated bonding flange 218 to allow a tile setter to adjust a height of the bonding flange for optimal performance. This can be accomplished by the tile setter, as opposed to a plumber, at the time of setting tile, rather than having to be done by the plumber at a much earlier stage in the construction project, as was typically done in conventional systems.
As will be appreciated by one of ordinary skill in the art having possession of this disclosure, the bonding flange body 216 illustrated in
In addition to the flexibility provided by the adjustability of the drain system, a great advantage is provided in that the two or more components of the drain system can be installed at different times. In a typical installation, the drain body 214 can be permanently attached to a drain fitting (e.g., 122 in
The drain body can be attached in a variety of manners known to those of ordinary skill in the art, using tools and materials commonly available to plumbers. In the embodiments illustrated in the figures, the drain body is configured to be attached to a conventional drain pipe fitting by way of a no-hub coupler, as is commonly done. It is also contemplated that a bonded interface can be utilized, a threaded fitting, fittings that utilize various other clamping mechanisms, etc.
The drain body 214 can include an upper support shoulder 225 that can extend outward beneath at least a portion of the integrated bonding flange 218. The upper support shoulder can advantageously rest upon an existing subfloor (e.g., 130 in
At the point in time in which the tile setter is ready to set the drain, he or she can very easily insert the bonding flange body 216 within the drain body 214, and then adjust a height of the bonding flange body to a proper position. This can be accomplished by the tile setter without requiring the use of tools and materials more commonly carried by, and used by, plumbers. Not only does the present system provide optimal adjustability in completing the installation of the drain, it can serve to protect the integrated bonding flange 218 from damage that might otherwise occur if all components of the drain were set by the plumber and left unattended for many days until the tile setter performs his or her function.
Generally speaking, the seal 220 will be attached (either directly or indirectly) to bonding flange body 216 or the drain body 214. In the embodiment illustrated in
The seal 220 can be formed from a variety of materials and in a variety of configurations. Exemplary materials include, without limitation, rubber materials, polymer materials, felt materials, ethylene, propylene, nitrile, polyethylene, silicones, and the like. One of ordinary skill in the art, having possession of this disclosure, would readily appreciate the various materials from which the seal can be formed.
In the embodiment illustrated at 212′ in
As shown in
It will be appreciated from
The various components of the drain system can be formed from a variety of materials. In one aspect of the invention, the drain body 214 and the bonding flange body 216 can be formed from a polymer material, such as ABS or PVC. In another aspect, the components can be formed from a metallic material, such as stainless steel. While not so required, a bondable fleece webbing (e.g., 132 in
In addition to the structural features discussed above, the present invention also provides a method for preparing a shower or bath area for installation of a bondable waterproof membrane. The method can include the step of installing a segmented drain system on a conventional drain fitting, the segmented drain system including: a drain body, operable to mate with a drain fitting installed in a bath or shower area; a bonding flange body, adjustable relative to the drain body; an integrated bonding flange, extending from the bonding flange body, the integrated bonding flange being operable to be sealably attached to a bondable waterproof membrane to provide a substantially waterproof seal between the membrane and the bonding flange body; and a seal, oriented between the integrated bonding flange body and the drain body, the seal being operable to provide a slidable, substantially water-tight interface between the integrated bonding flange body and the drain body. The method can include the step of temporarily removing the bonding flange body from the drain body to limit damage being done to the integrated bonding flange during completion of work in or adjacent to the shower or bath area.
A method for installing an integrated bonding flange in a shower or bath drain for use with a bondable waterproof membrane is also provided, including the step of slidably disposing a bonding flange body within a drain body installed on a conventional drain fitting, the bonding flange body including an integrated bonding flange, extending from the bonding flange body, the integrated bonding flange being operable to be sealably attached to a bondable waterproof membrane to provide a substantially waterproof seal between the membrane and the bonding flange body. The method can include the step of adjusting an elevation of the integrated bonding flange relative to the drain body by sliding the bonding flange body within the drain body.
It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present invention. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the present invention and the appended claims are intended to cover such modifications and arrangements. Thus, while the present invention has been described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred embodiments of the invention, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly and use may be made without departing from the principles and concepts set forth herein.
This is a continuation-in-part application of copending U.S. patent application Ser. No. 12/205,105, filed Sep. 5, 2008, which is a continuation-in-part of U.S. patent application Ser. No. 11/366,203, filed Mar. 1, 2006, now issued as U.S. Pat. No. 7,992,236; and this is a continuation-in-part of U.S. patent application Ser. No. 13/224,113, filed Sep. 1, 2011, which is a divisional of U.S. patent application Ser. No. 11/498,537, filed Aug. 2, 2006, now issued as U.S. Pat. No. 8,060,956; and this is a continuation-in-part of U.S. patent application Ser. No. 12/077,941, filed Mar. 20, 2008, now issued as U.S. Pat. No. 8,112,827, each of which is hereby incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 11498537 | Aug 2006 | US |
| Child | 13224113 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12205105 | Sep 2008 | US |
| Child | 13396480 | US | |
| Parent | 11366203 | Mar 2006 | US |
| Child | 12205105 | US | |
| Parent | 13224113 | Sep 2011 | US |
| Child | 11366203 | US | |
| Parent | 12077941 | Mar 2008 | US |
| Child | 11498537 | US |
